Doosan HM 1000 User manual

Machine Tools
HMC Maintenance Manual
(HM 1000/1250)

1
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............................................................................... 28
2. Assembling/disassembling the table.....................................................................30
2.1 Disassembling the table..................................................................................................35
2.2 Disassembling the piston shaft (designed for pallet clamping/unclamping).................... 38
2.3 Disassembling the piston (designed for table clamping/unclamping).............................. 39
2.4 Removing the worm shaft and worm wheel .................................................................... 40
2.5 Installing the worm shaft and worm wheel ...................................................................... 43
2.6 Assembling the piston (designed for table clamping/unclamping)................................... 47
2.7 Installing the piston shaft (designed for pallet clamping/unclamping) ............................. 49
2.8 Assembling the table (pallet base) .................................................................................. 50
2.9 Resetting the reference point for the B axis.................................................................... 52
3. Adjusting and repairing ATC.....................................................................................54
3.1 Resetting the reference point for ATC servo magazine................................................... 54
3.2 Adjusting the position of ATC sub changer...................................................................... 58
3.3 Alignment between ATC and spindle............................................................................... 60
3.4 ATC Hydraulic Circuit Line...............................................................................................62
3.5 Learning about ATC magazine touch panel..................................................................... 63
3.6 Tool Search Sequence Chart........................................................................................... 75
3.7 Tool Changing (M06) Sequence Chart............................................................................ 77
3.8 Tool Re-Charge Sequence Chart .................................................................................... 80
4. APC Sequence Chart.................................................................................................82
5. Assembling & disassembling the ball screw ............................................................88
5.1 Disassembling the ball screw on the X axis .................................................................... 88
5.2 Installing the ball screw on the X axis.............................................................................. 93
5.3 Disassembling the ball screw on the Y axis .................................................................... 99
5.4 Installing the ball screw on the Y axis............................................................................ 105

2
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....................................................................................................128
6.4 Straightness of Pallet Deck............................................................................................129
6.5 Squareness between coordinate axes...........................................................................130
6.6 Parallelism between pallet deck and X/Z axis................................................................134
6.7 Squareness in division of index table.............................................................................136
6.8 Parallelism between edge locator and X axis ................................................................136
6.9 Distance between base section of edge locator and swiveling center of table..............147
6.10 Difference in Y-axis height when in changing the pallet...............................................148
6.11 Parallelism between center line of spindle and movement of Z-axis............................148
6.12 Runout on the spindle..................................................................................................150
6.13 Movement of spindle in the Z-axis direction.................................................................150
7. Regular Checkpoints............................................................................................ 155
7.1 Auto Tool Changer (ATC) ...............................................................................................155
7.2 APC (Auto Pallet Changer) ............................................................................................156
7.3 Axes System ..................................................................................................................156
7.4 Spindle Head..................................................................................................................157
7.5 Table...............................................................................................................................157
7.6 Air Service Unit...............................................................................................................158
7.7 Lubrication Unit..............................................................................................................158
7.8 Hydraulic Unit.................................................................................................................159
7.9 Oil Cooler.......................................................................................................................159
7.10 Splash Guard...............................................................................................................160
7.11 Labels...........................................................................................................................160
7.12 Coolant & Chip Devices...............................................................................................160
7.13 Electric Devices............................................................................................................161
7.14 Check Oil Supply..........................................................................................................162

3
HM 1000/1250 HM1000MTE04
1. Assembling/disassembling the spindle cartridge
※Spindle Cartridge Parts List
139
138
122
143
142
141
140
137
144
145
133
125, 126
127, 128
129, 131
205
204
203
207
206
150
151
147
146
148
147
149
154
155
152
153
157
158
156
210
208
209
328

4
HM 1000/1250 HM1000MTE04
NO. Parts No. Description Material / Specification Q'ty Remarks
122 P74060006 Hex. Socket Plug(S) FPS-S1/8 8
125
C12011112 Sleeve SCM435 1
126 S2215561 Hex. Socket Head Bolt BB12×45 6
127
S8000160 O-Ring P11 6
128 S8000160 O-Ring P16 8
129
S8011900 O-Ring G190 2
131 C68012064D Hex Socket Plug (NPT1/16) 5
133
C12011021 Main Spindle SCM415 1
137 R55020A Labyrinth Seal L120×140×15 1 Fukuda
138
C12011042 Front Cove SM45C 1
140 C68012072C Bearing Support SM45C 1
141
S2209061 Hex. Socket Head Bolt BB8×25 6
142 P80300150 O-Ring S150 1
143
S5740480 Spring Pin SPP3×8 1
144 C81019044 Labyrinth SM45C 1
145
C81019054 Labyrinth SM45C 1
146 R10365 Ang. Con. Ball Bearing 100BNR10STYNDBBELP4 1 NSK
147
C12011053 Bearing Spacer (1) SCM435 2
148 C12011063 Bearing Spacer (2) SCM435 1
149
C81019134A Collar SCM435 1
150 C68012123B Stepped Sleeve SCM440 1
151
C68012134 Collar SCM435 1
152 C68012144 Collar SCM435 1
153
R11274 Roller Bearing NN3019MBKRCC0P4 1 NSK
154 C68012164A Labyrinth SM45C 1
155
C68012154 Labyrinth SM45C 1
156 C68012183A Stepped Sleeve SCM440 1
157
C68012172A Bearing Support SM45C 1
203 C85041074 Spacer. Collet SM45C 1
204
R76629 Collet(BT50) 1
205 R76628A Collet(DIN50) 1
206
C12011222 Draw Bar SCM440 1
207 R55374 Quad Ring QRAR04219 2 Busak
208
C81018524A Supporter. Spring SCM435 1
209 S80000320 O-Ring P32 1
211
C68011683B Disc Spring 70×32×3.5×5.4 1 Rolex
328 S8010650 O-Ring G65 1

5
HM 1000/1250 HM1000MTE04
※Tool Unclamp Cylinder Parts List
No. Parts No. Description Material / Specification Q'ty Remarks
159
C81018273C
Housing
SM45C
1
163
S3520506
Set Screw(Hex. S/Head)
BQ8×16
24
168
C81019104 Spacer STKM13A 1
169
R11324
Cyl. Roller Bearing
N1019BMR1CCG18P5
1
NSK
171
C81019113
Labyrinth
SM45C
1
172
C68011974 Parallel Key 10×8×37 2
173
C81019123B
Labyrinth
SM45C
1
174
S2209261
Hex. Socket Head Bolt
BB8×30
6
175
S8011900 O-Ring G190 1
176
C81019143A Disk SS41 1
181
C81018314A
Bolt
SM45C
4
182
C40011704
Washer
SM45C
8
183
C40011684A Disk Spring S266650 4
198
192
333
334
335
336
337
338
339
185
201
193
194
199
159
318
197
196
202
195
342
343
340
344
345
175
168
169
172
171
174
173
176
163
246
347
325
183
182
181
324
323
186
185
184
327
326
191, 190
189, 188
187
350
349
348

6
HM 1000/1250 HM1000MTE04
No. Parts No. Description Material / Specification Q'ty Remarks
184
C81018532C Cylinder SM45C 1
185
R46093
Elbow Connector
PL8-PT1/4
3
Sang-A
186
P74060006
Hex. Socket Plug (S)
FPS-S1/8
1
187
S8001350 O-Ring P135 1
188
C81018253B Cylinder Cap SM45C 1
189
S22215061
Hex. Socket Head Bolt
BB12×25
8
190
S8000140
O-Ring
P14
1
191
P51400012 Conical Washer ZC12 12
192
C81018304
Block
SM45C
1
193
S2208861
Hex. Socket Head Bolt
BB8×20
22
194
P51400008 Conical Washer ZC8 18
195
C81018243
Piston
SCM435
1
196
R56005B
SKY-Packing
SKY-50
1
Sakagami
197
P57108040 Parallel Pin (W/Tap) SPB8×40 1
198
C81018283B Lock Nut SCM445 1
199
C81018263B
Stopper
SCM435
1
201
C68011573B
Lock Nut
SCM435
1
202
R53313 Wear Ring GR6900500-T47 1 Hansung
246
C60016063C
Housing
GC25
1
318
S2205261
Hex. Socket Head Bolt
BB6×30
12
323
R53194 Quad-Ring 4430-366Y 1 Hansung
324
R54033
Back-Up Ring
BP6401300
1
Hansung
325
R53196
Wear-Ring
GR65-408L
1
Hansung
326
R53194 Quad-Ring 4430-366Y 1 Hansung
327
R54354 Back-Up Ring BU6401321 2 Hansung
333
ESWPX0265F
Proximity Switch/PNP
BES516-325-E5-C-S4
2
334
ECBLS0170F
Proximity S/W Cable
WWAKRT4-2
2
335
C50019154C Switch Bracket (1) SCP1 1
336
C50019164B
Switch Bracket (2)
SCP1
1
337
C50019123
Housing
SM45C
1
339
R46064 One Touch Elbow PL6-PT1/8 1 Sang-A
340
R27238
Rotating Union
ES×20M-6509Y
1
Deublin
342
C50019133B
R-Union Cap
SM45C
1
343
S8010550 O-Ring G55 1
344
C50019143C Oil Pan SCP1 1
345
R46636
Elbow Connector
PL12-03
1
Sang-A
347
C81018732
Cylinder Base
SM45C
1
348
C81018773 Unclamp Cylinder Ass’y 1
349
S2215501
Hex. Socket Head Bolt
BB12×45
4
350
S8011550
O-Ring
G155
1

7
HM 1000/1250 HM1000MTE04
※Spindle Head Gear Box Parts List
211
165
164
167
166
168
169
227
127
247
249
230
231
191
247
249
239, 240
241, 127
248
208
209
328
163
162
161
212
213
214
215
250, 251
252, 253
254, 255
256, 257
258
216
224
217
218
219
220
213
214
222
223
224
225
228
229
227
193
233
232
237
235
226

8
HM 1000/1250 HM1000MTE04
No. Parts No. Description Material / Specification Q'ty Remarks
127
S8000110
O-Ring
P11
6
193
S2208861
Hex. Socket Head Bolt
BB8×20
22
208
C81018524A Spring Supporter SCM435 1
209
S8000320
O-Ring
P32
1
211
C68011683B
Disc Spring
70×32×3.5×5.4
1
Rolex
212
C68011463A Cap(1) SS41 1
213
S2208661
Hex. Socket Head Bolt
BB8×16
8
214
S8010800
O-Ring
G80
2
215
C68011774 Spacer STKM13A 1
216
S6030570 Angular Ball Bearing 5307S 2 NTN
217
C68011474A
Sliding Key
SM45C
1
218
S2201461
Hex. Socket Head Bolt
BB4×8
4
219
P51400004 Conical Washer ZC4 4
220
C68011484A
Balance Key
SM45C
1
222
C81011133
Bearing Supporter (M)
SS41
1
223
S3504701 Set Screw (Slotted) BR8×10 1
224
P78120608
Fixed Orifice
FOC6×0.8
1
225
C81018452A
Shaft Gear
SCM415
1
226
C68011524 Shaft Spacer STKM13A 1
227
S6030080 Angular Ball Bearing 5208S 2 NTN
228
C68011833A
Gear (41Z)
SCM415
1
229
C68011944
Parallel Key
SM45C
2
230
C68011554 Bearing Supporter SS41 1
231
S8010750
O-Ring
G75
1
232
C68011534
Labyrinth
SS41
1
233
C68011543 Labyrinth SS41 1
234
S8011250
O-Ring
G125
1
235
C50019184B
Coupling
Rotex GS-P48
1
KTR
237
P64010040 Parallel Key (W/Tap) KSP10×8×40 2
239
C81018473A Seal Case GC20 1
240
S8012100
O-Ring
G210
2
241
S2210861
Hex. Socket Head Bolt
BB8×110
4
244
C68011493B Shaft SCM415 1
247
C81018493
Bracket. Motor
SS41
1
248
S8011350
O-Ring
G135
1
249
S2215461 Hex. Socket Head Bolt BB12×40 4
250
C81018072
Gear Ass’y
C68011803+C81018053
1
251
C81018053
Gear 21Z
SCM415
1
252
S3520486 Screw. Set(Hex. S/Head) BQ8×12 3
253
S5711062 Pin. Parallel SP8×20 3
254
C68011803
Gear Ass’y
C68011782+C81018072
1

9
HM 1000/1250 HM1000MTE04
No. Parts No. Description Material / Specification Q'ty Remarks
255
C68011813 Gear (76Z) SCM415 1
256
S3520486
Set Screw (Hex. S/Head)
BQ8×12
3
257
S5711062
Parallel Pin
SP8X×20
3
328
S8010650 O-Ring G65 1
※Spindle Head Gear Shifter Parts List
No. Parts No. Description Material / Specification Q'ty Remarks
286 C68011294 Bush S224397 1
287 S3500281 Set Screw (Slotted) BR5×6 1
288 C68011284 Guide Bar SS41 1
289 S8000160 O-Ring P16 1
290 S6500201 Retaining Ring (Shaft) RS20 1
292 C50018232B Cylinder GC250 1
293 S2209261 Hex. Socket Head Bolt BB8×30 3
294 S8010750 O-Ring G75 1
295 P74060006 Hex. Socket Plug FPS-S1/8 6
296 C50018193A Floating Piston SM45C 1
297 C50018203A Piston SCM435 1
299
298
286
287
295
300
288
289
290
306
305
304
303
302
301
292
293
294
295
296
295
297
330
309
308
307
305
302
290
310

10
HM 1000/1250 HM1000MTE04
No. Parts No. Description Material / Specification Q'ty Remarks
298 S6260050 Lock Nut AN05 1
299 S6270050 Lock Washer AW05 1
300 C60011142D Shifter SM45C 1
301 C50018183A Cylinder Cap SM45C 1
302 S2208861 Hex. Socket Head Bolt BB8×20 8
303 S8010400 O-Ring G40 1
304 R56162 SKY Packing SKY-32 1 Sakagami
305 P51400008 Conical Washer ZC8 8
306 C50018584 Collar SS400 1
307 C50018173B Cylinder Cap SM45C 1
308 R56162 SKY Packing SKY-32 1 Sakagami
309 S8010350 O-Ring G35 1
310 C68011324A Dog SS41 1
330 S8000340 O-Ring P34 1
※Hydraulic Flow Diagram of Spindle Head
P
T
Tool
Unclamp
P
T
A
B
P
T
A
B
P
T
A
B
Unclamp
Middle
High
Low
Tool
Clamp
Gear
Shifter
L M H
Φ1.0
Φ1.2
Φ1.0
C
D
E
Sol. C Sol. D Sol. E
Low Off Off On
Middle On Off On
High OFF On Off
C
D
E

11
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.
1) To facilitate work on the tool unclamp cylinder, remove hydraulic hose, coolant hose, air
tube, bracket, and proximity switch bracket.
▪As the HMC spindle has various hoses and devices installed around the tool unclamp
cylinder, it is recommended to take several pictures of the machine in various angles for
helping remember the components' respective position.
2) Pull out the proximity switch bracket.
▪Do not separate the proximity switch from the bracket; just pull out the assembly as a whole.
3) Remove C50019143C oil pan.
▪2-BB6×12
Switch
Bracket
Switch
Bracket
Oil
Pan
Fixing
Bolt

12
HM 1000/1250 HM1000MTE04
4) Remove C50019133B rotating union cap.
▪4-BB6×20
5) Remove C50019123 housing.
▪6-BB5×20
6) Remove R27234 rotating union.
※Note that the bolt on this union is left-
handed. Turn it to the right to loosen.
7) Pull out the C81018753 tool unclamp cylinder assembly as a whole.
※With the spring on the C81018314 bolt inserted, keep the assembly in a safe place.
▪4-C81018314 Bolt, 6-BB12×45
Housing
Rotating
Union
Rotating Union Cap
Rotating
Union Cap
Housing
Fixing Bolt
Fixing
Bolt
Tool Unclamp
Cylinder Ass’y
Fixing Bolt
C81018314

13
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.
9) Remove C81018263Astopper.
※Use the air tool to loosen the bolts (as they are too tight to loosen with an ordinary wrench).
If you have no air tool prepared, use the spanner to loosen the stopper while taking the
driving key on the front of the spindle.
▪16-BB8×20, 16-ZP8
10) Remove C81018732 cylinder base.
▪BB12×40
Stopper
Housing
Fixing Bolt
Set Screw
Housing
Set Screw
Fixing Bolt
Stopper
Lock Nut
Cylinder
Base

14
HM 1000/1250 HM1000MTE04
11) Remove C60016063C housing.
▪4-BB12×70
12) Loosen C68011573B lock-nut.
①Loosen two set-screws (BQ8×16) on two of 16 bolt holes, one for each, which reveal after
you removed C81018263Astopper.
※To help recognize the location of the set-screw, mark the location of the set-
screw
with the applicable disk when loosening it.
②Use the hook spanner 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. When using the chisel and hammer, care
must be taken to minimize scratches on the lock-nut.
13) To help remember the location
when inserting it back, mark the location of C81019143A
disk along with the spindle key before removing it.
※Do not loosen the set-screw that is located in the side of the disk as it is used for
adjusting the spindle balance.
Lock Nut
Housing
Fixing Bolt
Housing
Lock Nut
2-Set Screw
Disk
Disk

15
HM 1000/1250 HM1000MTE04
14) Remove both C81019123B labyrinth and C81019123B labyrinth. Then, pullout the parallel key
(KS10×8×37).
▪6-BB8×25, 2-KS10×8×37
15) The spindle tool unclamp cylinder and labyrinth are removed before removing the spindle
cartridge.
Key
Labyrinth
Labyrinth
Key
Labyrinth
Labyrinth
Spindle
Draw Bar
Ass’y

16
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.
1) Clean up the spindle head and remove the Y-axis
sliding cover.
2) Remove the lubrication tube and other connected tubes and pipes from C81018412Atop
plate of
the upper spindle head.
▪9-BB8×30
※Take caution not to lose the O-ring.
Top Plate
Top Plate

17
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.
4) Loosen the bolts on C12011112 sleeve, and insert 700mm or longer M12 stud bolts (x2) into
the place of the tap (2-M12, for removing the sleeve). While adjusting the balance slowly, pull
out the spindle cartridge.
▪6-BB12×45
※Note that when removing the spindle cartridge, hold the gear with hand through the top plate
hole so that it does not fall off and pull it out one by one when the spindle has passed.
Front Cover
Fixing Bolt
Front Cover
Space
Gear 97Z
Gear 57Z
Gear 63Z
Sleeve
Marking
Spindle Cartridge
Stud Bolt
Gear 97Z
Gear 57Z

18
HM 1000/1250 HM1000MTE04
5) By the time 2/3 of the sleeve has been revealed,
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.
6) Remove the rear spindle bearing from the spindle
head body.
※In principle, replacement of the spindle bearing for HM models should be done under our
control in our workplace where all necessary jigs and tools (shrink-
fit, assembling/disassembling
tools) are equipped. Removing the spindle bearing on site is difficul
t so the assembly is returned
to our workplace with just the spindle cartridge removed.
Bearing
Rope
Stud Bolt
Spindle Cartridge