Doosan HM 1000 User manual

Machine Tools
Installation Manual
(HM 1000/1250)

1
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
3.4 Splash Guard Assembly .................................................................................................................14
3.5 Tool Magazine & ATC Assembly ......................................................................................................16
3.6 Coolant Tank Assembly & Option ....................................................................................................17
4. Installing the machine temporarily......................................................................... 18
4.1 Temporary installation of the column bed (Z-axis bed) assembly ..................................................18
4.2 Temporary installation of the table bed (X-axis bed) assembly .....................................................20
4.3 Temporary Installation of ATC Base .............................................................................................21
4.4 Temporary Installation of APC......................................................................................................22
5. Second Round of Mortar Injection (Grouting) ....................................................... 23
5.1 Inspecting the foundation holes ...................................................................................................23
5.2 Selection of secondary grouting material .....................................................................................23
5.3 Mixing grout ................................................................................................................................23
5.4 Injecting grout .............................................................................................................................24
5.5 Curing the surface of mortar ........................................................................................................25
6. Assembling the main unit ....................................................................................... 26
6.1 Installing the duct ........................................................................................................................26
6.2 Connecting wires and hydraulic hoses .........................................................................................26
6.3 Removing the transit clamps .......................................................................................................30
6.4 Connecting the main power and main air sources ........................................................................31
6.5 Checking and fueling the oil tanks ...............................................................................................31
7. Power On .................................................................................................................. 33
7.1 Main Power Supply .....................................................................................................................33
7.2 Checking the pressure on each unit .............................................................................................34
7.3 Installing the coupling between Y-axis motor and ball screw.........................................................35
7.4 Keep Relay Settings ....................................................................................................................35
8. Machine Leveling ..................................................................................................... 36
8.1 Preparations for the leveling ........................................................................................................36

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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) ........................................... 43
9.3 Resetting the reference point for the Y axis (Y-axis stroke: 1250mm) ........................................... 44
10. Precision Accuracy & Correction ........................................................................ 45
10.1 Straightness of Z axis ................................................................................................................ 47
10.2 Straightness of X Axis ............................................................................................................... 48
10.3 Straightness of Y Axis ................................................................................................................ 50
10.4 Straightness of Pallet Deck........................................................................................................ 52
10.5 Squareness between coordinate axes ....................................................................................... 53
10.6 Parallelism between pallet deck and X/Z axis ............................................................................ 56
10.7 Squareness in division of index table ......................................................................................... 58
10.8 Parallelism between edge locator and X axis ............................................................................. 59
10.9 Distance between base section of edge locator and swiveling center of table............................. 70
10.10 Positioning precision and difference in changing the pallet ....................................................... 71
10.11 Parallelism between center line of spindle and movement of Z-axis ......................................... 72
10.12 Runout on the spindle.............................................................................................................. 73
10.13 Movement of spindle in the Z-axis direction ............................................................................. 73
11. Installing ATC & Alignment .................................................................................. 74
11.1 Installing ATC ............................................................................................................................ 74
11.2 ATC Alignment ........................................................................................................................... 76
12. ATC Alignment ...................................................................................................... 83
12.1 Adjusting APC ........................................................................................................................... 83
12.2 Fixing APC ................................................................................................................................ 85
13. Installing the covers ............................................................................................. 86
13.1 Installing the chip cover (sliding cover) on the bed ..................................................................... 86
13.2 Installing the splash guard ......................................................................................................... 88
13.3 Installing the front cover of the Y axis ........................................................................................ 95
13.4 Installing the footstep and guard of APC .................................................................................... 95
13.5 Installing ATC chip pan and guards ............................................................................................ 99
14. Installing the coolant tank & chip conveyor ......................................................102
14.1 Installing the coolant tank ........................................................................................................ 102
14.2 Connecting the coolant pump components .............................................................................. 103

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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. However, if it's inevitable, take caution
not to affect the machine with the vibration.
▪ Reinforced foundation, reinforced ground, and dustproof screen
2) The minimum bearing power of soil that is required to install the machine is 6 tons/㎡.
3) A 20-ton crane (total weight: 29 tons) with a lifting performance of 5m~6m should be
equipped in the installation site. The installation personnel should take into consideration
the dynamic relation between crane and foundation.
▪ If a crane meeting the above specification is not available, use alternatives such as
car crane, large forklift, etc. for moving the machine.
4) When determining the installation site, refer to the machine layout diagram to secure
room for installing the assemblies (ATC, APC, electric cabinet, hydraulic tank, chip
conveyor, etc) as well as enough room for repair (so that the doors are open/closed
without interruption).
5) Refer to the layout diagram below.
※ The below diagram is a standard machine layout for reference. The actual layout
may differ depending on the machine. Refer to the layout diagram that is specific to
the machine to install.

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HM 1000/1250 HM1000ISE99
※ Ref 1): Front View
※ Ref 2) : Right View
758
2532
2532
965
(967)
3815(4061)
590
(585)
929
(1179)
1493
803
8766

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HM 1000/1250 HM1000ISE99
※ Ref 3) : Top View
10840[120 Tool Magazine]
5822
10216[90 Tool Magazine]
9733(9747)[60 Tool Magazine]
967 4780 3715(4000)
5064
3130(3064)

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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.
② After completion of the foundation work, measure each checkpoint on the foundation
and take an appropriate action (mostly repair) if a problem is found.
2) Foundation work for installing the machine
① Foundation Diagram
※ Note)
1) Models applicable
▪ HM1000
▪ 2100(X) × 1250(Z)
▪ ATC : 60 Tool
▪ APC : ST2100
2) Tolerance for each checkpoint
▪ Top view: ±10mm
▪ Gap between holes: ±10mm
▪ Cumulative gaps between holes :
±20mm
▪ Size of foundation hole: ±10mm
3) Theoretical requirements of foundation
material
▪ First concrete: 16.1m³
▪ Second grout: 1.1m³
4) This diagram is a standard machine
layout for reference. The actual layout
may differ depending on the machine.
Refer to the layout diagram that is
specific to the machine to install.

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HM 1000/1250 HM1000ISE99
※ Detailed Diagram
No. Item No. Definition Mat. / Spec. Q’ty Remark
1 R00314 Stud Bolt
2 B14491044 Nut
3 C40021154A Level Bolt
4 C40021164A Nut
5 C12101233 Level Block
6 C40021183A Anchor
7 S2212461 Bolt BB10×40
8 S5000601 Washer ZP10
9 C68091364A Level Plate
10 C68091374 Collar
11 S3526386 Set Screw BQK6×10
12 C68091353A Anchor Bolt M20×400
13 S4001131 Nut NA20
14 S5001101 Washer ZP20
“A”
-
30 Holes
4
425
Min 45
45˚
80
Φ300
400
65
35
1
2
3
5
6
Section C
-
C
600
Second grout
First concrete
“B”
–
10 Holes
330
Φ240
400
32
260
28
80
7, 8
9
10
11
12,13,14

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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.
3) Use a wrinkle tube of larger than Ø300mm to inject mortar into the second
mortar surface in deeper than 400mm. Important: the tube must be removed
after the first foundation work.
4) The holes for the second mortar work should comply with the specifications in
the detailed diagram above.
5) Prepare nonshrinking grout for the second mortar work.
※ Ref) Grout manufacturers applicable:
▪ Ssangyong Cement: Bascon Plus
▪ Union: Grout GM
▪ Requirement Forecast : 120 sacks or so (25Kg)
6) Refer to the standard layout to check the location of the main power supply
pipe and prepare the wiring between electric cabinet and main power as well
as air service unit as appropriate for the work.
※ All these preparations should be based on "Foundation Work
Specifications”.

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HM 1000/1250 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.
(1) When the machine is delivered on site, check if every one of the units are all included
in the package based on the packing list.
(2) Use the crane or forklift to move the unit while keeping eye on the balance.
(3) In this process, take caution lest that the wire rope or shackles should impact on the
unit, and adjust the length of the rope as appropriate to prevent it from being
unbalanced.
1) Hooking the ropes to the crane
Column & Column Bed Table & Table Bed

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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

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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.
3.1 Column & Column Bed Assembly
Ass’y No. No. Dwg. No. Definition Q’ty Weight Check Remark
1 1 Column Unit 1 11Ton
1 2 C12162282A Top Cover 1
1 3 C1203 Top Cover 1
1 4-1 C12031313 Bracket 1
1 4-2 C12031323 Bracket 1
1 4-3 C12031333 Bracket 1
1 5 Servo Motor (Y) 1
1 6 C12163353 Rear Cover 1
1 7 C12163363 Rear cover 1
1 8 C12141223A Duct 1
1 9 C81021074D Adjusting Liner 2
1 10 C12021124 Packing 2
1 13-1 16 8 11/12
9 25
19
17
18
2
22
5
4-3
4-1
4-2
28
13-2
24
26
20
3
21
7
6
14
15
23
27

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HM 1000/1250 HM1000ISE99
Ass’y No. No. Dwg. No. Definition Q’ty Weight Check Remark
1 11 S2240362 Bolt 6
1 12 P57113050 Pin 2
1 13-1 C12021102B Coolant Pan (L) 1
1 13-2 120221112B Coolant Pan (R) 1
1 14 C12063331 Under Cover (Rear) 1
1 15 C12041313 Jack Bolt 2
1 16 C12021063 Slide Cover (Z) 1
1 17 C12141313 Front Cover (L) 1
1 18 C12031153 Front Cover (R) 1
1 19 C12131243A Packing 1
1 20 C12031253 Packing 1
1 21 C12031243A Cover 1
1 22 C12141433 Cover 1
1 23 C12141323 Oil Pan 2
1 34 C12141423A Cover 1
1 25 C12141053B Duct 1
1 26 C12141153B Duct 1
1 27 C12031112B Rear Cover 1
1 28 C12141252A Working Stand 1
3.2 APC Assembly
51
44
37
33 42 53
39
56 36
50
61
57
52
47
54
41-R
46
38
34
45
41-L
43
55
32 31 35
40 29
30 63-2
49
62
63-1
48

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HM 1000/1250 HM1000ISE99
Ass’y No. No. Dwg. No. Definition Q’ty Weight Check Remark
2 29 C12100001A APC Ass’y 2 1.8on
2 30 C121611743 Floor Work 4
2 31 C121611753 Floor Work 6
2 32 C121611763 Floor Work 2
2 33 C121611773 Floor Work 1
2 34 C121611783 Floor Work 1
2 35 C121611463 Pan Cover 1
2 36 C121611411A APC Pan (C) 1
2 37 C121611421A APC Pan (L) 1
2 38 C121611431a APC Pan (R) 1
2 39 C121611443 APC Pan (Front) 2
2 40 C121611453 APC Pan (Rear) 2
2 41-L C121611473 Cable Duct 1
2 41-R C121611484 Packing 1
2 42 C121611491 Front Guard (L) 1
2 43 C121611501 Front Guard (R) 1
2 44 C121611511 APC Guard (L) 1
2 45 C121611521 APC Guard (R) 1
2 46 C12161153 Switch Cover 1
2 47 R87049 Photo Switch Ass’y 1
2 48 C121611613 Pan Bracket (S) Set 4
2 49 C121611623 Pan Bracket (C) Set 4
2 50 C121611643 Pan Supporter 6
2 51 C121611593 APC Skirt 1
2 52 C121611731A Foot Step 1
2 53 C121611573 Conner Skirt (L) 1
2 54 C121611583 Conner Skirt (R) 1
2 55 C121611603 APC Skirt (L) 1
2 56 C121611563 APC Skirt (R) 2
2 57 C121611553 Front Skirt (L) 1
2 61 C12101213 Connection Bracket 1
2 62 C12101203 Connection Bracket 1
2 63-1 C121611693 Conner Cover(L) 1
2 63-2 C121611703 Conner Cover(R) 1

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HM 1000/1250 HM1000ISE99
3.3 Table Assembly
Ass’y No. No. Dwg. No. Definition Q’ty Weight Check Remark
3 58 C12111011B Pallet 2 2.4Ton
3 60 C12111053A Pallet Cover 4
3 64 C12042083 Slide Cover (Mag.) 1
3 65 C12042073 Slide Cover (OP.) 1
3 66 C12041063 Slide Cover (X) 2
3 67 Table Ass’y 1 7Ton
3 68 C12041173A Bed Cover 1
3 69 C12163273A Bracket 1
3.4 Splash Guard Assembly
88.1
71
79-2
88.2
85.1
85.2
82.1
83.1
74 73 72
84.2 84.1
86
82-2
70
80
83-2
79-1
81-1
78
77-2
76
75 76
77.1 81-2 87
67 66 64 47 60
58
68
69

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HM 1000/1250 HM1000ISE99
Ass’y No. No. Dwg. No. Definition Q’ty Weight Check Remark
4 70 C12160111B Main Guard Ass’y 1
4 71 C12160141C OP Door Ass’y 1
4 72 C12160131A ATC Door Ass’y 1
4 73 C12162103 Chip Cover (L) 1
4 74 C12162303 Chip Cover (R) 1
4 75 C12161653 Connection Cover (C) 1
4 76 C12161663 Connection Cover (2) 2
4 77-1 C12161673 Connection Cover (L) 1
4 77-2 C12161683 Connection Cover (R) 1
4 78 C12161933 Cover 2
4 79-1 C12161313A Rail Cover 1
4 79-2 C12161323A Cover 1
4 80 C12163173A Under Cover 1
4 81-1 C12161102A Rail Support 1
4 81-2 C12161081 Oil Pan (APC) 1
4 82-1 C12161061A Oil Pan (L) 1
4 82-2 C12161071A Oil Pan (R) 1
4 83-1 C12162403 Side Cover 1
4 83-2 C12162413 Side Cover 1
4 84-1 C12162113 Cover 1
4 84-2 C12162423 Pan Cover 1
4 85-1 C12162313 ATC Door Cover 1
4 85-2 C12162453 Cover 1
4 86 C12163263 Under Cover (2) 1
4 87 C12163183 Oil Pan Supporter 1
4 88-1 C12092733A Pan Bracket (1) 1
4 88-2 C12092743A Pan Bracket (2) 1

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HM 1000/1250 HM1000ISE99
3.5 Tool Magazine & ATC Assembly
Ass’y No. No. Dwg. No. Definition Q’ty Weight Check Remark
5 90 Magazine Ass’t 1
5 91 Guard Ass’y (1) 1
5 92 Guard Ass’y (2) 1
5 93 Door 1
5 94 C12092753 Mag. Supporter 1
5 95 C12092763 Mag. Bracket 1
5 96 C12092773A Pan Supporter 10
5 97 C12092021B Magazine Base 1
5 98 C12092662B Mag. Pan (1) 1
5 99 C12092652A ATC Pan 1
5 100 C12092671B Mag. Pan (90Tool) 1
5 101 C12092353B Manifold Cover 1
5 102 C12092682 Mag. Skiet (1) 1
5 103 C12092692B Mag. Skirt (90Tool) 1
5 104 C12092702 Mag. Skirt (R) 1
93
104
100
91
103
96
92
102
98
97
99
90
95
94
101

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HM 1000/1250 HM1000ISE99
3.6 Coolant Tank Assembly & Option
Ass’y No. No. Dwg. No. Definition Q’ty Weight Check Remark
6 105 Chip Conveyor Ass’y 1
6 106 중압 TSC 1
6 107 Oil Skimmer 1
6 108 Coolant Tank Ass’y 1
6 110 Transformer 1
6 115 Coolant Gun Ass’y 1
6 116 Air Gun Ass’y 1
6 117 High TSC (Line) 1
6 118 자동계측장치 1
6 119 자동계측장치 부속품 1 1
120 자동계측장치 부속품 2 1
6 121 High TSC (Paper) 1
6 122 High TSC (Dual) 1
6 123 자동공구길이 장치 1
6 125 Chip Bucket 1
6 126 Shower Coolant 1
115 116
120
119
110
123
117
121
112
118
126
106
107
125

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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.
② Pour water into each hole and let the concrete soak up moisture.
※ Keep the concrete soaked in water for at least 12 hours before injecting mortar,
and drain the water right before the injection. This is to enhance the adhesiveness
of the injected mortar and to prevent the mortar from drying too quickly as well as
to improve the fluidity of the mortar.
▪ If 28 days or more have passed since constructing the foundation concrete, soak
it in water for over 24 hours.
2) Locate the foundation component box from the
shipping package and prepare for installation.
3) Move the Z-axis bed (column bed) assembly
near the installation site.
▪ Weight: Approx. 11 tons
Fill the hole with water and
drain water after 12 hours.