Doosan DBC 130 II Installation Manual
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Doosan DBC 130 II Installation Manual

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DBC 130Ⅱ

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Summary of Contents for Doosan DBC 130 II

  • Page 1 Machine Tools Installation Manual DBC 130Ⅱ...

  • Page 3: Table Of Contents

    DBC 130II DBC130II ISE41 Table of Contents For enhanced performance, this installation manual is subject to change without notice Table of Contents ........................1 1. Installation Site ........................4 2. Foundation work ....................... 9 2.1 Foundation work timing and post checkpoints ............... 9 2.2 Foundation work for installing the machine ..............
  • Page 4 DBC 130II DBC130II ISE41 7.3 Installing the hydraulic power unit, electric cabinet, OP box and ducts ......53 7.4 Wiring ........................55 7.5 Connecting the hydraulic and air hoses ..............59 7.6 Connecting the tool magazine wires and hydraulic hoses ........... 60 8.
  • Page 5 DBC 130II DBC130II ISE41 16.1 Resetting the reference point for the W axis (W-axis stroke : 700mm) ....... 95 16.2 Resetting the reference point for the X axis (X-axis stroke: 3000mm) ......96 16.3 Resetting the reference point for the Z axis (Z-axis stroke: 1600mm) ......97 16.4 Resetting the reference point for the Y axis (Y-axis stroke: 2000mm) ......

  • Page 6: Installation Site

    DBC 130II DBC130II ISE41 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 7 DBC 130II DBC130II ISE41 ※ Ref 2) : Right View ※ Ref 3) : Top View...
  • Page 8 DBC 130II DBC130II ISE41 ※ Ref 4) : Front view of machine to install semi splash guard on (Optional) ※ Ref 5) : Right view of machine to install semi splash guard on (Optional)
  • Page 9 DBC 130II DBC130II ISE41 ※ Ref 6) : Top view of machine to install semi splash guard on (Optional)
  • Page 10 DBC 130II DBC130II ISE41 ※ Ref 7) : Top view of machine to install APC on (Optional)

  • Page 11: Foundation Work

    DBC 130II DBC130II ISE41 2. Foundation work ※ Foundation diagram: Use only the foundation diagram provided by the salesperson. - foundation diagram : “S/O NO._Serial No_drawing no” - Example of foundation diagram: 201077848_MB0003-000084_BG6C21601C ☞ (Note) The foundation diagrams illustrated in this manual are for reference only 2.1 Foundation work timing and post checkpoints 1) It is recommended to take at least a two-month schedule from completion of the foundation work to completion of the installation.
  • Page 12 DBC 130II DBC130II ISE41 ※ 60 Tool Magazine...
  • Page 13 DBC 130II DBC130II ISE41 ※ APC (Option) ※ Cross-sectional View Section View A-A (Cross-section of Foundation)
  • Page 14 DBC 130II DBC130II ISE41 ※ Detailed Diagram C-C (Kicker) Section View Section View B-B (Main Unit Bed) Section View D-D ( Center of Main E-E (APC) Section View Unit Bed) F-F (APC) G-G (APC) Section View Section View...
  • Page 15 DBC 130II DBC130II ISE41 Item No. Definition Mat. / Spec. Q’ty Remark B26491444 BA 24×260 B26491204 Adjust Bush SM45C Final-Set B26491014 Adjust Bush SM45C Pre-Set B26491073A Anchor GC300 B26491143E Level Block GC300 B26491423A Level Plate GC300 B26491213A Hex. Bar(2) SM45C MB36 B26491093B Hex.
  • Page 16 DBC 130II DBC130II ISE41 Note) 1) Reinforce the ground with stake driving, riprap piling and rebar reinforcement. (bearing power of soil: at least 10 tons/m²) 2) Tolerance for each foundation checkpoint ▪ Top view: ±10mm ▪ Gap between holes: ±10mm ▪...

  • Page 17: Transportation

    DBC 130II DBC130II ISE41 3. Transportation The boring machine 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 if using a forklift or crane for transporting purpose.

  • Page 18: What's Included

    DBC 130II DBC130II ISE41 4. What's included 4.1 Table Bed Ass’y Packing Item No. Definition Q’ty Weight remark 17 Ton 160301-00136A TABLE BED ASSY 110961-00144D TRAY;(1) 110958-01660 SUPPORT,TRAY 110961-00145D TRAY;(2) 110958-01660 SUPPORT,TRAY 110961-00146C TRAY;(3) 900115-00582A CONVEYOR,CHIP; 110510-00428B COVER,SLIDE;(X4000)R 110510-00427B COVER,SLIDE;(X4000)L BRACKET,SLIDE 110423-03265A COVER;X-R...
  • Page 19 DBC 130II DBC130II ISE41 Packing Item No. Definition Q’ty Weight remark 110961-00183 COVER;CENTER 110508-11089C COVER,REAR; 110423-03095A BRACKET;TRAY 110958-01647A SUPPORT;TRAY 14-1 110423-03095A BRACKET;TRAY 230104-01477 BUCKET;OIL L56301092B STAND, FLOOR 150119-00381 PAN; OIL...

  • Page 20: Column Bed Ass'y

    DBC 130II DBC130II ISE41 4.2 Column Bed Ass’y Packing remark Item No. Definition Q’ty Weight 11Ton 160301-00144A COLUMN BED ASSY 110510-00495 SLIDE COVER(FRONT) 110961-00150 TRAY(R) 110961-00153C TRAY(L) 101556-00002B REMOVER,CHIP(R) 101556-00348 REMOVER,CHIP(L) 110510-00020A SLIDE COVER(REAR) 250205-00868A BASE PLATE 110423-03229A BRACKET,FRAME 110508-00986B BASE COVER(R) 110508-10915C BASE COVER(L)
  • Page 21 DBC 130II DBC130II ISE41 Packing remark Item No. Definition Q’ty Weight 111001-00063 PROTECTOR; CHIP 110423-03590 BRACKE;PLATE,BASE B13210193A POSITION_BLOCK...

  • Page 22: Column Body Ass'y

    DBC 130II DBC130II ISE41 4.3 Column Body Ass’y Packing remark Item No. Definition Q’ty Weight 190108-00149C COLUMN ASSY 7Ton B26293123 MULTI COVER 160609-02656 FRAME, TOP COVER B26212173C BLOCK(T) 110508-10630 UPPER, COVER 110508-01007B UPPER, COVER 160609-02657 FRAME, SIDE COVER 110517-00573B COVER, SIDE(R-U) 110517-00574B COVER, SIDE(R-B) 110508-10978A...

  • Page 23: Spindle Head Ass'y

    DBC 130II DBC130II ISE41 4.4 Spindle Head Ass’y DBC250II DBC130II Item No. Packi remark Definition Q’ty Weight DBC130II DBC250II ng No. 160401-00176B 160401-00113 SPINDLE HEAD ASSY 2.5Ton B26290123 B26290123 BLOCK,SCALE(Y) 250205-01099 B25116023A PLATE,BACK(2) B14115073A B25116073B GIB,LOWER B14115063A B25116063B GIB,LOWER 250205-01098 B25116013A PLATE,BACK(1) B14115083A...

  • Page 24: Duct Ass'y

    DBC 130II DBC130II ISE41 4.5 Duct Ass’y Packing remark Item No. Definition Q’ty Weight NC, OP BOX B14210193H PUMP,LUBRICATION 400206-00202 COOLER, OIL 160609-02649B FRAME,COOLER 460103-00534A DUCT;(2) 110505-00276A COVER,DUCT;(2) 110505-00274A COVER, FRAME DUCT 460103-00533A DUCT;(1) 110505-00275A COVER,DUCT;(1) 130301-00254A CHAIN,CABLE;Z2000 110958-01897 SUPPORT;CABLE CHAIN 110958-01903 SUPPORT;FRAME 110516-00089...

  • Page 25: Coolant Tank, Chip Bucket, Chip Conveyor, Tsc Ass'y, T/F(Option)

    DBC 130II DBC130II ISE41 B26419323B SUPPORT;DUCT 110505-00321 COVER;DUCT(3) 110505-00277B COVER;DUCT(4) 110505-00278A COVER;DUCT(5) 4.6 Coolant Tank, Chip Bucket, Chip Conveyor, TSC Ass’y, T/F(Option) Packing remark Item No. Definition Q’ty Weight LIFT UP CHIP CONV B26575011 MAIN BODY COOLANT TANK MAIN 450102-00131A BODY C51221011E CHIP BUCKET...

  • Page 26: Tool Magazine Ass'y (Option)

    DBC 130II DBC130II ISE41 4.7 Tool Magazine Ass’y (Option) Packing remark Item No. Definition Q’ty Weight 100702-00154 40TOOLS MAGAZINE 2.4Ton 60, 90 TOOLS 100702-00172 4.5Ton MAGAZINE 860103-00533A FIXTURE;MAGAZINE 860103-00637 FIXTURE;MAGAZINE TOOL MAGAZINE BASE 160101-00277C...

  • Page 27: Semi Splash Guard - Operator Part (Option)

    DBC 130II DBC130II ISE41 4.8 Semi Splash Guard – Operator Part (Option) Packing remark Item No. Definition Q’ty Weight 110508-11061A COVER, TOP 110302-00536A BAR, SAFETY 110955-00203A STEP, OPERATOR 102302-00148B FENCE, OPERATOR(4) 102302-00149B FENCE, OPERATOR(5) 102302-00145B FENCE, OPERATOR(1) 102302-00171A FENCE, OPERATOR(2) FENCE, 102302-00144A ROTATING,OPERATOR...
  • Page 28 DBC 130II DBC130II ISE41 Packing remark Item No. Definition Q’ty Weight ATOR COVER;(2),FENCE,OPER 110508-12695 ATOR COVER;(3),FENCE,OPER 110508-11064 ATOR COVER,OPERATOR 110508-12502 FENCE(5) COVER,OPERATOR 110508-12505 FENCE(1) B31722324 STOPPER, DOOR B31722314 BRACKET, STOPPER 102301-00099B DOOR, OPERATOR(2) 102301-00098A DOOR, OPERATOR(1) B13722023 PLATE B13721313B GLASS(1), SAFETY R70177 HINGE;SPRING ESWSF0013...

  • Page 29: Semi Splash Guard - Magazine Part (Option)

    DBC 130II DBC130II ISE41 4.9 Semi Splash Guard – Magazine Part (Option) Packing Item No. Definition Q’ty Weight remark 910801-00035C ROOF, ATC FENCE 102302-00155B FENCE, ATC(4) 110508-12493A COVER, TOP 110958-02118 SUPPORT 102302-00154A FENCE, ATC(3) 110508-10979A COVER;ATC FENCE 160629-00005 FOOT,LEVELING 1 SET 102302-00172 FENCE, ATC(1) 102302-00151A...

  • Page 30: Semi Splash Guard - Table Part (Option)

    DBC 130II DBC130II ISE41 4.10 Semi Splash Guard – Table Part (Option) Packing Item No. Definition Q’ty Weight remark 102301-00506B DOOR;RATATING(R), TABLE 102301-00507A DOOR;RATATING(L), TABLE 102301-00504A DOOR;SLIDING(R),TABLE 102301-00505A DOOR;SLIDING(L),TABLE 102302-00207 FENCE;TABLE(2) 102302-00206 FENCE;TABLE(1) 102302-00208 FENCE;TABLE(3) 102302-00209 FENCE;TABLE(4) 102302-00210 FENCE;TABLE(5) 102302-00167 FENCE;ROTATING,SEMI TABLE 102302-00168 FENCE;ROTATING,SEMI TABLE...
  • Page 31 DBC 130II DBC130II ISE41 Packing Item No. Definition Q’ty Weight remark 110423-04201A BRACKET, LM BLOCK 110423-04472 BRACKET, LM GUIDE 130503-00023 LM GUIDE; SEMI GUARD 110423-03680 BRACKET;STOPPER 110956-00318 STOPPER,DOOR;TABLE 110508-14722 COVER, LM 250205-01144 PLATE; PACKING(2) 250205-00984A PLATE: PACKING 400606-00675 PACKING 120203-00418 CLAMP 110933-00036 LATCH...

  • Page 32: List Of Tools Related To The Foundation Work (1)

    DBC 130II DBC130II ISE41 4.11 List of tools related to the foundation work (1) Packing Item No. Definition Q’ty Weight remark B26491313A LEVEL BOLT 1 Set (6) STD. B26491334 NUT,HEX STD. B26491514 FIX.BOLT STD. 120112-01326 BOLT/NUT/WASHER SET STD. 120112-01327 BOLT/NUT/WASHER SET SEMI S/G B26491373A WRENCH, SLIDE COVER...

  • Page 33: List Of Tools Related To The Foundation Work (2)

    DBC 130II DBC130II ISE41 4.12 List of tools related to the foundation work (2) Q’ty Packing Item No. Definition Spec Std. 420026 CAN. PAINT(A20) A-PC100 420027 BRUSH. PAINT(A20) A-BR100 B26491014 BUSH. ADJUST B26491044 BRACKET B26491053A BLOCK. ADJUST B26491063C PLATE B26491073 ANCHOR B26491084 NUT.HEX...
  • Page 34 DBC 130II DBC130II ISE41 Q’ty Packing Item No. Definition Spec Std. T6510072 SPANNER. DOUBLE ENDED MB17X19 T6510075 SPANNER. DOUBLE ENDED MB19X22 T6510077 SPANNER. DOUBLE ENDED MB21X23 T6510079 SPANNER. DOUBLE ENDED MB22X24 T6510081 SPANNER. DOUBLE ENDED MB24X27 T6530028 COMBINATION WRENCHES MS36 T6550015 L-WRENCH MP14/SCM3...

  • Page 35: Bolt Kit Shipping List

    DBC 130II DBC130II ISE41 4.13 BOLT KIT Shipping LIST (1) DBC130 STANDARD Spec Option Location Item No. Q’ty R01024 BC6X12,PICR3 STD. DUCT 및 외곽 COVER류 R01009 BC6X12,BO STD. DUCT 및 외곽 COVER류 R01049 BC6X16,PICR3 STD. DUCT 및 외곽 COVER류 R01065 BC6X16,BO STD.
  • Page 36 DBC 130II DBC130II ISE41 (2) DBC130II SEMI SPLASH GUARD OPTION Spec Option Location Item No. Q’ty R01024 BC6X12,PICR3 SEMI DUCT 및 외곽 COVER류 R01009 BC6X12,BO STD. DUCT 및 외곽 COVER류 R01049 BC6X16,PICR3 SEMI DUCT 및 외곽 COVER류 R01065 BC6X16,BO SEMI DUCT 및...
  • Page 37 DBC 130II DBC130II ISE41 Spec Option Location Item No. Q’ty S5100301 SEMI S5100501 SEMI S5100601 ZS10...

  • Page 38: Installing The Machine Temporarily

    DBC 130II DBC130II ISE41 5. Installing the machine temporarily 5.1 Temporary installation of the column bed (Z-axis bed) assembly 1) Put final touches on the secondary mortar holes that were prepared for installing the machine. ① Clean up the inside of the holes. ②...
  • Page 39 DBC 130II DBC130II ISE41 4) Lift up the Z-axis bed (column bed) assembly using the crane or forklift, and move it near the temporary installation area. ▪ Weight: approx. 11 tons ▪ Rope-hooking position: 4 places in both sides of the bed 5) Smooth the surface of the level block installation area.
  • Page 40 DBC 130II DBC130II ISE41 7) Insert B26491143b level block, B26491423 level plate and B26491073 anchor into the anchor bolt as appropriate and tighten the bolt. ▪ To facilitate the work, install the level plate first and insert the level block between bed and level plate.

  • Page 41: Temporary Installation Of The Table Bed (X-Axis Bed) Assembly

    DBC 130II DBC130II ISE41 9) Place the level in the grinding side of both ends of the bed in the X and Z directions, set the height between floor and bottom of the bed at about 75mm (so that the level plate is located 10mm ~40mm under the ground) using the temporary bolt.
  • Page 42 DBC 130II DBC130II ISE41 3) Insert B26491014 adjusting bush and B26491204 washer into each anchor hole in the bed one after the other before inserting B26491444 anchor bolt. Then, insert B26491143b level block, B26491423 level plate and B26491073 anchor into the anchor bolt in this sequence and tighten the bolt.
  • Page 43 DBC 130II DBC130II ISE41 7) Based on the bolts (especially, reamer bolts) between X-axis and Z-axis beds, use the temporary bolt to set an approximate height. Place the level in the grinding side of either ends of the bed in the X and Z directions, and use the temporary bolt to perform the leveling until the overall difference of the leveling falls below 0.05mm/m.

  • Page 44: Temporary Installation Of Atc Base

    DBC 130II DBC130II ISE41 9) Refer to "Foundation Detailed Diagram” above to install a total of 6 adjusting blocks on the ends of X and Z beds. Bracket Bolt Adjust Block Adjust Bracket Block 5.3 Temporary Installation of ATC Base 1) Dismantling the tool magazine base Place the tool magazine vertically using the crane and loosen the fixing bolts between tool...
  • Page 45 DBC 130II DBC130II ISE41 4) Installing the tool magazine base temporarily Based on the bolt holes in the tool magazine bracket, place the tool magazine base on the block under the temporary bolt site. Place the level on the tool magazine base in the X and Z directions.

  • Page 46: Second Round Of Grout Injection

    DBC 130II DBC130II ISE41 6. Second Round of Grout Injection ※ When the temporary installation is completed, inject grout into the column bed, table bed and the foundation holes of ATC base before curing the surface. This process is very important because it affects the accuracy, strength and lifecycle of the machine and more.

  • Page 47: Blending The Grout Mixture

    DBC 130II DBC130II ISE41 6.3 Blending the grout mixture 1) Mix grout and water appropriately for more than 2 minutes using a motorized hand mixer or a mechanical mixer in compliance with the instructions provided by the grout maker. ▪ Pour a specified amount of water in the container and mix well while pouring grout slowly.

  • Page 48: Injecting The Grout Mixture

    DBC 130II DBC130II ISE41 6.4 Injecting the grout mixture 1) Pour the grout mixture in a single direction from one side of the foundation hole so that the mixture can fill in the hole evenly without the buildup of air bubbles. 2) Grout compacting Use a pipe or long thin pole to keep stirring in the grout mixture so that the mixture fills up the...

  • Page 49: Curing The Surface Of Grout

    DBC 130II DBC130II ISE41 6.5 Curing the surface of grout 1) Keep supplying an adequate amount of water on the surface in the course of grout curing. ▪ It is recommended that the surface be covered with a wet cloth to slow down moisture evaporation.

  • Page 50: Assembling The Main Unit

    DBC 130II DBC130II ISE41 7. Assembling the main unit 7.1 Installing the column 1) Placing the column vertically ① Insert a couple of bars into the side holes, or insert the rope through the side holes and move the column to a wider area using the crane where you can place it vertically.
  • Page 51 DBC 130II DBC130II ISE41 ③ Lift up the column and lower it onto the top of the column base. Stop lowering the Reamer column when it nearly contacts on the Bolt base, and tighten the reamer bolts first and go on with the other bolts. Then, resume lowering the column onto the bed.

  • Page 52: Installing The Spindle Head

    DBC 130II DBC130II ISE41 7.2 Installing the spindle head 1) Hook a rope (weight load: 3 tons or greater, length : 2M over) between eyebolts on the top of the spindle head and crane. Loosen the bolts from the spindle head fixture and move the spindle head in a wider area.
  • Page 53 DBC 130II DBC130II ISE41 5) Install the reference gib first, and tighten the bolt loosely. Back Plate Reference 6) Clean up the taper gib and apply grease before installing it. Back Plate Taper Gib 7) Connect the lubricant pipes that are already arranged on the top and bottom of the spindle head to the sleeve of each applicable gib.
  • Page 54 DBC 130II DBC130II ISE41 ※ If this process does not proceed as intended, insert a strong support between spindle head and column base and remove the eyebolt. Then, turn on the machine and lower the ball Support screw nut in Handle mode to mount it onto the spindle head.

  • Page 55: Installing The Hydraulic Power Unit, Electric Cabinet, Op Box And Ducts

    DBC 130II DBC130II ISE41 7.3 Installing the hydraulic power unit, electric cabinet, OP box and ducts 8 Cable 3 Duct 7 Piping Chain Support Frame 2 Duct 4 Duct 5 Duct 1 Electric Cabinet 6 Duct 7 Piping Frame 8 Cable Chain Support 3 Duct 1 Electric...
  • Page 56 DBC 130II DBC130II ISE41 1) Put cable chain support #8 into place and install it into the column bed. 2) Adjust the position and height of duct #3 so that it aligns with the cable chain support. 3) Move piping frame #7 into place where the hydraulic unit, oil cooling unit and lubricant unit are already installed.

  • Page 57: Wiring

    DBC 130II DBC130II ISE41 7.4 Wiring Untie the provided wires (that ship tied by the unit) and put them in order so that you can connect them in their respective position correctly. 1) Arranging wires from the table bed 2) Arranging wires around the column Stretched-out wires 3) Connecting wires to the spindle head Stretched-out wires...
  • Page 58 DBC 130II DBC130II ISE41 4) Wiring in the connection unit of the electric cabinet (1) Apply power in the duct's direction (Power supply direction) (2) Apply power in the upper direction (3) Apply power in the lower direction 5) Connecting the wires inside the electric cabinet Connecting the wires Connecting the power cable and inside the electric cabinet...
  • Page 59 DBC 130II DBC130II ISE41 6) Connecting the wires to each applicable servo motor Servo Motor in the Z axis Servo Motor in the X axis Servo Motor in the W axis Servo Motor in the Y axis 7) Arranging wires for the column bracket 8) Connecting the scale feedback cables to each axis X axis Y axis...
  • Page 60 DBC 130II DBC130II ISE41 Z axis...

  • Page 61: Connecting The Hydraulic And Air Hoses

    DBC 130II DBC130II ISE41 7.5 Connecting the hydraulic and air hoses When connecting the hoses, ensure that the number marked on the manifold matches with the number tag attached to the hose. Make connection one by one in an orderly manner and take caution not to leak the oil pressure.

  • Page 62: Connecting The Tool Magazine Wires And Hydraulic Hoses

    DBC 130II DBC130II ISE41 4) Air Hose Scale Air 7.6 Connecting the tool magazine wires and hydraulic hoses Put the tool magazine on the top of ATC base, or move the wires and hoses close to the base and plug in the connectors and connect the hoses: hydraulic, lubricant and air. Hyd.

  • Page 63: Removing The Transit Clamps

    DBC 130II DBC130II ISE41 8. Removing the transit clamps Remove the transit clamps that are designed to prevent the slippery table or column base by factory default. Z axis fixture X-axis (front) fixture X-axis (rear) fixture X-axis (rear) fixture Front fixture in X axis X-axis rear fixture Z axis fixture...

  • Page 64: Checking And Fueling The Oil Tanks

    DBC 130II DBC130II ISE41 9. Checking and fueling the oil tanks 9.1 Hydraulic tank 1) Position: Piping Frame 2) Type of Oil: HM32 Oil 3) Fueling Capacity: 37.5L 9.2 Oil Cooler Tank 1) Position: Piping Frame 2) Type of Oil: FC10 Oil 3) Fueling Capacity: 45L 9.3 Table 1) Position: Rear of the table base...

  • Page 65: Spindle Air Oil Tank

    DBC 130II DBC130II ISE41 9.5 Spindle Air Oil Tank 1) Position : Front of the spindle head tail bracket 2) Type of Oil: FC10 Oil 3) Fueling Capacity: 2L ※ If you fill the oil mist tank over the upper limit marked on the tank, the mist oil may not be supplied properly.

  • Page 66: Connecting The Main Power And Air Sources

    DBC 130II DBC130II ISE41 10. Connecting the main power and air sources 10.1 Connect the main power source 1) Connect the wires from the switch board to the terminal block of the main NFB in the electric cabinet. ▪ Power Capacity : 65KVA ▪...
  • Page 67 DBC 130II DBC130II ISE41 ※ Precautions on connection from air sources to machine (1) Make sure the air pipeline from the site ceiling is bent upwards before running it down to the machine. See the figures below. Do not run the pipeline to a side or straight down to the machine.

  • Page 68: Power On

    DBC 130II DBC130II ISE41 11. Power On 1) Check if the main power supply, hydraulic hoses, wires and connectors are properly connected before switching on the main NFB. 2) To check the rotating direction, press a contact point of KM31 magnate in the electric cabinet with a wrench or screwdriver, which will drive the hydraulic pump by force.

  • Page 69: Checking The Pressure On Each Unit

    DBC 130II DBC130II ISE41 12. Checking the pressure on each unit 1) Hyd. Power Unit : 55Kg/㎠ (55bar) (to be changed to a hydraulic pump) 2) Main Air : 0.5∼0.6MPa (5~6bar) 3) Oil Cooler : 0.7MPa (7bar) 4) Pressure of the lubrication pump: 15Kg/cm²(15bar) Check when the pump is operating.
  • Page 70 DBC 130II DBC130II ISE41 5) Table Lubrication Pump : 1.0Kg/㎠ (1bar) Lub. Table Lub. Pressure Gear Box 유압 Pump valve 6) Oil pressure on the table gear box: 10Kg/cm² (10bar) Pressure Gage 7) Spindle Air Oil Operation Pressure:16bar 8) Scale Air Operation Pressure: 1 bar Adjust the pressure using the wheel as shown.

  • Page 71: Assembling And Adjusting The Y Axis

    DBC 130II DBC130II ISE41 13. Assembling and adjusting the Y axis 13.1 Installing the ball screw nut in the Y axis 1) Take the Y-axis ball screw nut by hand and lower the Y axis slowly in "-" direction in Handle mode until it arrives on the installation site on the spindle head.

  • Page 72: Installing The Reference Gib

    DBC 130II DBC130II ISE41 13.3 Installing the reference gib When you have completed adjusting the taper Reference-gib Fixing Bolts (x2) gib, tighten the bolts on two reference gibs. 13.4 Installing the ball screw nut 1) Move the Y axis to "Y0". 2) Slightly loosen the ball screw nut fixing bolts on the Y axis.

  • Page 73: Machine Leveling

    DBC 130II DBC130II ISE41 14. 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 74 DBC 130II DBC130II ISE41 1) Move the machine to the coordinates of X1500. 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 75 DBC 130II DBC130II ISE41 3) Place the completed level in the center of the table deck in the X and Z directions. Then, feed the X axis to the coordinates of "X0, X750., X1500., X2250., X3000." in five distinct steps. Adjust the level block bolt to set the leveling roughly.
  • Page 76 DBC 130II DBC130II ISE41 5) Adjust the level bolts in the center of the bed. ▪ Table Bed: x3, Column Bed: x4 ① Push in the special block [(Fix. Bolt) located under each of 7 level bolts in the centers of table bed and column bed] through the center hole. ②...
  • Page 77 DBC 130II DBC130II ISE41 6) Place the completed level in the grinding side of the column in the X and Z directions. Then, while feeding the Z axis to the coordinates of "Z0. Z400. Z800. Z1200. Z1600." in five distinct steps, perform the leveling in the same way with the X-axis leveling above.
  • Page 78 DBC 130II DBC130II ISE41 ※ The above sample is the common instruction for reading the absolute value. As straightness is a general concern when installing the boring machine, it is easier for you to read only one-end gradation and compare five measuring points. ▪...

  • Page 79: Precision Accuracy & Correction

    0.030 / m PALLET #2 ▼ ▼ 0.001 PALLET #1 0.001 0.030 / m PALLET #2 0.001 ▶ Squareness between coordinate axis 0.001 0.020 / 500 0.001 0.020 / 500 0.001 0.020 / 500 M.DMF-Q7200-5(1992.2.10) A4(210×297mm) Doosan Infracore Co., Ltd.
  • Page 80 0.001 0.020 / 300 PLAN ▶Shaking inside the main spindle hole Front end 0.001 0.015 of the spindle 0.001 0.030 At 300 m m ▶Displacement of main spindle movement to Z axis 0.001 0.020 M.DMF-Q7200-5(1992.2.10) A4(210×297mm) Doosan Infracore Co., Ltd.

  • Page 81: Straightness Of Z Axis

    DBC 130II DBC130II ISE41 15.1 Straightness of Z axis 1) X－Y 2) Y－Z ⓐ Measure Install the level on the grinding side of the column in the X- and Z-axis direction and set the reference point. Feed the Z axis in 3-divided stroke and check the greatest Z axis difference of the level changes.

  • Page 82: Straightness Of X Axis

    DBC 130II DBC130II ISE41 15.2 Straightness of X Axis 1) X - Y 2) Y - Z ⓐ Measure Install the level in the center of the table deck in the X- and Z-axis directions and position it so that you can read the level gradation.

  • Page 83: Straightness Of Y Axis

    DBC 130II DBC130II ISE41 15.3 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. Move the Y Indicator Y axis axis to measure the parallelism.

  • Page 84: Straightness Of Pallet Deck

    DBC 130II DBC130II ISE41 2) Y - Z ⓐ Measure Install the square vertically on the pallet deck in the Z-axis direction and install the indicator on the spindle head. Move the Y axis to measure the parallelism. Set both Y axis ends of the square to “0”...

  • Page 85: Squareness Between Coordinate Axes

    DBC 130II DBC130II ISE41 15.5 Squareness between coordinate axes 1) X – Y Squareness ⓐ Measure Place the square on the table 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 86 DBC 130II DBC130II ISE41 2) Y – Z squareness ⓐ Measure Place the square on the table 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 87 DBC 130II DBC130II ISE41 (9) Wrap a thin tool (ex: scraper) with a clean cloth to wipe up the bottom of the column and the grinding side of the column bed. ※Clean it up. Even a slightest lubricant is not allowed to remain. (10) Insert the sliding plate back to the original and remove the screw jack.

  • Page 88: Parallelism Of Movement To X/Z Axis, Parallelism Of Pallet Deck, And Shaking Of Index Table

    DBC 130II DBC130II ISE41 ⓑ Correct You can use the bed positioning kicker between table bed and column bed to adjust the squareness between two beds. (1) Loosen the anchor nut on the column bed. (2) Check the mis-positioned direction and Adjusting Bolt use the kicker adjusting bolt to push the bed.
  • Page 89 DBC 130II DBC130II ISE41 ▪ To perform the scraping of the table base sliding plate ☞ Preparations: Scraper, whetstone, minium, screw jacks (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 90 DBC 130II DBC130II ISE41 2) Z-axis direction ① Measure Move the W axis to "0". Install the indicator at the end of the spindle and place the height measuring block 500mm away from Indicator Z axis the table center in the X and Z directions before setting the reference point.

  • Page 91: Squareness In Division Of Index Table

    DBC 130II DBC130II ISE41 3) Shaking of the table ① Measure Install the indicator at the end of the spindle and place the height measuring block 500mm away from the table center in the X and Z directions before setting the reference point ("0").

  • Page 92: Parallelism Of The X-Axis Movement For The T-Slot

    DBC 130II DBC130II ISE41 ② Correct As the angle division of the index table is performed using the precise position coder and mechanical devices, it is unlikely to make an error. However, if you encounter a significant error, that's because the position coder or mechanical device inside the table is contaminated with dust and impurities, or it is defective, damaged, or worn out.
  • Page 93 DBC 130II DBC130II ISE41 (If the item is already filled with a certain figure, just press +Input). ▪ Resetting the locating push position The locating pin or bush may be mis-positioned Positioning Fixing from the B-axis reference point or from the right Bolt angle (0˚, 90˚, 180˚, 270˚) due to such as an impact on the table.

  • Page 94: Parallelism Between Center Line Of Spindle And Movement Of Z-Axis

    DBC 130II DBC130II ISE41 15.9 Parallelism between center line of spindle and movement of Z-axis 1) X-Z ① Measure Insert the test bar into the spindle and move the X axis up to 300mm away to measure the runout on the highest point (stop moving the Y axis at the highest point).
  • Page 95 DBC 130II DBC130II ISE41 ② Correct ▪ As this has much to do with squareness between Y-axis column and Z-axis column bed, and squareness between center line of the spindle and Y-axis column, measure the Y-Z squareness at first. Then go on to the Y axis gib if no error is found.

  • Page 96: Run-Out On The Spindle

    DBC 130II DBC130II ISE41 15.10 Run-out on the spindle 1) How to measure 300 Position Mouth 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 spindle in a low speed, measure the Spindle Rotation...

  • Page 97: Resetting The Reference Point For Each Axis

    DBC 130II DBC130II ISE41 16. Resetting the reference point for each axis 16.1 Resetting the reference point for the W axis (W-axis stroke : 700mm) 1) Return the W axis to the reference point Spindle Head manually. Boring Spindle Milling Spindle 2) Install the indicator at the end of the table deck.

  • Page 98: Resetting The Reference Point For The X Axis (X-Axis Stroke: 3000Mm)

    DBC 130II DBC130II ISE41 16.2 Resetting the reference point for the X axis (X-axis stroke: 3000mm) 1) Return the X axis to the reference point manually. 2) In MDI mode, move the X axis to the middle stroke position (X1500). 3) Install the test bar into the spindle and move the W axis to "W0.".

  • Page 99: Resetting The Reference Point For The Z Axis (Z-Axis Stroke: 1600Mm)

    DBC 130II DBC130II ISE41 10) Move the X axis to set the indicator (currently contacting on the test bar) to 0. 11) Check the current position of the X axis from the "Machine Position" screen of the OP, and figure out the difference between current position and "X1500.". Then, move the X axis half of the difference.
  • Page 100 DBC 130II DBC130II ISE41 5) Check the current position of the Z axis from the "Machine Position" screen of the OP, and enter the difference between current position and "Z290." in the "parameter #1850 Z" field. ▪ To change the Z-axis grid shift parameter Read the machine position (coordinates) displayed on the OP screen.

  • Page 101: Resetting The Reference Point For The Y Axis (Y-Axis Stroke: 2000Mm)

    DBC 130II DBC130II ISE41 16.4 Resetting the reference point for the Y axis (Y-axis stroke: 2000mm) 1) Insert the test bar into the spindle. Block Indicator Test Bar Gauge 2) Put the block gauge (over 150mm) on the pallet deck, and install the indicator on it. Then, set the height of the block gauge to “0”.

  • Page 102: Adjusting Atc

    DBC 130II DBC130II ISE41 17. Adjusting ATC 17.1 ATC installation & leveling ※ Adjusting ATC should be performed after all of machine leveling, static accuracy work and resetting the reference point for each axis are completed. 1) Move the Y, Z and W axes to their respective secondary reference point. ( “MDI”...
  • Page 103 DBC 130II DBC130II ISE41 ② Front/Rear Position Use the front/rear positioning bolts to adjust the front/rear position and straightness of the rail spreading between ATC rail and column. ▪ If there is a difference between upper and lower sections of the rail, use the height bolt to adjust the height before proceeding with the front/rear position and straightness.

  • Page 104: Carriage Magazine Side Home Position Setting

    DBC 130II DBC130II ISE41 17.2 Carriage Magazine Side Home Position Setting 1) Insert the centering fixture between magazine pot (3) and changer gripper (2). 2) Move the changer to the magazine pot manually (jog mode). 3) Open the door of the electric cabinet and find the carriage AMP that is located in the inner front side.
  • Page 105 DBC 130II DBC130II ISE41 ② On the [ rd-off ] screen, set the DOWN key as a functional key to set the reference point. Reference Setting Mode ③ On the [Org.S - - ] screen, press and hold the SET key for 10 seconds. If you press and hold the SET key for 10 seconds on the [Org.S - - ] screen, the screen will blink and switch to [r0001].
  • Page 106 DBC 130II DBC130II ISE41 ③ On the [Jog.run] screen, press the SET key. jog run mode ④ On the [Jr.0000] screen, use the up/down arrow keys to feed the changer in a desired direction, and adjust the changer position for the pot.
  • Page 107 DBC 130II DBC130II ISE41 ⑥ On the [Jog.run] screen, press the MODE key. Ready to operate the jog ⑦ Back on the [ rd-off ] screen, press the up arrow key. Original mode run ⑧ On the [Org.S - - ] screen, press and hold the SET key for 10 seconds.

  • Page 108: Setting The Reference Point For The Tool Magazine Pot

    DBC 130II DBC130II ISE41 17.3 Setting the reference point for the tool magazine pot 1) Enter the pot number (for the changer position of the tool magazine) in parameter 8 on the servo AMP. 2) Insert the centering fixture between magazine pot (3) and changer gripper (2).
  • Page 109 DBC 130II DBC130II ISE41 4.1) Check the center position using the centering fixture above, and if it fits correctly: ① Press the MODE key on the start screen [r0000] of the servo drive to switch to the diagnosis mode. Diagnosis mode ②...
  • Page 110 DBC 130II DBC130II ISE41 ② On the [rd-off] screen, set the DOWN key as a functional key to set the reference point. Switch to the jog run mode ③ On the [Jog.run] screen, press the SET key. Jog run mode ④...
  • Page 111 DBC 130II DBC130II ISE41 ⑤ When the centering of the tool magazine's tool pot is complete, press the SET key. Return to the jog run mode ⑥ On the [Jog.run] screen, press the MODE key. Ready to operate the jog run ⑦...

  • Page 112: Fine-Tuning The Spindle Side Of The Changer Arm

    DBC 130II DBC130II ISE41 17.4 Fine-tuning the spindle side of the changer arm 1) Remove the driving key from the spindle and insert the centering fixture (3) and changer gripper (2) as well. 2) In jog mode, move the changer to the spindle side position.
  • Page 113 DBC 130II DBC130II ISE41 ③ On the [ALH --] screen, press the MODE key to display [0.0.0000]. Parameter setting mode ④ On the [0.0.0000] screen, press the MODE key to display [0.0.4095]. Parameter setting mode (0.0.: Parameter 0번) (4095: Setting value for parameter #0) ⑤...

  • Page 114: Setting Parameter #7 & Changer Movement

    DBC 130II DBC130II ISE41 17.5 Setting Parameter #7 & Changer Movement Movement (mm) Movement (mm) Offset (Pulse) Offset (Pulse) 1 mm 432.7 10 mm 4327.5 2 mm 11 mm 865.5 4760.2 3 mm 12 mm 1298.2 5193.0 4 mm 1731.0 13 mm 5625.7 5 mm...

  • Page 115: Installing The Covers

    DBC 130II DBC130II ISE41 18. Installing the covers ※ Put together or install the component parts such as covers, brackets, oil pans, fence, splash guards, chip conveyor, coolant tank and footsteps (all of which were removed for transportation of the machine) back in the original position. (The cover assembly is subject to change for enhanced performance or customers can change it to their preference.) 18.1 Installing the table bed covers...

  • Page 116: Installing The Column Bed Covers

    DBC 130II DBC130II ISE41 18.2 Installing the column bed covers Oil Pan (L) Slide Cover (R) Tray (L) Base Cover Slide Cover (R) Tray (L) Base Oil Pan (L) Plate Oil Pan (R) Chip Remover Base Cover Chip Tray Protector Bracket Slide Cover (F)

  • Page 117: Installing The Column Covers

    DBC 130II DBC130II ISE41 18.3 Installing the column covers Upper Cover Top Cover Frame Side Cover(L-U) Hose Cover Cable Chain Support Side Cover(L-B) Side Cover Frame Side Cover(R-U) Upper Front Cover Cover (U) Front Cover (B) Front Cover (R-U) Side Cover(R-B) Front Cover Multi...

  • Page 118: Installing The Semi Splash Guard (In The Table Side)

    DBC 130II DBC130II ISE41 18.4 Installing the semi splash guard (in the table side) Fence3 Fence1 Fence2 Table Door Fence4 Fence3 Table Fence(4) Fence Table Cover Table Fence(3) Rotating Semi Table Fence Table Fence(2) Sliding Table Door Table Fence(5) Door(R) Table Fence(3) Table...

  • Page 119: Installing The Semi Splash Guard (In The Operator Side)

    DBC 130II DBC130II ISE41 18.5 Installing the semi splash guard (in the operator side) Operator Fence (1,2) Operator Fence (4) Safety Rotating Operator Operator Top Cover Step Fence OP Door Roof Operator Fence(3) Operator Fence(2) Operator Fence(1) Operator Operator Operator Door(2) Fence(4) Door(1)

  • Page 120: Installing The Semi Splash Guard (In The Chip Conveyor Side)

    DBC 130II DBC130II ISE41 18.6 Installing the semi splash guard (in the chip conveyor side) Top Cover ATC Fence(2) ATC Fence Roof Top Cover Bracket ATC Fence(1) Rotating Fence ATC Fence Roof ATC Fence ATC Fence(2) ATC Fence Cover Support...

  • Page 121: Installation Complete

    DBC 130II DBC130II ISE41 19. Installation Complete...
  • Page 122 DBC 130II DBC130II ISE41 Revision History Installation Manual DBC 130Ⅱ Version Year/Month Revision history Created by sanghyun.jung yeonghee.lee 2013. 09 Official draft (DBC130ⅡISK39) minwoo.seo youngkuen.jung Addition to Scale air setting youngkuen.jung 2013. 12 (DBC130ⅡISK3C) Hyungil.shin Addition to Air Consumption& Precautions on Samyoung,Jung 2014.01 connection from air sources...

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