DBM2540 - MD0036ISE204 - English

Installation Manual
DBM2540
DOOSAN Machine Tools MD0036ISK204

Contents
CONTENTS
1. Preparation Before Machine Shipping ................................................................................ 3
1.1 Selection of Machine Installation site ............................................................................... 3

1.2 Machine Layout ............................................................................................................... 4
1.3 Foundation Work ............................................................................................................. 6
1.4 Foundation Drawing......................................................................................................... 7
1.5 Preparations Before Shipping Machine .......................................................................... 13
2. Machine Transport.............................................................................................................. 15
2.1 Main Transportation Unit Setup...................................................................................... 15

2.2 Unloading Machine Units ............................................................................................... 18
2.3 Unit Packing List ............................................................................................................ 19
3. Temporary Installation of Machine .................................................................................... 38
3.1 Temporary Installation of Bed......................................................................................... 38

3.2 Temporary Installation of Column Base & Column ......................................................... 42
4. 2nd Grout Injection............................................................................................................. 45
4.1 Pre-Checking of Foundation Holes ................................................................................ 45

4.2 Preparing Grout Material................................................................................................ 46
4.3 Grout Kneading ............................................................................................................. 47
4.4 Grout Injection ............................................................................................................... 48
4.5 Grout Curing .................................................................................................................. 49
5. Assembling the Machine.................................................................................................... 50
5.1 Cooling unit, hydraulic unit, and other units.................................................................... 50

5.2 Connecting the cables inside the electric cabinet ........................................................... 52
5.3 Connecting Various Units’ Cables .................................................................................. 54
5.4 Connecting Main Power and Main Pneumatic Source ................................................... 58
5.5 Disassembling Shipping Fixtures ................................................................................... 60
6. Power On ............................................................................................................................ 63
6.1 Turning On Main Power ................................................................................................. 63

6.2 Checking the Pressure of Each Part after Turning on Power ......................................... 65
1
Contents
7. Machine Accuracy Adjustment ......................................................................................... 66
7.1 Machine Leveling .......................................................................................................... 66

7.2 Machine Origin Setting .................................................................................................. 73
7.3 Machine Accuracy Measurement and Adjustment ......................................................... 76
8. AAC(Auto Attachment Changer) ......................................................................................103
8.1 AAC Alignment Related M-Code & Keep Relay ............................................................103

8.2 Check AAC (Auto Attachment Changer) Dummy Head’s alignment ..............................105
8.3 Alignment status check of AAC (Auto Attachment Changer) 90-degree Angle Head ..... 111
9. ATC Adjustment ................................................................................................................118
9.1 Assembling the Tool Magazine ..................................................................................... 118

9.2 Preparations for Adjusting ATC Unit Alignment .............................................................120
9.3 Adjusting Dummy Head’s ATC Alignment .....................................................................123
9.4 90º Angle Head Adjustment ..........................................................................................127
10. G120 (Five Face Automatic Offset) Auto Measurement................................................134
10.1 Preparations ...............................................................................................................134

10.2 Preparation for measurement .....................................................................................135
10.3 Measurement Using G120..........................................................................................137
11. Assembling the Cover.....................................................................................................140
11.1 Deploying Various Covers ..........................................................................................140

11.2 Assembling Covers for Crossing Parts ........................................................................141
12.3 Assembling Side chip, Conveyor, and Side Step ........................................................142
11.4 Assembly of X axis slide cover....................................................................................146
11.5 Assembling Frame, LM Rail Bracket ...........................................................................148
11.6 Assembling Covers for the Column and the ATC Door ................................................151
11.7 Assembling Semi Splash Guard..................................................................................154
11.8 Assembling AAC Door Cover ......................................................................................162
11.9 Assembling Magazine Fence Ass’Y ............................................................................166
11.10 Sealing Semi Splash Guard ......................................................................................168
2
1. Preparation Before Machine Shipping

1.1 Selection of Machine Installation site
1) Environmental Conditions
Avoid direct sun-light, high ambient temperature, temperature variation, and the place
where lots of dusts exist when selecting the machine installation location. A place with
lower vibration would be preferred, but, if vibration is unavoidable, take necessary action
not to impact the machine.
① If the ground is not rigid enough, soil reinforcement must be performed.
▪ Take into account the foundation reinforcement, soil reinforcement, and concrete
piling according to the ground conditions.
② If vibration of roads or other machinery affects the machine installation place,
construct anti-vibration membranes around the foundation ground.
③ Avoid dusty and strongly corrosive gas areas.
④ Prepare a separate power supply line if the installation place is near the equipment
such as high frequency generators, electric discharge machines, electric welders,
and other equipment which require much power.
⑤ Avoid places near direct sunlight and heat source, and areas of excessive
temperature change.
▪ Operating temperature range: 5 to 40 °C (avoid sudden temperature change; e.g.
1 °C/30 min)
▪ Allowable range of temperature change: ±2°C/24Hr or lower (less than 1°C per 30
mins)
▪ Humidity: 30-75% (no condensation)
▪ Temperature difference in the floor to 5 meters height range: within 1 ° C
⑥ The ideal machine operating environment requires the maintenance of 40 - 75%
humidity and 20℃.
2) Selecting a Location
① When selecting the foundation position, please refer to the machine layout chart to
secure the place for the assembly part (ATC, electric cabinet, hydraulic tank, chip
conveyor, etc.) in addition to the wall and machine body, as well as sufficient space
for maintenance (space where various doors can be opened). (An enough space for
assembling chip conveyor should be obtained between machines.)
② The building in which this machine will be installed requires a crane with a capacity of
over 30 tons and a lifting height of 12 m or higher. Also, there is a need to examine
the relationship between the crane travel position and the base position.
▪ If a crane as described above is not available, measures should be worked out to
secure other lifting vehicles such as a car crane of 100-ton class.
3
1.2 Machine Layout
1) Front view
4
2) Top View
3) Right View
5
1.3 Foundation Work
1) Caution
① Conduct foundation reinforcement, soil reinforcement, and concrete piling according
to the ground conditions.
② Conduct sufficient bar reinforcement to obtain sufficient foundation strength.
③ The required bearing capacity of soil is 10 ton/㎡ or higher.
④ Floor flatness should be at least 10 mm/m.
2) Foundation Work
① It is ideal to cure concrete for at least 2 months from the completion of foundation to
machine installation.
② Before receiving the machine, inspect each part of the foundation and if there is a
problem, the repair must be completed.
6
1.4 Foundation Drawing
1) Foundation Drawing (DBM2540)
7
2) Foundation Work (DBM2540)
8
3) Foundation Drawing (DBM2550)
9
4) Foundation Work (DBM2550)
10
5) Foundation Details (DBM2540 & 2550)
▪ DBM 2540 : Anchor Level Bolt = 30ea(Detail ‘H’), Level Block = 18ea(Detail ‘I’)
▪ DBM 2550 : Anchor Level Bolt = 34ea(Detail ‘H’), Level Block = 22ea(Detail ‘I’)
11
Q’ty
No. Item No. Description Mat./Spec Remark
2540 2550
1 120104-00009 Bolt, Foundation BFJA20X610 30 34
2 S4001132 Nut, Hex NA20 30 34
3 C40201024 Collar; Foundation 30 34
4 C68091374 Collar; Foundation 30 34
Screw, Set;Hex.
5 S3526386 BQK6 X 10 30 34
S/Head
6 250205-00271 Plate; Level 30 34
7 P88020070 Block; LBB 70 18 22
8 850406-00041 Block, Leveling 4
9 250205-04131 Plate ;T15 SS400 4
10 110951-02481 Spacer ;T1 SPCC 10
11 110951-02482 Spacer ;T2 SPCC 10
12
13
14
15
사진 필요
12
1.5 Preparations Before Shipping Machine
1) Preparation of Machine Unloading Workers

Precaution should be taken to avoid damage to the parts or change in their precision
when unloading the installation packing boxes or parts / units from the truck and moving
them to the installation site. You need to select a specialist handling company that has
sufficient experience in advance.
2) Machine Transport and Preparation of Installation Equipment

Prepare either one from an over 30-ton overhead crane, or a over 100-ton car crane
plus over 40-ton forklift for moving or assembling parts during installation.
Model Unit Weight (kg)
Bed & Table Unit 22000

DBM 2540 Cross & Column Unit and Ram & Saddle 17000
Column Base & Guard and Others 5000
Bed & Table Unit 26000
DBM 2550 Cross & Column Unit and Ram & Saddle 17000
Column Base & Guard and Others 5000
3) Preparation of Power and Pneumatic Air Source

Before the machine arrives, the customer should refer to the main power supply pipe
location shown in the foundation drawing to prepare the main power wiring (from the
factory switchboard to the machine) and pneumatic air source.
* Power capacity and cable thickness may vary depending on the option. Please contact
our service center when considering additional options.
▪ Power capacity: 82.5KVA
▪ Wire sectional area: 70㎟/AC200~220V, 50㎟/AC360~480V
▪ Allowable voltage fluctuation: ±10%
▪ Pneumatic source pressure : 5.5∼7.5Kgf
▪ Pneumatic Hose ID : Ø9
13
4) Preparation of Oil
The user should prepare oil for machine operation in advance.
Required
Usage ISO SHELL MOBIL TOTAL
amount
Hydraulic oil TELLUS S2 M AZOLLA
VG32 DTE24 ULTRA 105L
(Hyd.) 32 ZS 32
Lubricant TONNA S2 M VACUOLINE DROSERA
VG68 12L
(Lub.) 68 1409 MS68
Cooling oil MORLINA S2 VELOCITE
VG10 AZOLLA10 80L
(Cooling) BL 10 No.6
Angle Head
FC32 TURBO T 32 DTE Oil Light AZOLLA 32 1.5L
lubricant
5) Preparation of 2nd Grout for Installing the Machine

① Required grout amount (When grout is 25㎏s)
DBM2540 (47 bags), DBM2550 (54 bags)
▪ Refer to the foundation drawings and prepare an additional 20% of the required
amount.
② 2nd grout specification
▪ Compressive strength: 600㎏ / ㎠ or more(7 days curing), expansion rate: 0 ~
0.3%, bleeding: 0%
▪ Recommended grout: EMBECO, TASCON, Bascon Plus (Ssangyong Cement),
Grout GM (Union) Remitar GP600 (Hanil Cement)
14
2. Machine Transport
2.1 Main Transportation Unit Setup
DBM25 Series is designed to be transported in parts, installed on-site by way of

assembling.
Since all machine parts are heavy and their center of gravity is not stable, it is important to
balance machine units when they are carried by a crane or a forklift.
1) Units Shipped
① Table & Bed
▪ Total weight: 22,000 kg (DBM 2540) / 26,000 kg (DBM2550)
▪ Dimensions (domestic market model): DBM 2540 : 10.7ⅹ2.7ⅹ1.6 (M) / DBM
2550 : 12.7 x 2.7 x 1.6 (M)
▪ Shipping Box Dimension (overseas market model) :
② Cross / Ram Saddle / Column Base / Electric Cabinet / Operation Panel

▪ Total weight: 17,000Kg
▪ Machine Size (domestic market model): 6.2ⅹ3.3ⅹ3.3 (M)
15
③ Column Base
▪ Dimensions and Weight
-. Low Column : 2.6ton (1.3x2ea), 1.4ⅹ1.2ⅹ0.6(M)_2ea
-. High Column : 3.6ton (1.8x2ea), 1.4ⅹ1.2ⅹ0.9(M)_2ea
④ Magazine & Fence

▪ 40 Tools : 3.0ⅹ0.7ⅹ1(M)
▪ 60 Tools : 4.5ⅹ0.7ⅹ1(M)
▪ Fence : 1 Pallet
⑤ Attachment & 1 Aac (Opt.)

▪ Dummy Head (Std.)
▪ Angle Head, Extension Head (Opt.)
▪ 1 AAC (Opt.)
16
⑥ Side Chip Conv. Lift-Up Conv. Bucket – 1 unit

⑦ Coolant Tank, Oil Tank, Chip Cover / Semi Cover – 1 unit
17
2.2 Unloading Machine Units
1) Precautions for Unloading

DBM25 series machines are composed of many pre-assembled units including the
assembly of table & bed and assembly of column, cross rail, electric cabinet, and
operation panel. Various covers and splash guard are all pre-disassembled and
packaged separately for shipping.
Since all machine parts are heavy and the center of gravity is not stable, it is important to
balance the machine units when they are carried by a crane or a forklift, and to avoid
causing scratches or bending to splash guards and covers.
① Upon reception, all machine parts must be checked against parts list.
② Use a crane or a forklift to lift machine units and maintain overall balance.
③ When using the crane, be careful not to let the wire rope or shackle on the machine
collides with the machine and adjust the rope length exactly so that the machine
does not tilt when lifted.
④ Put soft pads between the machine and the rope to prevent damage to the machine.
2) Unloading Large Units

① Unloading Table & Bed Assembly Unit
(Unloading by using crane) (Unloading by using forklift)
② Unloading Column, Cross Rail, Electric Cabinet, and Operation Panel Assembly Unit
사진필요
(Unloading by using crane) (Unloading by using forklift)
18
2.3 Unit Packing List
Packing No. Model Packing Box Contents
1 DBM2540 Bed & Table Ass ’ Y, basic parts, TS27R (optional)

2 DBM2540 Column Ass ’ Y, Column Base, Electric cabinet, Bracket
3 DBM2540 Magazine (40, 60 tools)
C/Tack, Cooler, Oil Tank, Att. (Dummy, Angle Ext.),
4 DBM2540
1-AAC (optional), Chip Bucket (optional)
5 DBM2540 Side Chip Conveyor & Bracket
6 DBM2540 Slide Cover, Operator Step (optional)
7 DBM2540 Guard Frame, LM Guide Bracket (Semi S/G)
8 DBM2540 Chip Cover (Atc, Aac Door, Column Cover)
9 DBM2540 Semi Guard Fence(Semi S/G), Magazine Fence
10 DBM2540 Lift-Up Chip Conv. (Opt.)
19
1) Table & Bed Unit
30 50 (Opt.)
Disassemble DBM2550
Bracket
40 (X2)
10 50
Flooring blocks, installing tool and
etc. are put in the box shown in th
Should be disassembled w e photo and the box is included in
hen installing fixture the No. 1 packing box.
Packing No. No. Parts No. Definition Q’ty
1 10 - Main Bed & Table Ass ’ y 1

1 20 110934-00039 Cover (Slide Cover ’ s part) 2
1 30 110934-00041 Cover (Slide Cover ’ s part) 4
1 40 110423-14381 Bed Middle Cover 1 2
1 50 - Bed Middle Cover 2 1
20
2) Column, Cross, Saddle, RAM, Electric cabinet Ass’y
If Z1100 (optional) is applied,

10 <Z-axis> Motor should be
disassembled for shipping
Should be
disassembled when 30
installing Ram fixture
20
Should be
disassembled when
installing ATC fixture
When shipping the lower Should be disassembled Should be disassembled

side of the RAM, be sure to when installing Saddle when installing 2AAC
fix it tightly to avoid shock. fixture fixture
21

Column, Cross, Saddle, Ram,
2 10 - 1
Electric Cabinet Ass ’ y
2 20 110958-05388 Support; E Box(Std.) 1
Support; E Box
2 20 110958-05236A 1
(Opt. +300 Raising)
2 30 110508-47348A Cover; Ram 1
2) Column Base Ass’y
10
20
(Skid
L t)
22
2 10 160101-01559A Base; Column L 1

2 20 160101-01557A Base; Column R 1
2 10 160101-01573A Base; High Column L 1
2 20 160101-01574A Base; High Column R 1
3) Magazine Ass’y
10
3 10 101547-00980A 40t Magazine Ass’y 1

3 10 101547-00981A 60t Magazine Ass’y 1
23
4) Coolant Tank, Oil Tank, Oil Cooler, Chip Conv. Etc
10
(optional)
(standard)
30
20
(optional)
40
50 20
(optional)
(optional)
70 80
(optional) (optional)
24
Packing No. No. Parts No. Definition Q’Ty

Tank Ass ’ y; Coolant; Without Chip
4 10 450102-02419a Conv.(Std.) 1
Tank Ass ’ y; Coolant(Opt. W/Lift-Up
4 10 450102-02253b Chip Conv.) 1
Tank Ass ’ y; Coolant 1000l(Opt.
4 10 450102-02601a W/Lift-Up Chip Conv.1000l) 1
4 20 450105-01022 Tank Ass ’ y; Waste 1
4 30 - Cooler Ass ’ y 1
4 40 - Dummy Head Ass ’ y(Std.) 1
4 50 - Angle Head Ass ’ y(Opt.) 1
4 60 - Extension Head Ass ’ y(Opt.) 1
4 70 100703-00023a Changer, Sub; Aac(Opt.)
4 80 C50221062 Bucket, Chip;380L(Opt.)
Bucket, Chip (380L, rotary type,
4 80 C51221011e optional) 1
5) Side Chip Conv. Bracket, Side Step
(X2) 70 (X2) 30
(X4) 60
10
90 (X7)
20
80 (X3)
(X2) 40 50
25
5 10 900115-01935A Conveyor, Chip; Side L 1

5 20 900115-01934A Conveyor, Chip; Side R 1
5 30 - Rear Step Bracket 2
5 40 - Front Step Bracket 2
5 50 - Side Chip Conv. Step 1
5 60 110517-01720A Cover, Side; A 4
5 70 110517-01721A Cover, Side; B 2
6) Slide Cover, Step
10 20 30
50 (optional)
40 (optional)
(X8, Opt.)
X8
(optional) 60
6 10 110510-01690A Cover, Slide; XR 40 1

6 20 110510-01689A Cover, Slide; XR 40 1
6 30 - Chip Cover, Slide 2
6 40 250128-00182A Plate, Step 1
6 50 250128-00580 Plate, Step 1
6 60 120110-00017 Bolt, Leveling 8
26
7) Frame, LM Rail Bracket_Rasing+0
701 714 713 712
702 부착
703
704
705
711
710
709
708
706 707
Attach
Fasten supporting & leveling bolts

(on every frame)
27
7 701 160609-05544A Frame; Door 1

7 702 250122-00758A Plate, Support; Door 1
7 703 110406-05991 Bracket, Cover; LA 1
7 704 110406-05994 Bracket, Cover; LB 1
7 705 110406-06004A Bracket, Cover; LC 1
7 706 110508-43772B Cover, Bottom; F 1
7 707 110958-05282A Support 1
7 708 110423-15276A Bracket; RB 1
7 709 110423-15275B Bracket; RA 1
7 710 110406-05988 Bracket, Cover; RRA 1
7 711 110406-05989B Bracket, Cover; RRB 1
7 712 110958-05235C Support, Cover; R 1
7 713 110406-05987B Bracket, Cover; RLB 1
7 714 110406-05986 Bracket, Cover; RLA 1
8) Chip Cover(ATC,AAC Door, Column Cover)_Rasing+0
Disassemble and
812 Attach 810 separate packing
812 811
812
807
808
813
809
801
806
805 Attach
803
814
28

7 801 110508-45504A Cover, Chip 1
7 802 110508-43454A Cover, ATC 1
7 803 110517-01781A Cover, Side; L 1
7 804 110505-01072A Cover, Duct 1
7 805 110508-45011 Cover, Hole 1
7 806 110508-45027 Cover, Chip 1
7 807 102301-01907A Door; ATC 1
7 808 - Cylinder Ass’y 1
7 809 110916-00466 Chute; L 1
7 810 110508-42843B Cover, Front; L 1
7 811 110508-50850 Cover; IL 1
7 812 110508-42706B Cover; IL 1
7 813 110922-02224 Guide; Door 1
7 814 900130-00136 Rail, Guide; Door 1
8) Chip Cover(ATC, AAC Door, Column Cover)_Rasing+0
867 Attach 861
(Optional) 862
859
854
851 Attach
852 853 857 856
29
860 Attach
(Option) 868
Attach
(Optional. When not

selected, plug cover
is used)
865
858 864
853
Attach
(X2)
7 851 110508-45043 Cover; RB 1

7 852 110508-45044 Cover, Rear; B 1
7 853 110420-01575 Bracket, Mounting 1
7 854 110508-42729 Cover; RR 1
7 855 110508-50850 Cover; IL 1
7 856 110508-42705A Cover; IR 1
7 857 110916-00465 Chute; R 1
7 858 110508-43773 Cover, Bottom; RA 1
7 859 110508-45283A Cover; Front 1
7 860 110508-43777A Cover, Upper 1
7 861 250205-04394 Plate; Window 1
30
7 851 110508-45043 Cover; RB 1

7 852 110508-45044 Cover, Rear; B 1
7 853 110420-01575 Bracket, Mounting 1
7 854 110508-42729 Cover; RR 1
7 855 110508-50850 Cover; IL 1
7 856 110508-42705A Cover; IR 1
7 857 110916-00465 Chute; R 1
7 858 110508-43773 Cover, Bottom; RA 1
7 859 110508-45283A Cover; Front 1
7 860 110508-43777A Cover, Upper 1
7 861 250205-04394 Plate; Window 1
7 862 220209-00073 Glass 1
7 863 110958-05197A Support, Pipe 2
7 864 101563-00075A Pole; Std 1
7 865 101563-00074A Pole; Std 1
7 866 110508-45285A Aac Cover 1
7 867 110508-45009 Cover; Aac Hole 1
7 867 - 1 Aac Cover Ass’Y(Opt.) 1
7 868 - 2 Aac Cover Ass’Y(Opt.) 1
31
903 902 901 916 916 Attach
(X2)
916
904
909
910
911
Attach
907
908
(X3)
905
913 906 912
914
9 901 110517-01783 Cover, Side; L2 1

9 902 110508-45291A Cover, Front; L 1
9 903 110508-45292A Cover, Front 2
9 904 110508-45293A Cover, Front; R 1
9 905 102301-01901B Door; F 1
9 906 102301-01900B Door; F 1
9 907 110508-43711B Cover, Bottom; FA 1
9 908 110508-43712A Cover, Bottom; FB 3
9 909 110508-50479A 1
9 910 110508-44847 Cover, Hole 1
32
9 911 110508-43277 Cover, Hole 1

9 912 110925-00421 Handle Assy 1
9 913 110508-43765A Cover 1
9 914 110423-15270A Bracket; Key 1
9 915 B13721313B Glass(2), Safety 4
9 916 250205-04390 Plate; 4
9 917 110508-45028A Cover; Hole 1
931 932 933
(X4) 939
934
935
(X2) 940
(X2) 941
937 936 938 (X2)
942 949
943 Attach
(X6)
947
(X2)
950
948
Attach
944
945
946
33
9 931 110508-45294A Cover, Rear; LA 1

9 932 110508-45297A Coverlrear; LB 1
9 933 110508-45295C Cover, Rear; LC 1
9 934 110508-45299C Cover, Rear; RC 1
9 935 110508-45298A Coverlrear; RB 1
9 936 110508-45296A Cover, Rear; RA 1
9 937 110508-45300B Cover, Bottom; Box 1
9 938 110508-43290A Cover; Bottom 2
9 939 110508-43277 Cover, Hole 4
9 940 110508-44849A Cover, Hole 2
9 941 110508-44850 Cover, Hole 2
9 942 102301-01903C Door; RR 1
9 943 102301-01902B Door; RL 1
9 944 110508-43287A Cover, Bottom; Corner R 1
9 945 110508-43289 Cover; BC 1
9 946 110508-43288 Cover, Bottom; Corner L 1
9 947 B13721313B Glass(2), Safety 2
9 948 250205-04390 Plate 2
9 949 110925-00421 Handle Ass’y 2
9 950 110933-00037 Latche 1
34
9. Magazine Fence Assy(FL-960)
729 (X6) 720

703
713
725
701 715
702
714
706
716
710
712
704
724
709
708 727
707 723
728 (X2) 705 726 711
717
719
718
721 722
35
7 961 110406-05995A Bracket, Cover 1

7 962 110508-43542A Cover; Magazine 1
7 963 110508-43932B Cover; Magazine 1
7 964 101563-00056B Pole; Fence; (DL) 1
7 965 101563-00055A Pole; Fence; (DR) 1
7 966 110958-04740 Support; Frame 1
7 967 460103-01710 Duct; Magazine 1
7 968 110505-00858 Cover, Duct; 1
7 969 110958-04740 Support; Frame 1
7 970 102301-02017 Door; Magazine; (R) 1
7 971 110302-02056 Bar; Frame 1
7 972 101563-00056B Pole; Fence; (DL) 1
7 973 102302-00435A Fence; Magazine 1
7 974 110302-02104 Bar; Frame(1) 2
7 975 102301-01833A Door; Magazine; (F) 1
7 976 101563-00067 Pole; Safety Fence (L) 1
7 977 101563-00068 Pole; Afety Fence (M) 1
7 978 102302-00521A Fence; Atc(1) 1
7 979 102302-00522A Fence; Aac(2) 1
7 980 101563-00069A Pole; Safety Fence(R) 1
7 981 110423-15314 Bracket; Fix 1
7 982 110302-02105 Bar; Frame(2) 1
7 983 101563-00083 Pole; Fence; (A) 1
7 984 110302-02284 Bar; Frame(1) 1
7 985 102302-00582 Fence; Atc(M) 1
7 986 150119-00993 Duct, Oil 1
7 987 150119-00994 Duct, Oil 1
7 988 220206-00148 Handle 2
7 989 110927-00318 Hinge, Door; Semi SG 6
36
10. Lift-Up Chip Conveyor. (Opt.)
10
10 10 900115-01936A Conveyor, Chip; Liftup Fl960 1

10 10 900115-02124 Conveyor, Chip; Liftup Fl0 1
Conveyor, Chip; Liftup Fl960
10 10 900115-02277 1
(for DMTA shipping)
Conveyor, Chip; Liftup Fl0
10 10 900115-02264 1
(for DMTA shipping)
37
3. Temporary Installation of Machine

3.1 Temporary Installation of Bed
1) Making Foundation Holes

Before the machine arrives at the site, clean the foundation holes already constructed.
① Clean the inside of the holes.
② If the inside surface of the holes is too smooth, do some chipping on the surface.
Chipping
(Conduct chipping on the surface of holes) (Wet the surface with some water)
③ Pour water into each hole to allow the concrete to absorb enough water.
※ In order to improve the adhesiveness and fluidity of injected grout and to prevent
premature drying, put water for at least 12 hours before grout injection and drain
water just before the injection.
38
2) Check Parts for Foundation

① Pick foundation parts box from the shipped package and move it to near the place of
installation.
② Put 250205-00271 Leveling Plate to the 120104-00009 foundation bolts. Fix the
C68091374 Foundation Collar at a distance of about 300 mm from the floor-side end
of the bolt. (Leave the screw tip about 20 mm.)
300mm
※ Note) The bottom of the level bolt for the Leveling Plate to be used for anchoring work
is flat while the Level Block’s Level Bolt is in an arc shape. Always check this
when conducting assembly.
Future products will be color-coded for easier identification.
3) Unloading Machine Units

Using a forklift or crane, move the received machine parts to near the installation place.
▪ Bed & Table weight : DBM2540 = 22 tons / DBM2550 = 26 tons
39
4) Assembling Foundation Parts

① Lower down all leveling bolts fastened to the bed 27 mm from the bottom of the bed.
② Put the previously assembled Foundation Bolt and Leveling Plate together with the
Level Bolt and fasten M20 Nut.
▪ When fastening M20 nut, there should be at least 20 mm of thread length left.
Nut 20
Add a photo here
Nut
107
Leveling
Bolt 55
88
Leveling
Block
5) Temporary Leveling of Bed

① DBM unit, as a level block placed between foundation level plates, replaces
temporary level bolt. Lower the foundation bolt for level block down 14.5 mm to make
the bed maintains ground clearance of 84.5 mm.
40
② Put a supporting Level Block inside the bed where Column Base is assembled.
③ Clean both ends and the center of the table. Put 2 levels whose reference point have
been set in X & Y axes directions respectively. Roughly set machine height and level
using a hydraulic jack and level block.
Level
사진필요
유압
Jack
④ Using a 50 mm spanner, conduct temporary leveling work by adjusting all level

blocks.
a. Target absolute level value should be 0.04 mm/m or smaller when conducting
temporary leveling.
b. All bolts for temporary installation should be tightened using same torque as much
as possible.
c. Ground clearance should be about 84.5 mm.
41
3.2 Temporary Installation of Column Base & Column
1) Assembling Column Base

When the temporary leveling of X axis bed is over, assemble column base and then
conduct the temporary leveling of base itself.
① Clean the assembly surface of the bed and column base.
② Prepare proper ropes that can withstand the weight of the base selected and put it
into the eye bolt on top side.
(M36 Eye Bolt, STD = 1.3 ton/1ea, +300 Raising = 1.8 ton/1ea)
③ When conducting this work, refer to the assembly instruction for installing Foundation
Plate and Block onto the Column Base. Place the bolts close enough to fasten to the
level bed. For each base, make sure that the liners on both sides and top side can be
inserted smoothly.
④ Clean the attachment surface. By using the temporally leveled level in the center as a
standard, place the bolt in the center of the hole, adjust the level not to be pressed
down, and then fasten the bolt.
⑤ Each liner should be inserted smoothly and the liner on the top side should not be
under any load.
42
2) Preparing to Lift Column Ass’y: 17 ton

① Front: 1M Rope & 10 Ton Chain Block = 2 EA / Rear: 5M Rope = 2 EA
a. Connect 2 5M ropes to the rear side hook on the column. Connect 1M rope to the
front hook and balance the column by using a chain block.
b. Put aside hoses, wires, and other obstacles for assembling.
※ If the cealing height is too low, use a 3M Rope instead.
② Finishing Column Assembly

After cleaning the column attachment area, if there are scratches, polish and polish,
and then put the two levels in the X-axis and Z-axis directions and use the Level
Block below to get the absolute level as accurately as possible
Level
Y Direction
Level
X Direction
43
3) Lifting Column Assembly

Lift the assembly with Column, Cross, Saddle, Head, electric cabinet, and operation
panel fixed using shipping fixtures.
① Connect the rope for rear side to the both hooks on the back side of the cross.
▪ Length : The Column Ass’y should be lifted at least 1.5 m from the ground. (Base
assembling height from the ground: STD = 0.7 m / +300 Raising = 1 m)
▪ Thickness : A proper rope that can withstand Column Assembly’s weight of 17
tons.
② Connect a rope for front side and chain block to both front hooks. By adjusting the
chain block, match the length of rope for rear side.
③ When lifting the assembly, adjust the chain block to maintain overall balance.
④ Slowly lift it maintaining the balance and move it over to the column base to start
assembly.
4) Assembling Y Axis Perpendicularity Adjust Block

Temporarily fasten the column assembly to the base and then assemble 2
perpendicularity adjust blocks to both left and right columns.
44
4. 2nd Grout Injection

4.1 Pre-Checking of Foundation Holes
1) Is the concrete surface of each foundation hole roughly trimmed?

▪ This is for the adhesion of the concrete wall constructed in the 1st foundation work
and the 2nd grouting. As such, if the surface of the foundation holes is smooth, it is
necessary to asperate the surface. (Chipping)
Chipping
2) Is the foreign matter completely removed from each foundation hole?

▪ Clean the corrugated pipe pieces and concrete debris that were used to make the
foundation holes.
3) Are the foundation holes sufficiently wet with water?

▪ This work is very important to improve the adhesion and fluidity of grout and to prevent
the drying of grout too quickly. 12 hours before grouting, fill the foundation holes with
water and completely drain it just before grouting.
45
4.2 Preparing Grout Material
1) Prepare good grout material.

▪ The choice of a good grout will provide the reliable foundation of the machine, offering
sufficient contact with the leveling blocks required for the machine as well as sufficient
strength, compared with when using a regular mortar.
2) Grout amount required (25 kg bag)

▪ DBM2540 : 47 bags / DBM2550 : 54 bags
※ Refer to the foundation drawings and prepare an additional 20% of the required
amount.
3) Specification of grout
① Required compression force: at least 600 Kg/㎠
② Expansion rate : 0 to 0.3%
③ Bleeding (a phenomenon of water rising) : 0%
4) Recommended grouts
Ex.) : Bascon Plus(Ssangyong Cement), Grout GM(Union), Remitar GP600(Hanil
Cement) Embeco, Tascon, etc.
▪ Select a grout among the recommended grouts or other makers’ products of the same
or higher performance and material.
46
4.3 Grout Kneading
1) Using an electric hand mixer or mechanical mixer, knead the grout sufficiently until the
grout and water are thoroughly mixed (more than 2 minutes) according to the grout
maker's construction method.
▪ Pour the correct amount of water into the container first and knead the grout slowly by
pouring it slowly.
2) In the grout kneading, keep the correct mixing ratio of water to grout. (Add water of
about 16% of the grout weight and knead it.)
※ When the water more than the specified amount is added, the strength of the grout
will drop, and it may cause air holes at the bottom of the level plate when drying. (It is
better to prepare a weighing beaker, etc. to accurately measure the amount of water.)
▪ Quantity of water : 4.0L per one box of 25Kg (water ratio 16%)
3) Grout kneaded with water causes chemical action within 30 minutes after kneading, so
the injection should be completed within 30 minutes after kneading.
4) When injecting, the temperature of dough should be about 10 ~ 20℃.
▪ Adjust the temperature of the dough properly by using hot water during winter and
cold water during summer.
(Small mechanical mixer) (Electric hand mixer)
※ Change of compressive strength of grout according to water ratio (Example)
Compressive strength (Kgf/㎠) 20˚C Flow Start time of

Water
(30 mins) hardening
ratio Day 1 Day 3 Day 7 Day 28 (mm) (Min)
13% 490 700 830 850 160 30
14% 440 660 815 830 190 40
15% 340 640 800 810 220 60
16% 320 550 630 680 240 70
17% 290 480 550 620 260 80
47
4.4 Grout Injection
1) Grout Injection
Pour the kneaded grout in one direction continuously from one side of the foundation
hole to flow into the entire foundation hole without being mixed with air bubbles.
① Injecting grout into the unit (Bed & Column)
2) Grout compaction
During the pouring of the kneaded grout, use a pipe or a long stick to continue the
compaction, so that the dough spreads completely through the foundation hole, and the
likely air bubbles are easily removed during work.
▪ During grout injection, do not use the vibrator for compacting concrete.
참고 사진
참고 사진
3) Finishing Work
After fully injecting the grout into the foundation hole, finish the floor clean.
48
4.5 Grout Curing
1) Replenish water
Pour enough water to the surface while the grout is curing.
▪ To prevent water evaporation, it is advisable to cover the surface with a damp cloth.
사진 교체 필요 사진 교체 필요
2) Curing period
The longer the curing period, the stronger the strength, so in the case of grout at least 5
days, generally about 7 days is good. During the winter season, give an additional 2-3
days of curing.
3) Cautions during curing period
During the curing period, reduce the vibration, impact, and load to a minimum in the
surroundings, and keep the surrounding temperature above 10˚C.
▪ When the temperature is low in winter, it is important to maintain proper temperature
by using a heater or an hot air fan during curing period.
49
5. Assembling the Machine

5.1 Cooling unit, hydraulic unit, and other units
1) Moving the Cooling Unit

Remove the packaging vinyl of the cooling unit and move it next to the magazine.
2) Connecting power cable
Find the power cable (WM0710, WM0720) tied on top of the unit and connect it to the
electric cabinet.
Contain the cable inside

the hydraulic unit WM0720 WM0710
3) Connect the hose

By referring to the numbers below, connect the hose from cooling unit’s inlet/outlet pot to
the distributor in the back of magazine. (Spindle cooling P(1), T(2), Hydraulic Pump
P(3),T(4), Axis system cooling P(5), T(6), Flood(7), TSC(8))
▪ It is also divided by color cable ties at the time of shipment.
1 6
8 7 6 5 4 3 2 1
8
4 3
50
4) Temperature Sensor Connection

Connect the cooling unit’s temperature sensor cable connector to the temperature
sensor of the column.
Cooling temperature sensor

Connector connection
51
5.2 Connecting the cables inside the electric cabinet
1) Deploying the cables

Untie and spread the cables shipped with the X axis bed.
2) Inserting cables inside the electric cabinet
Among the cables, select the ones to be connected and insert them into the hole of the
electric cabinet.
- Cables to connect to Modular Connector unit
- Cables to connect to Servo Drive Unit (Power Cable, Feedback Cable, etc.)
52
3) Connect the Modular Connector

Using the numbered stickers on each empty Modular Connector Unit, start connecting
cables.
(1) X Axis - XA1A0 : WC1A00(X AXIS EMG, REF)
(2) Coolant - XA401 : WJ4010
(3) Tool Measuremnt Unit - XA570 : WJ5700, Connect the modular connector
(4) Side Chip Conveyor (WM0620,0630)
-. XA760,770: Connect the modular connector (connected together to XA700th
number)
3 2
Modular
Connector
4) Connect the Servo Drive Unit

Insert the Power Cable Connector and Feedback Cable Connector that are connected
with X axis Servo Motor to the corresponding pots of FANUC AMP.
-. WJ11V0(Power), WJ11F0(Encoder)
Fanuc
Amp
Power
Cable
Feedback
Cable
53
5.3 Connecting Various Units’ Cables
1) Connecting Tool Magazine

① Connect the Servo Motor Cable
Route the Tool Magazine Servo Motor cables (Power Cable & Feedback Cable)
inside the magazine’s frame to connect to the Tool Magazine Servo Motor. Arrange
the cables using cable ties.
-. WJ285V (Power), WJ285F (Encoder)
-. WJ1D00 (Main Safety Switch), WJ1E00 (Sub Safety Switch)
-. WJ2600 (Operation Panel)
ATC-related
cables
Feedback Power
Cable Cable
WC2600
WC1E00
WC1D00
② Connect the Tool Pull Out Confirm 의 연결

Mind the color of Tool Pull Out Confirms when connecting them. (Brown-Brown,
Black-Blue)
54
2) Connect the AAC unit

① Connect wires between the column and the bed avoiding entanglement.
-. Connect 2 Station AAC Door Control (MP730(WC7300))
(attached to the red-colored Guard Frame at the bottom)
② Avoiding entanglement, connect wires between the column and the bed by passing
them through gap between covers.
-. WC1C00 (Door Safety Switch)
WC1C00
MP730
(WC7300) Refer to the
location of
MP730
attached
4 potter
③ Connect Modular Connector

Re-assemble MP710 & MP720 to assemble the whole module
WC1C00
55
3) Connect the Waste Tank

-. Put the Waste Tank beneath the electric cabinet and connect the cable WK5730 to the
No. 7 of MP530.
Connect
to ‘No.7’
of MP530
WK5730
4) Connect the Bed Drain Hose

-. By routing under the bed, connect the drain hose located at the end of X axis bed to
the Waste Tank
56
4) Connect the Lift up & Side chip conveyor, and Coolant

① Connect the left & right motor of WC0620, WC0630 chip conveyors
Right (U62, V62, W62, PE) & left (U63, V63, W63, PE)
② Connect the left & right motor of WC0620, WC0630 chip conveyors
(When finished, turn the power on and check again))
③ Manual (main operation panel button)/Automatic (M-CODE) check
TSC: M07 / Flood: M08 / Coolant Gun: No M-CODE exists
Check Oil skimmer by turning on/off the toggle switch attached to the main unit
④ Check PCB board’s dip switch / Enable the lift up chip conveyor emergency stop
before checking
Check if conveyor’s forward/reverse rotation switch works fine
⑤ Check if machine’s Ready state turns off normally by pressing the emergency switch
on the operation panel of lift-up chip conveyor. (The unit and lift-up chip conveyor
should all be cross checked)
⑥ Check if M24/M25 commands work fine
COOLANT
TSC GUN
U
V FLOOD
W Oil skimmer
WC4010
PE
WC0610
Lift-up chip
conveyor
EMG
WC0610
ATC Panel EMG
57
5.4 Connecting Main Power and Main Pneumatic Source
1) Main Power connection

Connect the wires from the switchboard of the factory to the terminal block of the main
NFB.
① Connect R, S, T to L1, L2, L3 in order.
② Connect the ground wire to the ground terminal next to the NFB.
▪ Power capacity: 82.5KVA
▪ Wire sectional area: AC 200V/220V = 70㎟, AC 360V/480V = 50㎟
▪ Allowed voltage: 200V/220V (50Hz/60Hz) ±10%
Factory
main
power
Earth line
2) Connecting the Main Pneumatic Source

Connect main air line to the Main Air Supply Unit’s air supply pot
Factory
Air
58
※ Note) Precaution for connecting factory pneumatic source and the machine
(1) Make sure that the pipe coming down from the factory air line to the machine
installed on the ceiling of the factory has been so constructed that it goes upwards,
then downwards. If the pipe is installed sideways or downwards, the water inside the
pipe may flow directly into the machine.
▪ It will adversely affect the machine so you must persuade the constructor to re-
install the pipe.
Factory
pneumatics
Machine
(Connect the pipe upwards.) (An example of pipe connection)
(2) Install a distribution tank to be connected to the pipe coming down from the ceiling
of the factory before it is connected to the machine so that the water generated from
the compressed air is filtered once again.
▪ Compressed air can be used safely by installing a water removal system.
(3) The inner diameter of the air hose or tube should be 9mm or more.
(4) The pressure of the pneumatic source should be 0.55 ~ 0.75 Mpa (5~7 kg/㎠) or
higher.
(5) The consumption of the pneumatic source should be at least 0.5 Mpa (5 kg / ㎠).
(6) The air must be clean and free from moisture. If moisture is contained, install a
water removal device or an air dryer.
Ф9
Air
Hose
Hose
Band
(Example of air distribution tank (The air hose diameter should be

installation)) large enough)
59
5.5 Disassembling Shipping Fixtures
When shipped, the machine’s all axes (X, Y, and Z) are fixed using fixtures for safety
purpose.
The fixtures must be removed before installing and operating the machine.
1) Removing X-axis fixture
Disassemble and remove the X axis fixture that holds the bed and the table.
2) Removing Y-axis fixture

Disassemble left/right Y axis fixtures that hold saddle.
3) Disassembling Z axis fixture

From the top side of the Z axis, disassemble the Z axis fixture that hold column and ram.
60
4) Disassembling ATC Changer fixture

Disassemble the ATC fixture that holds Tool Changer and Arm.
5) Disassembling AAC fixture

Disassemble the AAC fixture that holds AAC.
6) Disassembling Lift fixture

Disassemble front & rear Lift Hook.
61
7) change Pendant Arm Stopper Bolt

Bellows Cover Move to the Stopper Bolt position fastened to the upper frame and fasten.
(Red circle at the time of shipment  Corrected to yellow circle position during)
Stopper Bolt
correction
position
62
6. Power On
6. Power On
6.1 Turning On Main Power
1) Checking the Power

Turn the switch of factory switchboard to "ON"
and use the electric tester to measure the
voltage of the factory's main power supplied to
the main NFB and check if there is any
problem.
▪ Voltage tolerance : 220V ± 10% (60Hz area)
200V±10% (50Hz area)
2) Turning On Main NFB

Make sure again that the main power, hydraulic
hose, various wires and connectors are
properly connected, then raise the main NFB.
3) Checking of Main Power Connection

① Press NC Power ON  Machine Ready
Switch.
(NC Power ON)
(Machine Ready)
② Check if power for the Oil Cooler is normally

supplied.
63
6. Power On
※ If oil cooler cannot be turned on, turn off the

switch connected to the machine from the
switchboard. Then, of the main power
connection cables, interchange and connect
the U line (R) and W line (T).
U line (R) W line (T)
4) Machine Ready
When the 3-phase connection of power is
confirmed, press NC Power ON  Machine
Ready Switch in sequence.
When Machine Ready is done, the current
machine status can be checked, and check the
alarms displayed according to the status to
solve problems one by one.
64
6. Power On
6.2 Checking the Pressure of Each Part after Turning on Power
1) Hydraulic pressure of oil cooler :

▪ 0.5 MPa (5 Kg / ㎠)
2) Pressure of lubricating oil pump :

▪ 15 Kg / ㎠ (to be checked when operating
the pump)
3) Main air pressure :

▪ 0.5∼0.6 MPa (5∼6 Kg/㎠)
65
7. Machine Accuracy Adjustment

7.1 Machine Leveling
※ Machine Leveling
The machine leveling directly influences the maintenance of the accuracy of the
machine. So carefully conduct the work. Normally, leveling shall in principle be
conducted together with machine accuracy adjustment.
▪ Required tools : 4 levels, square ruler (500 x 500), test indicator (0.002mm), Magnetic-
Stand, Test-Bar and other leveling tools (Spanner: 50mm, 60mm),
Pipe(1” length 1.5m), etc.
1) Absolute leveling by using a cured Level plate bolt

① When levels’ zero point setting is done, place them in 3 positions (at both ends of
the table and in the center) in X & Y directions.
② Using the absolute level as a standard during temporary installation, make sure that
all bolts support the load evenly.
③ Where, loosen the Level Block’s level bolts used for the temporary installation so that
they are not under too much load. Ensure that the absolute level is maintained by the
support of level plate.
66
2) Level’s Zero Point Setting

① Place the level in the center of the table and read the dimension of one part of the
level droplet accurately.
② At the same position, rotate the Level 180 ° to read the droplet dimension in the
same direction.
③ Use the “-” screwdriver to rotate the origin adjustment screw so that the middle of
the droplet dimension (halfway between the two directions) between the first droplet
dimension and the droplet dimension when turning 180˚can move.
④ Repeat ①∼③ again to make sure to adjust the water droplet to the same position
when turning both directions.
⑤ Put the level whose zero point setting is done on the table in X & Y directions along
the table’s center line.
Origin
adjusting
bolt
※ How to Read Level Left Right

Baseline Baseline
“-”direction “+”direction
▪ Level ’ s value = (the right end of droplet＋ the left end of droplet) ÷ 2
= ( “ -50 ” + “ -40 ” ) ÷ 2 ＝ -45
In case of the above level, the left is 45 μ/m higher.
Note) When setting a level or leveling a machine, it is a good practice to read the
standard level instead of reading the one on one side.
※ There is some distance between the level instrument ’ s scale plate and the
droplet tube. Thus, the number reading may be different depending on the
viewing angle. Make sure, when you read the level scale, to read the scale at
the right viewing angle.
67
3) Leveling
① Send the table to the mid point of X axis stroke, measure the table height in the Y
axis direction, and make adjustment within the specified range using the level bolt of
the column base.
The torsion of the level put on the table should also be checked during the
adjustment.
▪ Height of table top in Y axis direction = 0.02/2000 mm
▪ X axis Stroke : DBM2540 = 4250 mm / DBM2550 = 5250 mm)
Y-Axis
② Adjust the feed level of the Y axis to

0.01mm / Stroke by attaching a right angle
level to the Ram.
▪ The abnormality of the transfer level of
the Y axis is due to the torsion of the
cross rail.
③ Based on the level of the column position adjusted above, the X axis is divided into 8
sections (X0., X-500., X1000., X1500., X2000., X2500., X3000. X3500., X4000.).
Continue to work within 0.02mm / all sections.
When the level is fixed to some extent, adjust the bolt of the released level block
while supporting it.
68
※ It is convenient to make a program before level work.
▪ Program example)O 0001;

G90 G00 X0.; X-4000.;
M01; M01
X-500.; X-3500.;
M01; M01;
X-1000.; X-3000.;
M01 M01
X-1500.; X-2500.;
M01; M01;
X-2000.; X-2000.;
M01 M01
X-2500.; X-1500.;
M01; M01;
X-3000.; X-1000.;
M01 M01
X-3500.; X-500.;
M01; M99;
④ Using the method described above, move the table and log the level amount on a
paper. Keep leveling until the level difference is less than 0.02/m.
※ How to log the level on a paper (example)
Y direction 10 10 20 30 30 Y direction: 20
X direction X direction: 20
15 15 20 30 30
X0 X1000. X2000. X3000. X4000.
※ Cautions for leveling work

① Make sure that the torque used for the level bolts for Level Block are the
same.
▪ Unbalanced torque among level bolts may lead to overall level
inconsistency.
② The leveling work must stop in the direction the level bolts are locked.
69
4) Column accuracy correction

When the level value is within the target range, before locking the anchor nut, check and
adjust the static accuracy of the column on-site installed.
① Parallelism between Y axis and table top
Using the leveling bolt of the column base, adjust the parallelism enough to be a
reference for leveling. Put an indicator on the spindle head, set a gauge on top of the
table, and then feed the Y axis to measure the parallelism of the table top.
▪ The reference parallelism is within 0.02/2000 mm. Measure at 3 points (center, + &
- ends on Y axis) to identify the biggest difference.
Y-Axis
② Parallelism between the Y-axis motion and table T-groove.

Attach an indicator on the spindle, touch a gauge to the table’s T-groove in the
center, and then move the Y axis to measure the parallelism.
▪ If it does not fall within 0.03/2000 mm, then use a column adjusting bolt to match
the parallelism between the cross and table T-groove.
▪ After adjusting the T-Slot, it is necessary to re-confirm the Y-axis level, and in some
cases, it is necessary to loosen the twist using the Adjustment Block in the Y-axis
direction located in the column.
Y-Axis
70
Column Column Column Column

Adjust the Fixing Bolt Adjust the Fixing Bolt
position position
Bolt Bolt
③ Parallelism between X, Y, and Z axes

Put a square ruler on top of the table and check parallelism between axes. For any
segment that does not satisfy the tolerance, adjust parallelism by performing leveling
work.
▪ Tolerance: X-Y = 0.012/500mm, X-Z & Y-Z = 0.015/500mm
Z-Axis
X-Axis
71
6) Finish leveling work

If machine’s static accuracy is normal and level value comes back to normal, start
finishing the leveling work.
① Lock the Anchor Nut.
a. Fasten the Level Block adjusting bolt 1/8 turn (45˚) and then fasten the nut using
an appropriate torque.
b. Measure the level accuracy again and make adjustment by using Level Block
adjusting bolt if necessary.
▪ There may not be big difference if all bolt have been fastened with same torque.
c. Tightly fasten the anchor nut measuring the X axis feed level.
② Tighten level bolt fastening nut
If leveling is finished, use a 60 mm spanner to fasten the level bolt fastening nut.
※ Importance of level bolt fastening nut
Fastening the anchor nut has a purpose to lock the level bolt. Locking Level
Bolt fastening nut fixes the machine’s bed and Level Bolt, that is, anchor
fastens the machine.
In other words, if Level Bolt fastening nut is not locked, the anchor fastens
only the Level Bolt instead of the machine creating a gap as much as the
Level Bolt’s backlash.
Anchor
Nut
사진 필요 사진 필요
Level Bolt
고정 Nut
72
7.2 Machine Origin Setting
When machine is installed and the leveling is done, the machine’s X, Y, and Z axes’ origin
must be reset.
Servo Motor of each axis is absolute coordinate motor so the origin is stored even when
the machine power is off. It does not need origin setting.
However, if the origin is forgotten due to the disassembling of the servo motor or ball
screw, a battery discharge, etc., the origin coordinate should be reset.
1) X-axis Origin setting (X-axis stroke: X-4250.∼X0)

① Feed the X axis to the mid point of stroke (X-2125.) manually or by using MDI.
② Put an indicator on the spindle and set a gauge’s tip at the side of the T-groove.
Rotating the spindle by hand slowly, locate the highest protruded point that touches
the indicator and set the point as zero.
③ Turn the spindle 180 degrees to find the highest point that touches the opposite-side
T-groove. Move the X axis in Half Mode (that is, use only a half of the indicator value)
to set both side to “0”.
Spindle
Rotate
④ Check the machine coordinate (machine position) on the CRT screen, in Half Mode,
feed the X axis 2125 mm (half of X axis stroke) in “+” direction or run the “G91 G00
X2125.;” program in MDI Mode.
▪ In the operation panel select [POS.]  [RELATIVE]  [(OPRT)]  [ORIGIN] 
“X”  [EXEC] in sequence, then change X-axis relative coordinate (position) to
X0.000 and move X axis to the position +2125.000.
⑤ Change the parameter No.1815#4(APZ) X axis from “1” to “0” (where, “PW0000
POWER MUST BE OFF” alarms occur on the screen.) Change “0”  to “1” and
Power Off  Power On, the machine coordinate on CRT screen changes to
“X0.000” and X-axis origin setting is completed.
73
2) Y axis Origin setting (Y axis Stroke: Y-3350.∼Y+350.)

① Move the Y axis to the mid point of the stroke. (Y-1500.)
② Put an indicator on the spindle and set a gauge’s tip at the side of the table center
groove. Rotating the spindle by hand slowly, locate the highest protruded point of the
table center groove that touches the indicator and set the point as zero.
③ Turn the spindle 180 degrees to find the highest point that touches the opposite-side
table center groove. Move the Y axis in Half Mode (that is, use only a half of the
indicator value) to set both side to “0”.
Spindle
Rotate
④ Check the machine coordinate (machine position) on the CRT screen, in Half Mode,
feed the X axis 1500 mm (half of X axis stroke) in “+” direction or run the “G91 G00
Y1500.;” program in MDI Mode.
▪ In the operation panel select [POS.]  [RELATIVE]  [(OPRT)]  [ORIGIN] 
“Y”  [EXEC] in sequence, then change Y-axis relative coordinate (position) to
Y0.000 and move Y axis to the position +1500.000.
⑤ Change the parameter No.1815#4(APZ) Y axis from “1” to “0” (where, “PW0000
Power Off  Power On, the machine coordinate on CRT screen changes to “Y0.000”
and Y-axis origin setting is completed.
74
3) Z axis Origin setting

▪ Z axis Stroke : STD = Z-800.∼ Z0. / +300 Raising Option = Z-1100.∼ Z0.
▪ Preparation (example)
Test bar : length = 310 mm
Block Gauge : 1-100mm (higher than 150 mm when using a Raising Block), 1-10mm
Indicator Stand
① Attach a Test Bar to the spindle, attach a 5∼10 mm Block Gauge to the 100 mm
Block Gauge so that the measurement can be done at the bottom, and then set the
indicator value to “0”.
② Move the Z-axis in Handle Mode, so that the end of the Test-Bar touches the
indicator to set it to "0".
③ Calculate the distance from Z0 position by the following equation. (In case of
standard stroke)
800 - (Test Bar length＋Block Gauge height–“A”), If “A”= Z0., distance to the table
Example) If Block Gauge : 100mm, Test bar : 310mm,
then : 800 - 310 + 100 – 200 = 590
Where, the distance from current position to the machine zero point (Z0.) is 590.mm.
In case of +300 Raising Option, use 100 in place of 800 to calculate.
Z0.
Test Bar
800
1000
“0” Setting
Block Z-800.
Gauge
200
Table Table
④ Check the machine coordinate (machine position) on the CRT screen, in Handl
e Mode, raise the Z axis as much as the value calculated above or run the pr
ogram “ G91 G00 Z590.0 ; ” .
▪ In the operation panel select [POS.]  [RELATIVE]  [(OPRT)]  [ORIGIN] 
“Z”  [EXEC] in sequence, then change Z-axis relative coordinate (position) to
0.0 and raise the Z axis to the point desired.
⑤ Change the parameter No.1815#4(APZ) Z axis from “1” to “0” (where, “PW0000
Power Off  Power On, the machine coordinate on CRT screen changes to “Z0.0”
and Z-axis origin setting is completed.
75
7.3 Machine Accuracy Measurement and Adjustment
※ DBM Test Report Sample
GEOMETRICAL TEST (기하학적 정밀도) 2/8
Angular deviation (각도 편차)

Unit : mm
Result
NO. Item (검사 항목) Diagram (측정 방법) Tolerance (허용 공차)
(측정 결과)
0.040/M for 4250

a) ZX Plane 0.040/M for 5250
(EBX)
Checking of [ZX평면] Local tolerance(부분 허용 값) :
angular 0.020/M for 1000
deviations of
the movement
of the table
1
(X-axis)
[테이블
운동(X축)의
각도 편차 0.030/M for 4250
검사] b) YZ Plane 0.030/M for 5250
(EAX)
[YZ평면] Local tolerance(부분 허용 값) :
0.020/M for 1000
Straightness (진직도)
Unit : mm
0.040/4250
a) XY Plane 0.050/5250
(EYX)
[XY평면] Local tolerance(부분 허용 값) :
Checking of 0.010/1000
straightness of
movement of
the table
2
(X-axis)
[테이블
운동(X축)의
진직도 검사] 0.030/4250
b) ZX Plane 0.040/5250
(EZX)
[ZX평면] Local tolerance(부분 허용 값) :
0.010/1000
76
Straightness (진직도) Unit : mm
Result
(측정 결과)
0.030/3000
Checking of a) XY Plane
straightness of (EXY)
Local tolerance(부분 허용 값) :
the horizontal [XY평면]
0.010/500
movement of
the
3 milling head
(Y-axis)
[밀링 헤드
(Y축)의 0.030/3000
b) YZ Plane
수평방향 운동 (EZY)
의 진직도] Local tolerance(부분 허용 값) :
[YZ평면]
0.010/500
0.015/800
a) YZ Plane 0.020/1100
(EYZ)
Checking of [YZ평면] Local tolerance(부분 허용 값) :
straightness of 0.010/500
the Z-axis
4 motion
[Z축 운동의 0.015/800

진직도] b) ZX Plane 0.020/1100
(EXZ)
[XZ평면] Local tolerance(부분 허용 값) :
0.010/500
Squareness (직각도) Unit : mm
Checking of squareness
between
the movement of the table
(X-axis) and
5 0.012/500
the horizontal movement
of the milling head (Y-axis)
[테이블 운동(X축)과 수평 밀링
헤드(Y축)과의 직각도 검사]
77
Squareness (직각도) Unit : mm
Result
(측정 결과)
a) the
movement of
the table
(X-axis) 0.015/500
Checking of
[테이블의
squareness
운동
between the
(X축 방향)]
vertical
movement of
the milling
6
head (Z-axis)
and
b) the
[밀링 헤드의
horizontal
상하 운동(Z축)
movement of
과의 직각도
the milling
검사]
head 0.015/500
(Y-axis)
[밀링 헤드의
수평 운동(Y축
방향)]
a) the X-axis
movement of
the table
0.015/300
[테이블의
Checking of X축 방향
squareness 운동]
between the
vertical milling
spindle axis of
7 rotation and
[수직 밀링
스핀들 회전
중심선과 b) the Y-axis
운동과의 movement of
직각도 검사] the spindle
head
0.015/300
[스핀들
헤드의
Y축 방향
운동]
78
Parallelism & Run out (평행도 & 흔들림) Unit : mm
Result
(측정 결과)
0.030/4000(DBMXX40)
0.035/5000((DBMXX50)
a) the Local tolerance(부분 허용 값) :

movement 0.010/1000
of the table
(X-axis) *Repeat 3-times at mid, +end, -end.
[테이블의 Record the maximum difference at each
Checking of 운동 test. the lagest one of 3 records is the
parallelism of (X축 방향)] result.
the table [중앙, +끝, -끝에서 3번 측정 한다. 각 측정 값
8 surface to 의 최대차를 구한다. 3개의 값 중 가장 큰 1개
[테이블 윗면 값이 결과 이다.]
의 평행도
검사]
0.020/2000(DBM25XX)
b) the
0.010/1000
movement of
the milling
*Repeat 3-times at mid, +end, -end.
head (Y-axis)
Record the maximum difference at each
[밀링 헤드의
test. the lagest one of 3 records is the
운동
result.
(Y축 방향)]
[중앙, +끝, -끝에서 3번 측정 한다. 각 측정 값
의 최대차를 구한다. 3개의 값 중 가장 큰 1개
값이 결과 이다.]
*Standard
(표준)
a) the
0.030/2000(DBM25XX)
movement of
the milling
head (Y-axis)
0.010/1000
Checking of [밀링 헤드의
the parallelism 운동
of median (Y축 방향)]
9
T-slot to
[중앙 T홈과 *Option(옵션)
평행도 검사] b) the
0.050/4000(DBMXX40)
movement
0.060/5000((DBMXX50)
of the table
(X-axis)
[테이블의
0.010/1000
운동
(X축 방향)]
79
Parallelism & Run out (평행도 & 흔들림) Unit : mm
Result
(측정 결과)
a) in the
vertical
YZ plane 0.015/300
[수직 YZ 평면
Checking of 내에서]
parallelism
between the
spindle axis
10
and the Z-axis
motion
[주축과 Z축과
의 평행도] b) in the
vertical
ZX plane 0.015/300
[수직 ZX 평면
내에서]
a) at spindle
nose
Checking of 0.005
[스핀들
run-out of 끝에서]
internal taper
of the milling
11 spindle
[밀링 스핀들
의 내부 b) at 300
테이퍼 구멍의 distance
흔들림 검사] [스핀들
0.015
끝에서
300mm 의
위치에서]
Checking of the milling

spindle :
periodic axial slip
12 [밀링 스핀들 검사 : 0.005
주기적 축 방향의
움직임]
80
[1] Angular Deviation
1. Angular Deviation Test of Table Movement (X axis)
1) XZ plane
2) YZ plane
① Measurement
Place a level in the center of the table in X & Y axes directions. Check if the level
reading is possible and then, feeding the X axis in 500 mm of stroke as a unit
measure the biggest level difference.
▶ Measuring point : X125. X625. X1125. X1625. X2125. X2625. X3125. X3625.
X4125. (500mmⅹ9 segments)
▶ Tolerance : X direction : 0.04mm / for the full stroke
Y direction : 0.03 mm / for the full stroke
X Y X Y
direction direction direction direction
Level Level Level Level
X- direction
② Adjustment
There ’ s a possibility of angular deviation in X axis (table) movement and it is t
hought to be the cause of feed level abnormality. So, by referring to “ Machine
Level Wok ” , conduct the leveling work again.
▪ If leveling doesn’t solve the issue, (X axis) L/M Guide alignment could be the
cause. Conduct L/M Guide replacement or re-alignment in this case.
81
[2] Straightness
2. X Axis Movement Straightness
1) YX plane
2) ZX plane
① Measurement
Using a laser measuring instrument, measure the horizontal (YX plane) and vertical
(ZX plane) straightness of X axis’ full stroke.
▪ If no laser measuring instrument is available, conduct measurement by preparing a
Straight Edge of at least 1,000 mm and lay it on the table (XY plane).
Measurement should be done with the Straight Edge standing on its end (vertical,
ZY plane). Try placing it as many points as possible to measure all segments and
use the result as the highest parallelism value.
▶ Measurement position : Full stroke of X axis X0. ∼ X4250.
▶ Tolerance : Y-X direction : 0.04mm / for the full stroke
Z-X plane: 0.03 mm / for the full stroke
Straightness
measuring
instrument Laser
measuring
instrument
X- direction
② Adjustment
There’s a possibility of angular deviation in X axis (table) movement and it is thought
to be the cause of feed level abnormality. So, by referring to “Machine Level Wok”,
conduct the leveling work again.
82
3. Straightness of Milling Head (Y axis) Movement
1) XY plane
2) ZY plane
① Measurement
Using a laser measuring instrument, measure the horizontal (XY plane) and ver
tical (ZY plane) straightness of Y axis ’ full stroke.
Straight Edge of at least 1,000 mm and lay it on the table (XY plane).
Measurement should be done with the Straight Edge standing on its end (vertical,
ZY plane). Try placing it as many points as possible to measure all segments, add
the result value, and use it instead.
(If the indicator holder can be extended, placing a Straight Edge in the center of
the table and conducting measurement on different places can be an option.)
▶ Measuring point : Full stroke of Y axis: Y0. ∼ Y3000.
▶ Tolerance : 0.030mm / 3000mm
Laser
Y direction measuring
instrument
Laser
measuring
instrument
② Adjustment
There’s a possibility of straightness deviation in Y axis movement and it is thought to
be the cause of level abnormality of columns on both sides. So, by referring to
“Machine Level Wok”, conduct the leveling work again. Measure each axis’ (X-Y, Y-
Z, X-Z) squareness at 3 points (midpoint of Y axis and both ends) and make them as
similar as possible.
83
4. Straightness of Z Axis Movement
1) YZ plane
2) XZ plane
① Measurement
Using a laser measuring instrument, measure Y direction (YZ plane) and X direction
(XZ plane) straightness of the full stroke of Z axis.
square and put it on the table in X & Y directions. By adjusting the length of
indicator holder to measure all segments, add the result value, and use it instead.
▶ Measuring point : Z0. ∼ Z800. / Z1100.(Option)
▶ Tolerance : 0.015mm / 800mm, 0.020mm / 1100mm(Option)
Laser
measuring
instrument
X direction
② Adjustment
The assembled state of Gib that adjusts the gap between the Ram and Saddle as
well as ball screw alignment error can be the causes of Z axis movement’s angular
straightness error. So the Gib and the ball screw need to be checked.
▪ If adjusting the Gib or ball screw does not solve the issue, Ram’s polished surface
problem could be the cause. The Ram should be replaced or re-polished in this
case.
84
※ Note) Re-adjusting Ram Gib

(1) Feed the axis to the midpoint of its stroke. (This is to minimize the
interference with ball screw caused by axis vibration. For more exact
result, measure with the ball screw nut fixing bolt loosened.)
(2) Among the Gib adjusting bolts, loosen the one in the center (BQ Bolt).
(3) Slowly fasten the fixing bolt (BB Bolt) until it is felt that the Gib has been
fastened enough. This is regarded as zero gap between the Gib and
Ram.
(4) Unfasten the fixing bolt (BB Bolt) half turn (180˚).
(5) Among the Gib adjusting bolts, fasten the set screw (BQ Bolt) and loosen
the BB Bolt by turning it half revolution to remove the Gib.
▪ Target gap of Gib: 0.01mm
85
[3] Squareness
5. Check Squareness Between Table Movement (X axis) and

Horizontal Milling Head (Y axis)
1) X - Y plane
① Measurement
Attach an indicator to the spindle. Lay down a 500 ⅹ 500 square, move the
indicator in X axis direction (ⓐ－ⓑ) and set both ends to “0”. Adjust the parallelism
in X axis direction by hitting the high point. Measure the parallelism of the square’s Y
axis direction (ⓒ－ⓓ) and use the biggest difference as the measured value.
▪ If 500ⅹ500 square is not available, use one of 300ⅹ300 for measurement and
then double the measured value.
▶ Measuring point : X-2125. Y-1350.,

X-2125. Y-300.,
X-2125. Y-2700.,
X-3950. Y-1350.,
X-300. Y-1350.,
ⓓ
Y direction
ⓒ
ⓐ ⓑ
X direction
② Adjustment
Adjusting X-Y squareness is to adjust Y axis based on X axis. Adjust the column
position by using adjust block.
86
※ Note) Column Position Adjustment

(1) By referring to the “X-Y squareness” above to measure exact
squareness.
(2) Slightly unfasten Column Base and Column fixing Bolt (10-BA30ⅹ110)
on one side.
(3) When measuring the squareness, adjust the column (based on ⓒ and
in the direction of ⓓ) by using the front & rear 100201-04345 Adjust
Blocks that are between Column Base and Column.
① If ⓓ is “+” :
There are adjusting bolts in the adjust Block. Slightly unfasten the
short pulling bolt (BB16ⅹ60) and slowly fastening the pushing bolt
(BB16ⅹ60) to adjust the squareness.
② If ⓓ is “-” :
Contrary to the above, adjust the squareness by pulling the column
backwards.
(4) In either case, the work should be finished with the pulling & pushing
bolts are well tightened.
(5) Strongly fasten Column Base and Column fixing Bolt (10-BA30ⅹ110).
(6) Repeat this procedure until a satisfactory squareness is obtained.
Pull
adjusting
Fixing bolt Push
Bolt adjusting
Column bolt
Adjust Column Fixing Adjust

Block Base Bolt Block
87
6. Check Squareness of The Milling Head ’ s Vertical Movement (Z axis)
1) Table movement (X-Z plane)

① Measurement
Attach an indicator to the spindle and put a square upright on the table in X axis
direction. Let ⓑ and ⓒ be “0” in the figure and assign symbols to the ⓑ － ⓐ
measurement and ⓒ - ⓓ measurement. If ⓐ and ⓓ are the same symbol, then
take the sum of the two axes’ measured values as the measured value. If the
symbols are different, subtract the smaller of the two axes' measured values from the
bigger measured value to take the difference as the measured value.
※ Conduct measurement in the same way at different locations on X and Y a
xes.

X-2125. Y-300.,
X-2125. Y-2700.,
X-3950. Y-1350.,
X-300. Y-1350.,
Z direction
ⓐ ⓑ
ⓒ
X direction
② Adjustment
The X-Z squareness can be adjusted by column leveling or by thickness adjusting of
liner on top of L/M Guide Block on Y axis (saddle).
X-Z squareness has a direct relationship with other parts’ accuracy. So it is required
to measure each part, check the relationship, and then select between column
leveling and L/M Guide Block’s liner thickness adjustment.
a. Squareness between vertical Milling Spindle’s centerline of rotation and linear
motion axis.
b. Parallelism of Z axis and Test Bar
88
※ Note) L/M Guide Block Readjustment (X-Z direction)

(1) By referring to the “X-Z squareness” above to measure exact squareness.
(2) Slightly unfasten 4 L/M Block fixing bolt above the saddle and then
remove the Adjust Block.
▪ Leave the bottom L/M Block as is.
(3) When measuring the squareness, (based on ⓓ) if ⓒ is “+”, grind the
same amount and if it is “-”, put a thicker Adjust Block.
(4) Tighten the L / M Block fixing bolts.
L/M Adjust
Block Plate L/M
Guide
Fixing
Bolt
Adjust
Plate L/M
Guide
L/M
Block
2) Horizontal motion of Milling Head (Y-Z plane)

① Measurement
Attach an indicator to the spindle and put a square upright on the table in Y axis
direction. Let ⓑ and ⓒ be “0” in the figure and assign symbols to the ⓑ － ⓐ
measurement and ⓒ - ⓓ measurement. If ⓐ and ⓓ are the same symbol, then
take the sum of the two axes’ measured values as the measured value. If the
symbols are different, subtract the smaller of the two axes' measured values from the
bigger measured value to take the difference as the measured value.
X-2125. Y-300.,
X-2125. Y-2700.,
X-3950. Y-1350.,
X-300. Y-1350.,
89
Y direction
Z direction
ⓐ ⓑ
ⓒ
② Adjustment
The Y-Z squareness can be adjusted by thickness adjusting of liner on the side of
L/M Guide Block on Y axis (saddle).
※ Note) L/M Guide Block Readjustment (Y-Z direction)

(1) By referring to the “Y-Z squareness” above to measure exact squareness.
(2) Slightly unfasten 4 on top and 4 at the bottom L/M Block fixing bolts
above the saddle.
▪ A half turn of the fixing bolt is enough.
(3) When measuring the squareness, (based on ⓓ) if ⓒ is “+” then insert
a screw jack between the brackets under the left (right if it is “-”) L/M
Block and remove the Support Liner on the side of the L/M Block by
slightly lifting the saddle.
(4) Grind the removed Support Liner. Grinding volume should be same as the
squareness error amount.
(5) Tighten the L/M Block fixing bolts.
Support
Liner
L/M
L/M Block
Guide
L/M
Block Screw
Jack
Fixing L/M
Bolt Bracket Guide
90
7. Squareness between vertical Milling Spindle’s centerline of rotation and linear

motion axis.
1) X axis direction movement of table

① Measurement
On the center of the table, attach an indicator to the spindle end. Snap the pin at the
point of 150 mm away from the spindle center, place a measuring block on the table.
Rotate the spindle by hand, set the X axis to “0”, turn the spindle 180°, move X axis
300 mm, and measure the block height.
▶ Measuring point : (With a point on the table as a center, at X-150. and X150.
positions) The block height of 2 positions on table top when
spindle is turned 180°
X direction
Spindle Y direction
Indicator
Measuring
Block X direction
② Adjustment
The squareness between X axis and spindle’s centerline of rotation can be adjusted
by thickness adjusting the liner of L/M Guide Block on Y axis (saddle).
But this has a direct relationship with other parts’ accuracy. So it is required to
measure each part and check their relationships.
a. X-Z squareness
c. Height difference in X axis direction on the table
91
※ Note) L/M Guide Block Readjustment (X-Z direction)

(1) By referring to the “X-Z squareness” above to measure exact squareness.
(2) Slightly unfasten 4 L/M Block fixing bolt above the saddle and then
remove the Adjust Block.
▪ Leave the bottom L/M Block as is.
(3) When measuring the squareness, (based on ⓓ) if ⓒ is “+”, grind the
same amount and if it is “-”, put a thicker Adjust Block.
(4) Tighten the L / M Block fixing bolts.
L/M Adjust
Block Plate
Fixing
Bolt
Adjust
Plate L/M L/M
Guide Guide
2) Spindle Head’s Y Axis Direction Movement

① Measurement
On the center of the table, attach an indicator to the spindle end. Snap the pin at the
point of 150 mm away from the spindle center, place a measuring block on the table.
Rotate the spindle by hand, set the Y axis to “0”, turn the spindle 180°, move Y axis
300 mm, and measure the block height.
▶ Measuring point : (With a point on the table’s Y axis as a center, at Y-150. and
Y150. positions) The height difference when spindle is turned
180°
Y direction
Spindle
Indicator
Measuring
Block
92
② Adjustment
The Y-Z squareness can be adjusted by thickness adjusting of support liner on the
side of L/M Guide Block on Y axis (saddle). But this has a direct relationship with
other parts’ accuracy. So it is required to measure each part and check their
relationships.
a. Y-Z squareness
※ Note) L/M Guide Block Readjustment (Y-Z direction)

(1) By referring to the “Y-Z squareness” above to measure exact squareness.
(2) Slightly unfasten 4 on top and 4 at the bottom L/M Block fixing bolts above
the saddle.
▪ A half turn of the fixing bolt is enough.
(3) When measuring the squareness, (based on ⓓ) if ⓒ is “+” then insert
a screw jack between the brackets under the left (right if it is “-”) L/M
Block and remove the Support Liner on the side of the L/M Block by
slightly lifting the saddle.
(4) Grind the removed Support Liner. Grinding volume should be same as the
squareness error amount.
(5) Tighten the L/M Block fixing bolts.
Support
Liner
L/M
L/M Block
Guide
L/M
Block Screw
Jack
Fixing L/M
Bolt Bracket Guide
93
[4] Parallelism & Run Out
8. Table Top Parallelism

① Measurement
Attach an indicator to the spindle, set the X axis center to “0” using a measuring
block, and move the X axis to measure the height difference between + direction’s
both ends.
▪ An alternative way that does not use measuring block is to directly touch the
indicator to the table top and move X axis.
▶ Measuring point : Measure 3 locations. (Table X axis direction’s center, end of +,
end of -) Calculate the biggest difference among measurement
values. The result is the biggest among the three.
▶ Tolerance : 0.030mm / 4,000mm
Indicator Indicator
Measuring
Block
Measuring
Block X direction
② Adjustment
If there’s a problem on the top of table, correct it by self-cutting.
2) Motion of Milling Head (Y axis direction)

① Measurement
Attach an indicator to the spindle, set the Y axis center to “0” using a measuring
block, and move the Y axis to measure the height difference between + direction’s
both ends.
▪ An alternative way that does not use measuring block is to directly touch the
indicator to the table top and move Y axis.
▶ Measuring point : Measure 3 locations. (Milling Head Y axis direction’s center,
end of +, end of -) Calculate the biggest difference among
measurement values. The result is the biggest among the
three.
94
Indicator
Y direction
Measurement
Block
② Adjustment
If there’s a problem on the top of table, correct it by self-cutting.
※ Note) Table Top Self-Cutting

(1) Before Self-Cutting, check the machine accuracy and fix it if necessary.
① X-Z, Y-Z squareness (0.015 mm / 500mm)
② Squareness between the centerline of spindle and X, Y axes
movement (0.010mm/300mm)
(2) Measure the height of whole table to decide the amount of rough cut.
(Roughing amount: 0.4mm∼0.5mm)
(3) Attach a tool for self-cutting to the
spindle.
(4) Send the tool to cutting start
position and run the entered Self-
Cutting program.
(5) After the rough cutting, leave it for a day. Measure the table’s overall
height to see if there has been any change. Start finishing cut if no
change is found.
Finishing cut volume : 0.03mm
95
▪ Table top Self-Cutting Program example

O1000 (Self Cutting)
S230M03; G91G00X300Y-2050
G91Z-50
G90G00G53X-3924.9Y-2525
G91G01Y2050F800
G91Z50
G91Z50
M3S800
G91G00X300Y-2050
G91Z-50
G91Z-50
G91G01Y2050F800
G91G01Y2050F800
G91Z50
G91Z50
G91G00X300Y-2050
G91G00X300Y-2050
G91Z-50
G91Z-50
G91G01Y2050F800
G91G01Y2050F800
G91Z50
G91Z50
G91G00X300Y-2050
G91G00X300Y-2050
G91Z-50
G91Z-50
G91G01Y2050F800
G91G01Y2050F800
G91Z50
G91Z50
G91G00X300Y-2050
G91G00X300Y-2050
G91Z-50
G91Z-50
G91G01Y2050F800
G91G01Y2050F800
G91Z50
G91Z50
G91G00X300Y-2050
G91G00X300Y-2050
G91Z-50
G91Z-50
G91G01Y2050F800
G91G01Y2050F800
G91Z50
G91Z50
G91G00X300Y-2050
M05
G91Z-50
M30
G91G01Y2050F800
G91Z50
(6) When the cutting program ends, the table top Self-Cutting is finished.
96
9. Parallelism Between Center T Groove and Axis Feed
1) Motion of Milling Head (Y axis direction)

① Measurement
Attach an indicator to the spindle, touch the gauge to the side of T groove (Y
direction) on the table center and measure the parallelism of + direction’s both ends
by moving the Y axis.▶ Measuring point : Table Y축 방향 T홈 측면. 전구간
Indicator
Center T
groove
Y direction
Indicator
② Adjustment
If an issue is found in the table’s T groove parallelism, correct it by self-cutting.
Ø24
End Mill
97
※ Note) Table T Groove Self-Cutting Program

O1001
G90G00G53X-4150Y-2600 G91G01Y2190F1610
S230M3 G91G0X140
G91G01Y2190F1610 G91G01Y-2190F1610
G91G0X150 G91G0X160
G91G01Y-2190F1610 G91G01Y2190F1610
G91G0X150 G91G0X140
G91G01Y2190F1610 G91G01Y-2190F1610
G91G0X140 G91G0X160
G91G01Y-2190F1610 G91G01Y2190F1610
G91G0X160 G91G0X140
G91G01Y2190F1610 G91G01Y-2190F1610
G91G0X140 G91G0X160
G91G01Y-2190F1610 G91G01Y2190F1610
G91G0X160 G91G0X140
G91G01Y2190F1610 G91G01Y-2190F1610
G91G0X140 G91G0X160
G91G01Y-2190F1610 G91G01Y2190F1610
G91G0X160 G91G0X140
G91G01Y2190F1610 G91G01Y-2190F1610
G91G0X140 G91G0X160
G91G01Y-2190F1610 G91G01Y2190F1610
G91G0X160 G91G0X140
G91G01Y2190F1610 G91G01Y-2190F1610
G91G0X140 G91G0X160
G91G01Y-2190F1610 G91G01Y2190F1610
G91G0X160 G91G0X140
G91G01Y2190F1610 G91G01Y-2190F1610
G91G0X140 M05
G91G01Y-2190F1610 M30
G91G0X160
98

① Measurement
Attach an indicator to the spindle, touch the gauge to the side of the middle Key
groove (X direction) on the table center and measure the parallelism of + direction’s
both ends by moving the X axis.
▶ Measuring point : Side of the middle key groove on the table’s X axis direction.
For the full stroke.
Middle Key
Groove
Middle Key
Groove
Indicator
X direction
② Adjustment
If an issue is found in the table’s key groove parallelism, correct it by self-cutting.
※ Note) Self-Cutting Program for Table X Direction Key Groove

O1002
G90G00G53X-4200Y-2349.6
G91Z50
M3S800
G91Z-50
G91G01X4200F800
G91Z50
G91G01X-4200Y850F5000
G91Z-50
G91G01X4200F800
G91Z50
G91G01X-4200Y850F5000
G91Z-50
G91G01X4200F800
G91Z50
M05
M30
99
10. Parallelism between the Centerline of the Spindle and the Z-axis Feed
1) Vertical YZ plane
2) Vertical XZ plane
① Measurement
Set up a test bar on the Spindle and an indicator on the Table. Contact the gage at
the highest point at the end of the test bar. Measure the spindle run-out by rotating
the spindle by hand. Stop the spindle at the middle point between the max. and min.
run-out. Measure the difference between the entrance and end of the test bar by
feeding the Z-axis..
▶ Measuring point : Test Bar’s entry point and the end
Z direction
X-Z
direction Test Bar
Y-Z
direction Indicator
2) Adjustment
In general, it is very unlikely that axial or spindle squareness deformations will occur in
L/M guide machines, but if orthogonally deformed due to severe collision, the
squareness can be corrected by adjusting the thickness of 250114-00443 Adjusting Plate
that attaches to the spindle housing.
※ Loosen the fixing bolts of the spindle housing to see if any part has been push
ed to one side. Since the accuracy is relevant to “ 6.7 Squareness between ve
rtical Milling Spindle ’ s centerline of rotation and linear motion axis ” (X-Z dir
ection) and “ 6.8 Squareness between the centerline of spindle and Y axis
movement ” (Y-Z direction), errors and directions must be checked before makin
g corrections.
100
11. Run-Out of Internal Taper of The Milling Spindle
1) Spindle end point (entrance)

2) 300 mm from the spindle end
① Measurement
Install the test bar on the spindle and turn the spindle at low speed or manually with
the indicator touching the entrance and 300 mm from the entrance. Rotate the
spindle manually or at a low speed to measure the run-out and take the maximum
run-out as the measured value.
▶ Measuring point : Test-Bar entrance and 300 mm from the entrance
▶ Tolerance : Entrance : 0.005mm,
300 : 0.015mm
Indicator
Entrance
300mm
position
Test Bar
2) Correction
① Because there is a possibility of dents and the like being created on the spindle taper
surface, remove pull stud using a test bar or a new tool, apply a thin red lead or
stamp pad to the taper portion, rub the taper surface against another, and, from the
touched traces, cut out the dented areas using sandpaper.
※ You must not polish the taper surface with a grinder or the like, and when the
taper surface is seriously damaged, the spindle must be re-polished.
② Touch an indicator to Spindle Taper surface to check Run-Out. If the measurement
exceeds 0.005 mm, Spindle Main Bearing or Main Spindle can be the cause of the
problem. Repair or replacement of bearing or spindle is required.
101
12. Milling Spindle Periodic Axial Slip
1) Measurement
Insert Test Bar into the spindle and apply grease to the polished surface of Test Bar
end’s cross section or the center drilling position. Attach a steel ball and measure the
Run-Out at the highest point of the ball using an indicator.
▶ Measuring point : Cross section of Test Bar’s end
▶ Tolerance : 0.005mm
Spindle
Indicator
2) Adjustment Method
The movement of the spindle in the Z-axis direction is presumed to be associated with
the problem of the spindle main bearing, so the bearing needs to be replaced.
102
8. AAC(Auto Attachment Changer)

8.1 AAC Alignment Related M-Code & Keep Relay
① AAC related Keep relay & M-Code
Keep Relay Description

K23.6 Attachment Clamp
K23.7 Attachment Unclamp
K90.0 K dummy(when installed, required virtual dummy)
K90.1 K Angle
② AAC auto operation M-Code
Macro program to call Description

M400A0 Return all attachments to AAC Station
After returning current attachment,
M400A1
Attach Dummy Head at Rack no. 1 to the Ram.
After returning current attachment,
M400A2
Attach Angle Head at Rack no. 2 to the Ram.
③ AAC Manual operation M-Code
M-Code Description
M470 AAC Door Open
M471 AAC Door Close
Function Dummy Angle Remark

Advance M404 M406
ATT. Rack
Retract M405 M407
ATT. Pullstud ② Clamp M410, [K23.6]

(Side 4ea) Unclamp M411, [K23.7]
SPD Pullstud ① Clamp M148, Yellow button

(Center) Unclamp M149, Yellow button
④ Angle Attachment Rotation

M488C** Rotate the attachment at the commanded angle (C**)
103
⑤ If an error occurs while rotating Angle Head

▪ Check the functionality of Curvic Clamp, check the status of Horizontal ATT button
lamp on the NC operation panel, and run the M code below

M487C** Make current angle recognized as C** by the NC
104
8.2 Check AAC (Auto Attachment Changer) Dummy Head’s alignment
1) AAC shipping status

All 2 attachments are fixed by external cradles when shipped. They should be installed
inside the AAC Station using a crane before installing AAC cover.
After Rack 1 & 2 alignment check, auto change in AAC Auto mode can be enabled.
2) Check alignment of AAC Dummy Head

Preparations for checking the alignment of Dummy Head
① In the Ref mode, move it to the home position of Y & Z axes.
② In the MDI mode, run the following M codes in the order.
a. M5 (Spindle Stop)
b. M470 (2 Station AAC Door Open)
 If cover is not installed, change it to K7.2[1] AAC DOOR NOT USE KEEP
instead.
c. M404 (2 Station AAC Upper Rack Advance, Dummy)
105
3) Check flatness of Dummy Head in X axis direction

① Attach an indicator to the rotating part of the spindle. Using the entered value in D-
DATA 7008 (Y axis coordinate of AAC RACK1), change the mode to ‘HANDLE’ and
feed the Ram to Y axis.
② Measuring ATT top side flatness
▪ Since the space between the Dummy Head and the Ram attachment surface is too
narrow (within 100 mm),
Measuring height difference in 4 directions (+ & - of Y, + & - of X) is not easy,
measure them with the following method.
a. Attach an indicator to the Ram body fixed part
b. Measure X direction flatness (yellow) - Attach an indicator to the rotating part of
the spindle. Measure the height difference in 2 directions (+ & - of X) of Dummy
Head attachment (bottom) surface by rotating the spindle.
c. Measure Y direction flatness (blue) - Attach an indicator to the fixed part of the
Ram. Measure the height difference in 2 directions (+ & - of Y) of Dummy Head
attachment (bottom) surface by feeding the Y axis.
▪ If the measurement result exceeds the tolerance, use height adjusting bolts
for each 4 positions for Dummy Head to make the value fall within the
tolerance (0.1 mm).
Under the Dummy

Head, use the height
adjusting nut to adjust
the flatness
106
4) Measure Y-direction parallelism of Dummy Head

① Change the mode to ‘HANDLE’, feed to ‘0’ position on Z axis, and run M19 Spindle
Orientation command.
② With the Rack no. 1 Advance state, attach an indicator to the Ram’s fixed part, set ‘0’
for the tapered part of the no. 1 Pull stud (image below), and then, for the no. 2 Pull
stud, measure Y direction’s parallelism.
③ If Y direction’s parallelism adjustment is needed, use the bolts for Dummy Rack
Advance & Retract position adjustment.
Adjust Y-direction
parallelism of Dummy tool
Adjust Y-direction parallelism

of 90 Angle head
5) Dummy Head Attachment Unclamp

① After changing to MDI mode, execute K23.7 Attachment Unclamp.
※ Always ensure the Unclamp state to prevent the collision between attachment
and Ram.
ATT
Unclamp
ATT
Clamp
107
6) Check Dummy Head AAC position coordinate’s D-DATA

① Change the mode to ‘HANDLE’ and slowly feed the Ram to the coordinate below.
▪ (D-Data 7008) Rack1 AAC Change Y(-) Position
▪ (D-Data 7012) Rack1 AAC Change Z(-) Position
② Visually check whether the Ram and Dummy Head interfere with the block key entry
section.
Dummy Head
Guide Key
③ Set Z direction gap

a. Disassemble the block key to measure the gap.
b. After changing the 'Handle' mode(D-Data 7012) , it is finely transferred in the Z (-)
direction with reference to the value entered in Rack1 AAC Change Z (-) Position.
c. Finely feed the Z (-) direction until the niche gauge is in close contact with the
niche gauge in the state where the niche gauge is placed on the attachment
surface of the Ram and Dummy Head of the Block Key Slot.
▪ Ram and dummy head clearance allowance : 1.4mm
(When attaching the dummy, the gap between the ram: 1.1mm + the gap between the
dummy head and the AAC seat: 0.3mm)
Block Key
Disassembly
Key Disassembly
BB M10ⅹ35 2EA
Dummy Head D-Data 7012

clearance 1.4mm
108
④ Enter the Z-axis value of the machine coordinate in the D-Data below in the 1.4mm
gap between the ram and dummy head.
▪ (D-Data 7012) Rack 1 AAC Change Z(-) Position
※ Ex) In case of Z machine coordinate value -99.300mm, D-Data7012 input value is
-99300.
⑤ When the gap setting is completed, reassemble the disassembled Block Key.
a. When reassembling, feed Ram in Z (+) direction to escape block key on the
Dummy head attachment surface.
b. Fix only slightly enough to have a direction gap, and feed the ram in the Z (-)
direction to fix it in the key way.
c. Fasten the fixing bolt strongly an intense state.
☞ Since the Y & Z axes positions set at the factory can be changed depending on the
machine’s installation condition, AAC position setting should always be checked
during installation.
7) Check Dummy Head Attachment seat position

① AAC Y & Z axes’ coordinate setting is finished, by referring to SYSTEM  D-
DATA7008 (RACK1 AAC CHANGE Y(-) POSITION), 7012(RACK1 AAC CHANGE
Z(-) POSITION), change the mode to ‘HANDLE’ and then slowly feed to the
coordinate.
② Run command K23.6[1] (Attachment Clamp) and then check the state of Dummy
Head Clamp.
※ Note : How to change Keep relay Change K23.7 (ATT Unclamp) [1]  [0] and
then change K23.6(ATT Clamp) [0]  [1]
③ Run the command K23.7[1] (Attachment Unclamp) and then check if an interference
occurs at the guide corn of RACK’s seating position. To change position, unfasten the
fixing bolt of seating position’s Guide corn loose enough to freely move, repeat
clamping & unclamping 2-3 times, fasten the bolt in unclamped state.
Guide corn
Guide corn
고정
Fixing볼트
bolt
2EA
109
8) Ram Z & Y axes zero return

① In MDI mode, change K23.7[1] to [0]to initiate Attachment Unclamp and change the
mode to ‘HANDLE’ to return to ‘0’ position on Z axis.
② Feed to Y axis (+) direction to completely go out of AAC segment.
▪ Feed to the Y coordinate that is set in D-data 7152 (Rack1 AAC Door Open Y
Position)
③ Run Commands M403 (Dummy Rack Retract)  M471 (AAC Door Close) to finish
the AAC Dummy Head alignment work.
Dummy Head
back off
110
8.3 Alignment status check of AAC (Auto Attachment Changer) 90-degree Angle Head
1) Align Angle Head

Preparations for checking the alignment of AAC Angle Head
▪ In the Ref mode, feed to the zero point on Z & Y axes.
▪ Disassemble the spindle drive keys (2EA).
▪ In the MDI mode, run the following M codes in the order.
a. M5 (Spindle Stop)
b. M470 (2 Station AAC Door Open)
 When installing the machine, change the Keep relay instead K7.2 [1]AAC DOOR
NOT USE KEEP
c. M406 (2 Station AAC Lower Rack Advance, Angle)
2) Check Angle Head flatness

① Attach an indicator to the rotating part of the spindle. Using the entered value in D-
DATA 7128 (RACK2 AAC CHANGE Y(-) POS), change the mode to ‘HANDLE’ and
feed the Ram to Y axis.
② On a flat surface on the ATT’s top side, put an indicator set to ‘0’ and measure the
difference in 4 directions, that is, Y(+ & -), X(+ & -). If the measurement result
exceeds the tolerance, use height adjusting bolts for each 4 seating positions for
Angle Head to make the value fall within the tolerance (0.1 mm).
Under the Angle Head, use

the height adjusting nut
to adjust the flatness
111
3) Measure Y-direction parallelism of Angle Head

① Change the mode to ‘HANDLE’, feed to ‘0’ position on Z axis, and run M19 Spindle
Orientation command.
① With the Rack no. 2 Advance state, attach a magnet indicator to the Ram & spindle,
set ‘0’ for the tapered part of the no. 1 Pull stud (image below), and then, for the no. 2
Pull stud, measure Y direction’s parallelism.
② If Y direction’s parallelism adjustment is needed, use the bolts for ANGLE RACK
ADVANCE & RETRACT position adjustment.
4) Angle Head Attachment Unclamp

① With the Angle Head attached to the Ram, using the M-Code command does not
initiate ATT Unclamp. This is a safety feature to prevent falling. When installing the
machine, use K90.0[1] command to recognize it as Dummy Head and then start
aligning work.
▪ “K90.0 = 1”
☞ Recognizes the Angle Head attached to the Ram as a Dummy Head.
Changing the Keep relay as described above, the following message alarm
appears in the NC operation panel.
※ 2294 NOW MACHINE IS ADJUSTING STATUS. PLEASE CHECK KEEP RELAYS.
112
② After changing to MDI mode, run M-code as follows. Operation status can be
checked visually and in the STATUS screen.
Command
Order Description How to check
Method
(When installing) Check by
1 M19 Spindle Orientation
indicator, Visual check
2 Yellow button Spindle Tool Unclamp X1.0, Visual check
3 M145 Spindle Collet Air Off Visual check
4 K23.7[1] Attachment Unclamp Y6.2[1], Visual check Collet
※ To prevent the collision between Ram and Attachment when 90-degree Angle
Head’s AAC position.
ATT
UNCLAMP
ATT
CLAMP
5) Check D-DATA at Angle Head position coordinate

① Change the mode to ‘HANDLE’ and slowly feed the Ram to the coordinate below.
▪ Rack 2 AAC Change Y(-) POS (D-Data 7128)
▪ Rack 2 AAC Change Z(-) POS (D-Data 7132)
② Visually check if an interference at the insertion area of the guide key for the Ram
and the Angle Head.
Angle Head Guide

key inserted
113
③ Set Z direction gap

a. Disassemble the block key to measure the gap.
b. After changing the 'Handle' mode, , slowly feed to Z(-) direction refer to the D-Data
7132 Rack 2 AAC Change Z(-) Position.
c. As shown in the photo below, the feeler gauge(1.1mm) put to the gap between the
Ram and Angle Head section. Slowly feed the Z (-) direction until the feeler gauge
is tight and does not move while it is put on the surface.
▪ Allowable clearance between ram and angle head (1.1mm)
(When the angle is attached, the gap between the ram : 1.0mm + the gap between
the angle head and the AAC seat : 0.1mm)
Key disassemble Block Key

BB M10ⅹ35 2EA disassemble
Feeler D-Data
Gauge 7132
The gap between

Ram and Angle
Head 1.1mm
④ check the machine coordinate at the gap 1.1mm between the Ram and Angle Head,
input current Z position to the D-data 7132 Rack2 AAC Change Z(-) Position
▪ (D-Data 7132) Rack2 AAC Change Z(-) Position
※ Example) When the Z-axis machine coordinate value is -310.030mm, the input
value of D-Data 7132 should be -310030
⑤ When the gap setting is completed, reassemble the Block Key.
a. When reassembling, feed Ram in Z (+) direction to escape block key on the angle
head attachment surface.
b. Fix only slightly enough to have a direction gap, and feed the ram in the Z (-)
direction to fix it in the key way.
c. Fasten the fixing bolt strongly an intense state.
☞ The Y-axis and Z-axis positions set at the time of production may vary depending on
the installation status of the equipment, so make sure to check the AAC position
setting during installation.
114
6) Angle Head Clamp & Unclamp position check

① Run command K23.6[1] (Attachment Clamp) and then check the state of Angle Tool
Attachment Clamp.
② Run the command K23.7[1] (Attachment Unclamp) and then check if an interference
occurs at the guide corn of RACK’s seating position. To change position, unfasten the
fixing bolt of seating position’s Guide corn loose enough to freely move, repeat
clamping & unclamping 2-3 times, fasten the bolt in unclamped state.
Guide Corn
Fixing bolt
2ea
7) Moving inside the machine after Angle Head Clamp

① Angle Head Clamp Command
▪ Spindle clamp  JOG mode Yellow Clamp button
▪ Attachment Clamp  K23.6[1] command
② Set the Angle Head’s position on Z axis when manually feed the Angle Head from
Rack 2 to inside the machine.
▪ When manually feeding the Angle Head from Rack 2 to the inside the machine, the
Z position is set in D-Data 7136 RACK2 AAC CHANGE Z-DECK POS.
▪ Change the mode to ‘HANDLE’ and slowly feed using the entered D-data 7136
value checking interference between Angle Head and Rack.
▪ If Z position is reached, feed in Y (+) direction using the handle and see if any
interference occurs.
▪ If an interference occurs between the RACK and Angle Head, modify the D-Data
7136 Z-DECK POS value.
Check
interference
Block gauge
contact
115
8) Ram Z & Y axes zero point return

① In MDI mode change the Keep relay below, change the mode to ‘HANDLE’ and
carefully feed to the Z axis zero point.
Order Command Description How to check
1 Yellow button Spindle Tool Unclamp X1.0[1], visual check

2 K23.7[1] Attachment Unclamp Y6.2[1], Collet visual check
※ Before conducting Z & Y axes zero return

(1) In JOG mode, push the yellow SPINDLE UNCLAMP Button next to Ram
▪ Yellow light is lit if Unclamp is enabled
▪ STATUS(Condition) X1.0[1] (SPINDLE TOOL UNCLAMP CHECK) can
be checked
(2) Be sure to check the change to K23.7 [1] ATTACHMENT UNCLAMP
▪ STATUS(condition) Y6.2[1] can be checked
▪ If one of the two methods (attachment or clamp with Ram) is used to
feed Y & Z axis the attachment may fall down. So be sure to check the
unclamp status of the two methods and then feed in Z (+) direction.
② Feed to Y axis (+) direction to completely go out of AAC segment.

▪ Feed to the Y coordinate that is set in D-data 7152 (RACK2 AAC DOOR OPEN Y
POSITION)
③ Run commands M407 (ANGLE RACK RETRACT)  M471 (AAC DOOR CLOSE) to
finish the Angle Head alignment work.
116
Angle Head
back off
117
9. ATC Adjustment
9. ATC Adjustment
9.1 Assembling the Tool Magazine
When shipping DBM25, ATC (Auto Tool Changer) and AAC (Auto Attachment Changer)
Units are pre-installed on to the column. Only the magazine is disassembled and packed
separately. When installing on-site, alignment work can be done right after mounting the
magazine.
1) How to Assemble The Magazine

① Connect a rope to the I-Bolt at the top of the magazine and move the magazine to
the part to be attached to.
② Since there is a risk that bottom support and the bolt may be damaged, adjust the
bolt length to be rather short, make moves, and fix it in place.
③ When the alignment of the support at the bottom of the magazine is done, fix it on the
ground using a Set anchor.
※ Caution) After attached the magazine to the machine, the supporting bolt attached
the bottom of magazine should be touched to the floor. It is necessary to
check if it is done, and it may not be touched the floor with the change
machine leveling condition. All after completing the machine level
adjustment be sure to check whether the magazine floor is touched.
Magazine Disassembled
Hook up when shipped
118
9. ATC Adjustment
2) Precautions for Magazine Attachment

① Put the magazine to the guide bracket (Reference Surface) on the right side of the
magazine and then assemble the left guide bracket.
The reference bracket on right has a positioning pin. Press the magazine against the
reference surface, align the bracket’s guide groove, and then fix it.
② When attaching the magazine to the magazine frame, check if the fixing blots (8EA)
have been tightened. When conducting magazine centering check after basic
assembly, fine tuning may be necessary. Gap is pre-adjusted before shipping but
should be adjusted on-site again if necessary.
③ When attaching the magazine, mind the interference with the Y axis servo motor.
Magazine
gap adjusting
bolt 8 EA
119
9. ATC Adjustment
9.2 Preparations for Adjusting ATC Unit Alignment
1) ATC Alignment Preparation Work

▪ To adjust the ATC Alignment of DBM25 equipment, adjust the dummy head first and
then work in the order of 90 degree angle head.
※ Manual operation method for each section of ATC

1) Method using CUSTOM1 (EOP screen)
CUSTOM1 (EOP screen)  SOPP (Soft Operation panel)  ATC OP
screen  Activate OPER.ON Button and operate Cycle Start Button for
each section
2) How to operate by changing the keep relay
▪ Among the two methods above, this manual proceeds by using Keep relay
change.
1) ATC Alignment work

After confirming the main power and hydraulic operation after removing the fixed
bracket, move the ATC Unit to the initial position using the Keep relay.
※ The location of the ATC Unit at the time of shipment is as follows.
▪ Fixture attachment position (Magazine Side + Arm In + Arm Down + Arm Right)
1 Magazine Side
○ 2 Arm In
○ 3 Arm Down
○ 4 Arm Right
○
[K22.0] [K21.6] [K22.5] [K22.2]
“ATC fixing
Bracket _ 2”
“ATC fixing
Bracket _ 1”
▪ Remove the fixing bracket. Check the main power and hydraulic function and then
move the ATC unit to home position using the Keep relay.
▪ ATC home position (Magazine Side + Arm In + Arm Up + Arm Right)
1 Magazine Side
○ 2 Arm In
○ 3 Arm Up
○ 4 Arm Right
○
[K22.0] [K21.6] [K22.4] [K22.2]
120
9. ATC Adjustment
▪ The Keep relays used for ATC centering are listed in the table below.
Keep relay Description Keep relay Description
K 7.6 ATC Not Use Keep K 22.0 Magazine Side

K 91.7 ATC Service Mode K 22.1 Spindle Side
K 7.0 ATC Chip Door Use K 22.2 Changer Right
K 21.4 ATC Arm CW K 22.3 Changer Left
K 21.5 ATC Arm CCW K 22.4 Changer Up
K 21.6 Changer Arm In K 22.5 Changer Down
K 21.7 Changer Arm Out K 51.0 Machine Service Mode
※ ATC Sequence table
Step 90º Angle Head Step Dummy Head

1 T Command 1 T Command
2 Auto Mode 2 Auto Mode
3 Initial Position 3 Initial Position
4 Magazine Index 4 Magazine Index
5 Magazine Stop 5 Magazine Stop
6 Changer Left Position 6 Changer Left Position
7 Changer Arm Out 7 Changer Arm Out
8 Changer Arm Spindle Side 8 Changer Arm Spindle Side
9 Changer Arm In 9 Changer Arm In
10 - 10 Changer Arm Down
11 M06 Macro Call 11 M06 Macro Call
12 Check Spindle Orientation 12 Check Spindle Orientation
13 M06 command 13 M06 command
14 Changer Right Side 14 Changer Right Side
15 Spindle Tool Unclamp 15 Spindle Tool Unclamp
17 Changer Rotator 180°(Cw) 17 Changer Rotator 180°(Cw)
19 Spindle Tool Clamp 19 Spindle Tool Clamp
20 Changer Left Side 20 Changer Left Side
121
9. ATC Adjustment
Step 90º Angle Head Step Dummy Head

Check Z axis first reference Check Z axis first reference
21 21
point point
22 - 22 Changer Arm Up
24 Changer Magazine Side 24 Changer Magazine Side
26 Changer Right Side 26 Changer Right Side
27 M06 Finish 27 M06 Finish
122
9. ATC Adjustment
9.3 Adjusting Dummy Head’s ATC Alignment
1) Preparation for ATC Alignment

① In MDI mode, run the command M400 A1 (Automatic ATT Replacement) to attach it
to Dummy Head Ram.
② Disassemble the spindle drive key (2ea) and then install an alignment fixture.
※ Note for removing spindle drive key

For the compatibility with BT/DIN tools, the left & right drive keys are in
different length. Mark exact positions to make sure that the parts can be
assembled back. Usually the length of the key in the direction of ATC unit is
short after running M19 Spindle Orientation command.
“Jig 1” “Jig 2”
“Jig 2”
“Jig 3” Attach spindle
ATC AAC
direction direction
key is key is
short long
123
9. ATC Adjustment
2) Measure Parallelism of Dummy Head and Charger Arm

① In MDI mode, move the ATC Unit to the Tool Change position by using Keep relay.
▪ ATC Unit Movement Sequence
1 Spindle Side
○ 2 Arm In
○ 3 Arm Down
○ 4 Arm Right
○
[K22.1] [K21.6] [K22.5] [K22.2]
※ There are cases where Keep relay cannot be changed to [1]. This is because of self-
hold in PLC. To clear the self-hold state and move to a desired segment, a change to
K22.7 [1] ATC CHANGER K22.0-K22.5 ZERO is needed.
② In MDI mode, change the value for Keep Relay 7.0 ATC Door Use as follows.
▪ Change it to K7.0 [0] *[1] - Use, [0] - not use
③ In MDI mode, change it to Keep relay 91.7[1] to switch to ATC Service state.
▪ Change it to K91.7[1] -> Advance to ATC area by using the ‘HANDLE’ mode
☞ When changed to K91.7 [1], the following message alarm occurs. Be careful of
collision.
* 2294 Now Machine Is Adjusted Status. Please Check Keep Relay.
“Vertical ATC
position”
④ Attach an indicator to the spindle, measure the cross-section parallelism of the fixture
no. 1 that is attached to the Changer Arm, and adjust the value if necessary.
(Tolerance: 0.1mm)
▪ Y direction (Axis feeding) adjusting method: Spacer on ATC Unit Column attaching area
▪ X direction (vertical 2-way height difference) adjusting method: Changer Arm Up &
Down Stopper Bolt
Y-direction parallelism spacer on-site fitting X-direction parallelism down Stopper
124
9. ATC Adjustment
3) Adjusting ATC Alignment of Dummy Head

1 Spindle Side
○ 2 Arm In
○ 3 Arm Down
○ 4 Arm Right
○
[K22.1] [K21.6] [K22.5] [K22.2]
② Change the mode to ‘HANDLE’ and feed the Ram to ATC position. To avoid collision
between Changer Arm and the spindle, carefully feed checking interference by fine
feeding.
※ “Tolerance of the gap between the spindle’s cross section and alignment
fixture (2 mm)”
▪ D-Data(7024) Rack 1 ATC Change Y(-) POS
▪ D-Data(7028) Rack 1 ATC Change Z(-) POS
③ Adjust Y & Z direction alignment

a. Adjust concentricity of Y direction
Among the fixtures for centering work, use the “fixture 3” to check the centers of
“fixture 1” and “fixture 2”. Where, fine feed the Y axis in “HANDLE” mode trying to
center as correct as possible.
b. Adjust concentricity of X direction
Make fine adjustment using positioning bolt that adjusts the whole ATC Unit.
125
9. ATC Adjustment
“Y direction axis
feeding”
“X direction fine
adjustment”
c. Change to D-Data
When the Y-axis direction adjustment is complete, change the Y-axis machine
coordinates displayed in the machine coordinates of the “POS” screen to D-Data,
and record the entered values in the shipping information sheet.
④ Adjust Z axis direction (gap)

Using a Feeler gauge, adjust the gap between the “fixture 1” (for Changer Arm) and
“fixture 2” (for spindle) making it smaller than the tolerance, that is, 2.0 mm.
a. How to adjust gap width: Change the mode to “HANDLE” and fine feed the Z axis
b. When Z direction gap setting is done, enter the Z coordinate in the D-Data field:
2 mm
⑤ When the clearance adjustment between the spindle and the alignment fixture is
completed, mount the actual tool on the spindle and check the contact between the
changer arm and the ‘V’ groove of the tool as shown in the picture below.
※ When changing the tool, it is ideal to adjust the clearance so that when the
changer arm is in close contact with the 'V' groove of the actual tool, it contacts
the inclined surface in the direction in which the tool comes out.
126
9. ATC Adjustment
Real Tool 0.3∼0.5 mm
Check gap width
⑥ Z & Y-axis zero return

Change to ‘HANDLE’ mode, zero-return Z & Y axes, and then conduct 90º Angle
Head adjustment.
9.4 90º Angle Head Adjustment
1) Attachment of Angle Head

In 'MD' I mode, command M400 A2 and attach a 90 degree Angle Head to the Ram.
2) 90 degree angle head and changer arm parallelism measurement

① Move the ATC Unit to the Tool Change position by using Keep relay.
1 Spindle Side
○ 2 Arm In
○ 3 Arm Up
○ 4 Arm Right
○
[K22.1] [K21.6] [K22.4] [K22.2]
② In MDI mode, change the value for Keep Relay 7.0 ATC Door Use as follows.
▪ Change it to K7.0 [0] *[1] - Use, [0] - Don’t use
③ In MDI mode, change it to Keep relay 91.7[1] to switch to ATC Service state.
▪ Change it to K91.7[1] - Advance to ATC area by using the ‘HANDLE’ mode
☞ When changed to K91.7 [1], the following message alarm occurs. Be careful of
collision.
* 2294 Now Machine Is Adjusted Status. Please Check Keep Relay.
127
9. ATC Adjustment
④ Attach an indicator to the spindle, measure the cross-section parallelism of the fixture
no. 1 that is attached to the Changer Arm, and adjust the value if necessary.
(Tolerance: 0.1 mm)
▪ Y direction adjustment : Magazine & SPINDLE SIDE Stopper bolt
▪ Z direction adjustment : Changer Arm UP & DOWN Stopper bolt
Y direction parallelism
adjustment
Z direction parallelism adjustment
3) Adjusting ATC Alignment of 90º Angle Head

Spindle Side Arm In Arm Up Arm Right

[K22.1] [K21.6] [K22.4] [K22.2]
② Change the mode to ‘HANDLE’ and feed the Ram to ATC position. To avoid collision
between Changer Arm and the spindle, carefully feed checking interference by fine
feeding.
※ “Gap tolerance (2 mm)”

③ Adjust Y & Z direction alignment

a. Adjust concentricity of Y & Z axes
Among the fixtures for centering work, use the “fixture 3” to check the centers of
“fixture 1” and “fixture 2”. Where, moving the Y & Z axes in “HANDLE” mode trying
128
9. ATC Adjustment
to center as correct as possible.
b. Upon finishing Y & Z axes direction adjustment, change and enter the Y & Z axes
machine coordinate displayed in the “POS” screen into D-Data field. Record the
the entered value in the shipping information sheet
④ Adjust X axis direction (gap)
Using a Feeler gauge, adjust the gap between the “fixture 1” (for Changer Arm) and
“fixture 2” (for spindle) making it smaller than the tolerance, that is, 2.0 mm.
▪ Make adjustment by using the X direction gap adjusting bolt located in the front of
Changer Arm.
※ After adjusting the clearance bolt in the X direction, convert to dummy

head reconfirm
After adjusting the gap of 90 degree angle head, it is necessary to recheck
the gap in the vertical direction.
Recheck vertical direction gap “D-Data (7028) Rack 1 ATC Change Z(-) POS”
and change the value again.
X direction gap a
djusting bolt
2mm
129
9. ATC Adjustment
⑤ When gap width setting between the spindle and alignment fixture is done, attach an
actual BT Type tool to the spindle and, as shown below, check the adherence state
between Changer Arm and tool’s V groove.
▪ Ideally, the outer slope of the Changer Arm Griper should be adjusted back and
forth so that the inner slope has a clearance of 0.3 to 0.5 mm when it touches the
tool.
Real Tool 0.3∼0.5 mm
Check gap width
⑥ Z & Y-axis zero return

Change to ‘HANDLE’ mode, zero-return Z & Y axes, and then conduct magazine
alignment.
130
9. ATC Adjustment
9.5 Adjusting Magazine ATC Alignment
1) Preparation for Magazine ATC Alignment

Alignment of temporally attached magazine and Changer Arm
① Check the adherence state of the magazine-fixing bracket and fasten the fixing bolts
that are connected to the main unit’s bracket.
② Make the magazine’s bottom support touches the floor and fasten it in place.
Check the adherence

“Magazine fixing bracket” to the groove
2) Adjusting Magazine Alignment

① Mount the alignment “fixture 1” onto the ATC Changer Arm and “fixture 2” onto the
magazine pot.
▪ Fixture 1 : fixture for Changer Arm
▪ Fixture 2 : fixture for magazine pot
▪ Fixture 3 : Center Bar
② Remove the drive key of the magazine pot.
“Jig 1”
“Jig 1”
“Jig 3” “Jig 2”
131
9. ATC Adjustment
③ Mark the positions of the bolts fixed to the main unit’s bracket and 8 Level Screws
(120112-01805). Slightly unfasten them to avoid collision between the Changer Arm
and the magazine.
“Bolt, Level
Screw”
“Magazine
Changer Arm
gap
“Bolt, Level
Screw”
④ In MDI mode, using the Keep relay, move the Changer Arm to the magazine pot in
the following order..
Description Changer Arm Out Changer Arm Left Changer Arm In
Keep relay K21.7 K22.3 K21.6
※ In the M6 Tool Change Macro program,

CHANGER ARM RIGHT is executed first. At
the time of alignment, however, the gap
between the magazine and Changer Arm has
not been identified, follow the steps above to
avoid the collision.
⑤ Adjusting Magazine Alignment

▪ Adjust X & Z direction alignment
a. Adjust X direction if necessary: CHANGER ARM RIGHT positioning stopper
b. Adjust Z direction if necessary: Adjust the height of magazine’s bottom support
bolt
132
9. ATC Adjustment
X direction adjustment
Changer Arm LEFT
adjusting stopper
Z direction
adjustment
Magazine
Support
Bolt(2ea)
※ Note
Disassemble magazine motor’s power cable for shipping. During installation,
connect the magazine motor’s power cable, check alignment, and reset the
magazine’s reference point. Where, rotate the whole magazine segments 2-3
full turns to check alignment again.
133
10. G120 (Five Face Automatic Offset) Auto Measurement

10.1 Preparations
1) Five-way sensor area 5 way

sensor
▪ Five-way sensor : 301308-00664
▪ Sensor stand : 860101-00528 Sensor
stand
▪ Magnetic base : 860101-00529
Magnetic
base
2) Ball Bar area

▪ Ball Bar(Ø20) : 101566-00037
Milling
▪ Zero Fit Type Milling Chuck : BT50-CZF25- Chuck
165(NIKKEN)
Ball
▪ Straight Collet : KM25 Bar
▪ Milling Chuck Spanner : 9HC25
3) Five-way sensor I/F Unit Sensor

▪ Five-way sensor I/F Unit : 300628-00590 I/F Unit
134
10.2 Preparation for measurement
1) Connect 5-way sensor I/F Unit cable

In the electric cabinet, connect cables for SKIP(X4.7), 1L+, and M
SKIP 1L+, M
2) 5-way sensor signal check

Assemble 5-way sensor, stand, and magnetic
base. Press each directional sensor to check if
the lamp works and if X4.7(SKIP) signal
changes to 0 or 1.
3) 5-way sensor parallelism adjustment

Install a 5-way sensor in the center of the table
and adjust the parallelism to make it within 2㎛.
Setting within 2µm

of parallelism
4) Operation Test M184 ;

As shown on the left, for safety purpose, use G91G31Z10.F10 ;
the G31 command. That is, touch each 5-way M00;
sensor to see if the feed axis stops at the SKIP M99;
signal. (5 ways: top side, X+, -, Y+, -)
135
5) Standard Ballbar Assembly

① Attach Dummy Cover - M400 A1;
② Install reference ball bar tool spindle
③ Make adjustment of the ball bar’s runout to
be within 5µm.
6) Measure reference ball bar length

① Fix the indicator on the table, find the highest point of the existing ball bar, and start
setting origin for all axes. (Figure 1)
② Using a TEST BAR or a DATUM TOOL with exact length, measure the tool’s cross
section to calculate the reference ball bar length. (Figure 2)
EX) TEST BAR length minus the relative coordinate value of ② equals the length of
the reference ball bar.
※ The tool length error may lead to overall error. Be sure to check 2-3 times
Figure
그림 11. Figure
그림 22
136
10.3 Measurement Using G120
1) With a dummy cover attached (M400 A1;), place the reference ball bar to make it
position in the center of the 5-way sensor’s top side in X & Y directions.
2) Feed the Z axis and, at the point where the top side sensor is on, be sure to set work
offset on X, Y, Z-axes in the G56 coordinate. (X0. Y0. Z0. in the G56 coordinate)
3) Move the Z axis 100 mm in the + direction.
4) Auto measuring dummy reference

G120 A1 Hxx Rxx Txx W56;
M30;
Using the above command in MDI starts auto measuring.
A1 = Measure currently attached head only and exit
Hxx = Reference ball bar length offset number
Txx = Reference ball bar Tool number
5) Manually or automatically remove the reference ball bar and replace it with a 90 degree
Angle Head. (M400 A2;)
6) Connect the reference ball bar to the 90 degree Angle Head and re-adjust the Run Out
7) Place it 10 mm away from the 5-way sensor’s top side.
8) Automatic Measurement of 90 degree Angle Head reference
G120 A1 Hxx Rxx Txx W56 M2;
M30;
M2 = Measure C axis at a 45-degree
※ ANGLE HEAD & U-HEAD always need M2 command
137
4) Auto measuring dummy reference

G120 A1 Hxx Rxx Txx W56;
M30;
Using the above command in MDI starts auto
measuring.
A1 = Measure currently attached head only and
exit
Hxx = Reference ball bar length offset number
Txx = Reference ball bar Tool number
5) Manually or automatically remove the reference ball bar and replace it with a 90 degree
Angle Head. (M400 A2;)
6) Connect the reference ball bar to the 90 degree Angle Head and re-adjust the Run Out
7) Place it 10 mm away from the 5-way sensor’s

top side.
8) Automatic Measurement of 90 degree Angle
Head reference
G120 A1 Hxx Rxx Txx W56 M2;
M30;
M2 = Measure C axis at a 45-degree
※ ANGLE HEAD & U-HEAD always need M2
command
9) Verify the measurement result

The offset amount of 90-degree unit on C axis
can be viewed in the EOP screen.
▪ Screen path
[CUSTOM2]  [SOPP]  [4. ATT STATUS]
 [OFFSET]  [90D ANGLE ATT]
138
▶ Description of measuring program

G120 Axx Hxx Rxx Wxx Txx Mxx Qxx ;
-. A : 1 = Measure currently attached head only and exit
0 or non-defined = Measure all attachment head by using AAC
-. H : Reference ball bar length offset number
-. R : Reference Ball Bar radius
-. W : Work Coordinate System (G56)
-. T : Tool change number
-. Q1 : Verification after a measurement Should be skipped during measurement
▪ Omit for actual measurement.
-. M2 : Used when measuring medium angle (C axis 45 degree or B axis 30 degree)
※ M2 must be used for measurement in case of universal head option
G120 D99 ;
-. -Restore the initial work coordinate system
※ ※ Must be performed when checking dummy cover measurement error
G120 M0 ;
-. -Run when G120 Macro Alarm occurs after a dummy cover measuring error
▶ During machine installation, if verification of the AAC operation and measurement of

overall attachment head is finished, an automatic measuring of attachment head can be
performed by using A0 or no parameter.
139
11. Assembling the Cover

After completing the leveling work, origin setting work, static precision work, ATC adjustment
work, etc. of the machine body, install or assemble various covers, brackets, fence, chip
conveyors, coolant tank, etc. which were assembled and disassembled for machine
transportation and installation at the factory.
11.1 Deploying Various Covers
1) Unpacking
Unpack the box that contains covers, bracket, splash guard and other parts. (Packing
No.5, 6, 7, 8, 9)
2) Deploying Various Covers

For protection purpose, lay the protective materials on the floor and arrange covers,
bracket, Splash Guard, etc.
▪ There are many parts and sometimes it’s hard to find a desired part. So lay and
spread all parts on the floor for easier finding.
140
11.2 Assembling Covers for Crossing Parts
1) Assemble Y axis Bellows Cover (110504-00231)

① Unstrap the shipped Y axis Bellows Cover.
Bellows
Cover
② Assemble the left and right Bellows Covers to the crossing part using fixing bolts.
Bolts to the Bolts to the

crossing part crossing part
141
12.3 Assembling Side chip, Conveyor, and Side Step
No. Part No. Part Name Quantity
10 900115-01935A Conveyor, Chip; Side L 1
20 900115-01934A Conveyor, Chip; Side R 1
30 Rear Step Bracket 2
40 Front Step Bracket 2
50 Side Chip Conv. Step 1
60 110517-01720A Cover, Side; A 4
70 110517-01721A Cover, Side; B 2
80 Support Bracket 3
90 Support Bracket 7
142
1) Assembly of Support Bracket

① Prepare 10 Support Brackets (No. 80: 3 Long Support Brackets, No. 90: 7 Short
Support Brackets).
② Assemble 3 80 Support Brackets from the left side of the bed in front of the machine
(OP side). (4 for DBM2550)
③ Assemble the No.90 Support Bracket to the front of the machine (OP side), two on
the right side of the bed, and five on the back of the machine.
※ When assembling, check the length of the support bracket and note that they change.
80 Support 90 Support
Bracket Bracket
Support
Bracket
Assembly
Site
④ Assemble 3 80 Support Brackets from the left side of the bed in front of the machine
(OP side). (4 for DBM2550)
⑤ Assemble the 90 support brackets on the front side of the machine (OP side) and 2
on the right side of the bed and 5 on the back side of the machine.
※ When assembling, check the length of the support bracket and note that they change.
80 Support 90 Support
Bracket Bracket
80 Support
Bracket
90 Support
Bracket
143
2) Side Conveyor Assembly

① The Front & Rear Side Chip Conveyor shipped separately in the factory is placed on
the already assembled Support Bracket with the separated part at a distance of
about 100 mm.
② After disassembling the proximity sensor, remove the tension of the conveyor motor
using the adjustment bolt.
Tension
adjustment
bolt
Proximity
Sensor
Proximity
Sensor
③ Pull the loose Hinge Belt from both sides, recombine the separated part, insert the
pin, insert the split pin at the end of the pin, and open the end.
Hinge
PIN (Link)
Split Pin
④ When the Hinge (Link) of the Side Chip Conveyor is connected, fit the gasket on the
A and B contact surfaces (see photo), seal the gasket on both sides, and then fasten
it with a fixing bolt.
※ Since the front side chip conveyor fixing bolt may interfere, use the bottom bolt as
a short bolt or turn the bolt head to the right to assemble it.
Gasket
Be aware of
interference
A B
X+ X-
144
⑤ After assembly of the conveyor, restore the motor tension and disassembled
proximity sensor.
※ The Conveyor Motor Chain Tension is suitable to be loose enough to be pressed
slightly without tightening when the chain is pressed by hand.
Tension
adjustment
bolt
Proximity
Sensor
Proximity
Sensor
3) In-place operation of Side Chip Conveyor

① Position the Side Chip Conveyor on the Support Bracket so that it is 59 mm out of the
front reference X-axis slide Cover of the device. (To match the interval when
assembling the upper cover)
59mm
② Side Chip Conveyor Adjust the feet of both legs to touch the floor.
Step
Bracket
Adjustable
feet
145
11.4 Assembly of X axis slide cover
1) Assembly of X axis slide cover

① Packaging Remove the packaging of the slide cover that was shipped packed with
plastic, insert the rope into the rope loop, and hang it on the crane.
Slide Cover
Slide Cover
② Balance the slide cover and lift it up with a crane to put it on the ends of the L / M
guides on both sides of the bed.
▪ When assembling the + direction, move the X axis to +, and when assembling the -
direction, move the X axis to - as much as possible.
Slide Cover
③ Assemble the rope loop position of the X-axis slide cover by rotating it 180 degrees
to prevent collision with TS27R.
Rope loop
146
④ Unscrew the slide cover fixing bolts on both sides of the table and check if the O-
rings assembled on both sides are properly inserted.
⑤ When the slide cover is folded the most by moving the table as far as possible in the
X + and X - directions, assemble it with a fastening bolt.
O-ring
Fixed to table
⑥ Check the operation of the assembled slide cover by moving all the strokes along the
X-axis, and check if there are any noises.
`
147
11.5 Assembling Frame, LM Rail Bracket
701 160609-05469A Frame; Door 1

702 250122-00724A Plate, Support; Door 1
703 110406-05991 Bracket, Cover; LA 1
704 110406-05994 Bracket, Cover; LB 1
705 110406-06004A Bracket, Cover; LC 1
706 110508-43772B Cover, Bottom; F 1
707 110958-05282A Support 1
708 110423-15276A Bracket; RB 1
709 110423-15275B Bracket; RA 1
710 110406-05988 Bracket, Cover; RRA 1
711 110406-05989B Bracket, Cover; RRB 1
712 110958-05235C Support, Cover; R 1
713 110406-05987B Bracket, Cover; RLB 1
714 110406-05986 Bracket, Cover; RLA 1
148
1) Spread out all frames on the floor.
2) Assembly of ATC Side Bracket

① First, Cover Bracket; LA 703, Cover Bracket; LB 704, Cover Bracket; LC 705, Cover
Bracket; RLB 713, Cover Bracket; Prepare RLA 714.
② Assemble the prepared frame on the support bracket already installed on the ATC
side.
※ When assembling the frame, rotate the support bolt so that it does not come into
contact with the ground, and adjust it to receive the force evenly when the splash
guard installation is complete.
703 704 714

713
3) Assembly of AAC Side Bracket

① Cover Bracket; RB 708, Cover Bracket; RA 709, Cover Bracket; RRA 710, Cover
Bracket; Prepare the RRB 711.
② Place the prepared frame on the support bracket already installed on the AAC side
(OP side) and then assemble it.
709
710
708 711
149
4) Assemble The Support

① Prepare Cover Support and LM Guide.
② Assemble the support (707) after attaching the LM Guide to the cover support
attachment position.
※ To assemble the bottom cover to be assembled in the future, when assembling
the support, assemble it in close contact with the AAC cover.
Attach LM Guide
707
5) ) Assemble The Lower Cover

① Bottom Cover; Prepare F 706.
② Assemble the bottom cover based on the
already installed bracket.
706
6) Assembly of Door Frame and Door Support Plate

① Prepare the Door Frame (701) and the Door Support Plate (702).
② Place the Door Frame (701) over the already installed Side Conveyor Frame and
assemble the bottom height adjustment bolt on the floor.
③ Door Support Plate (702) is attached in alignment with the Door Frame (701).
701 702
150
11.6 Assembling Covers for the Column and the ATC Door
801 110508-45504A Cover, Chip 1

802 110508-43454A Cover; ATC 1
803 110517-01781A Cover, Side; L 1
804 110505-01072A Cover, Duct 1
805 110508-45011 Cover, Hole 1
806 110508-45027 Cover, Chip 1
807 102301-01907A Door; ATC 1
808 - Cylinder Ass’y 1
809 110916-00466 Chute; L 1
810 110508-42843B Cover, Front; L 1
811 110508-50850 Cover; IL 1
812 110508-42706B Cover; IL 1
813 110922-02224 Guide; Door 1
814 900130-00136 Rail, Guide; Door 1
151
1) Install the cover for the column assembly

For convenience, assemble in the order of 810  812  809  801.
① Assemble Front Cover L (810) to Column.
② Next, the cover IL 812 is assembled.
※ Before assembly, apply silicone to the red dotted area and assemble.
② 812 Cover
① 810 Cover
③ Install Chute; L(809).

④ Install Cover, Chip(801).
※ The specifications of Cover801 and 809 can be different depending on Z axis
Stroke option.
⑤ Install Cover; IL (811).
④ 801 Cover ③ 809 Chute
⑤ 811 Cover
2) Assemble ATC Door

① Assemble the Duct Cover (804) according to the position of the door.
804 Duct
152
② Assemble the ATC Cover (802) on top of the Door Frame (701).
802 Cover
701 Frame
③ Assemble the ATC Cover (807).
807 Cover
④ Assemble Cylinder Ass'y (808) to Duct Bracket.
Duct Bracket
⑤ Assemble the Side Cover L (803).
803 Cover
153
11.7 Assembling Semi Splash Guard
When installing Semi Splash Guard and covers, to prevent coolant leak, completely seal all
the gaps where the bed and covers contact other parts.
154
No. Part No. Part Name Quantit
901 110517-01783 Cover, Side; L2 1

902 110508-45291A Cover, Front; L 1
903 110508-45292A Cover, Front 2
904 110508-45293A Cover, Front; R 1
905 102301-01901B Door; F 1
906 102301-01900B Door; F 1
907 110508-43711B Cover, Bottom; FA 1
908 110508-43712A Cover, Bottom; FB 3
909 110508-50479A 1
910 110508-44847 Cover, Hole 1
911 110508-43277 Cover, Hole 1
912 110925-00421 Handle Ass’y 1
913 110508-43765A Cover 1
914 110423-15270A Bracket; Key 1
915 B13721313B Glass(2), Safety 4
916 250205-04390 Plate; 4
917 110508-45028A Cover; Hole 1
931 110508-45294A Cover, Rear; LA 1
932 110508-45297A Cover, Rear; LB 1
933 110508-45295C Cover, Rear; LC 1
934 110508-45299C Cover, Rear; RC 1
935 110508-45298A Cover, Rear; RB 1
936 110508-45296A Cover, Rear; RA 1
937 110508-45300B Cover, Bottom; Box 1
938 110508-43290A Cover; Bottom 2
939 110508-43277 Cover, Hole 4
940 110508-44849A Cover, Hole 2
941 110508-44850 Cover, Hole 2
942 102301-01903C Door; RR 1
943 102301-01902B Door; RL 1
944 110508-43287A Cover, Bottom; Corner; R 1
945 110508-43289 Cover; BC 1
946 110508-43288 Cover, Bottom; Corner; L 1
155
No. Part No. Part Name Quantit
947 B13721313B Glass(2), Safety 2

948 250205-04390 Plate 2
949 110925-00421 Handle Ass’y 2
950 110933-00037 Latche 1
1) Install Rear Cover

① Prepare the Rear Cover FA (931), place it on the Cover Bracket that is already
assembled, and fasten the fixing bolt.
▪ Assemble by applying silicone on the red dotted area. For detailed sealing
instructions, refer to 9.10.
931 Cover
156
② Prepare the rear cover LB (932), apply silicone to the assembly joint, and then
assemble it on the cover frame.
932 Cover
③ Prepare the Rear Cover LC (933), apply silicone to the assembly joint, and assemble
it on the cover frame.
933 Cover
④ Prepare the Rear Cover RA (936), put it on 936 Cover

the Cover Bracket that is already
assembled, and fasten the fixing bolt.
157
⑤ Prepare the rear cover RB (935), apply silicone to the assembly joint, and assemble
it by placing it on the cover frame.
935 Cover
⑥ Prepare the rear cover RB (934), apply silicone to the assembly joint, and assemble
it by placing it on the cover frame.
934 Cover
934 Cover
158
2) Install Rear Door

① Prepare Door RR, RL (942, 943) and assemble between Rear Cover LC (933) and
Rear Cover RC (934).
942 Cover 943 Cover
3) ) Installation of Front Left Cover

① Prepare the Side Cover L2 (901), place it on the left side of the Frame Cover and on
the Cover Frame, apply silicone to the assembly and then put it on top to assemble it.
▪ Adjust the correct position so that there is no step difference between the covers,
and then tighten the bolts.
901 Cover
159
② Prepare the Front Cover L (902), put it on the Cover Frame, apply silicone to the
assembly joint, and then assemble it.
902 Cover
4) Install Front Cover

Prepare and lift the front cover (903) to assemble the left and right covers.
903 Cover
5) Install Front Right Cover

Prepare the front cover R (904), put it on the cover frame, apply silicone to the assembly
joint, and then assemble it
904 Cover
160
6) Install the Door

Prepare Door F (905, 906) respectively and assemble as shown in the photo.
905 Cover
906 Cover
7) Install the Front Cover

① Prepare 3ea of Bottom Cover FB (908) and assemble it as Bed side (OP side) picture.
Bottom Cover;
FB(908): 3ea
② Assemble the Bottom Cover FA (907) in the

same way.
907 Cover
161
11.8 Assembling AAC Door Cover
851 110508-45043 Cover; RB 1

852 110508-45044 Cover, Rear; B 1
853 110420-01575 Bracket, Mounting 1
854 110508-42729 Cover, Side; L 1
855 110508-50850 Cover; IL 1
856 110508-42705A Cover; IR 1
857 110916-00465 Chute; R 1
858 110508-43773 Cover, Bottom; RA 1
859 110508-45283A Cover; Front 1
860 110508-43777A Cover, Upper 1
861 250205-04394 Plate; Window 1
862 220209-00073 Glass 1
863 110958-05197A Support, Pipe 2
864 101563-00075A Pole; STD 1
865 101563-00074A Pole; STD 1
866 110508-45285A AAC Cover 1
867 110508-45009 Cover; AAC Hole 1
162
1) Install AAC Door Cover

① Temporally install Front Cover (859)
859 Cover
2) Install AAC Cover Frame

① Pipe Support (863, 2ea), two are assembled first.
② After bolting the STD Pole (864) to the front cover (859) that had been
preassembled, fit the Set Anchor into the lower hole of the STD Pole (864).
③ The rest of the cover and pole are assembled and anchored.
859 Cover
864, 865 Frame

Position 863 Frame 864 Frame
163
3) Install AAC Door Cover

① Install Cover IR (856)
② Install Chute R (857)
▪ Assemble by applying silicone to the red dotted area.
856 Cover
857 Cover
③ Install Cover IL (855)
855 Cover
4) Install AAC Cylinder Ass’y (Opt.)

① Install Front Cover (859)
② Assemble the AAC Cylinder Ass'y (868) on the attached front cover (859).
868 Cylinder
868 Cylinder
Ass’y
859 Cover
164
③ Connect MP730 Multi Connector to Bracket (868).

④ Connect the main air hose (door) according to the cylinder symbol.
Main Hose
연결
MP730
5) Install AAC Cover

① Install AAC Cover(866)
866 Cover
866 Cover
② Cover RR (854), Cover RB (851), Rear Cover B (852), Mounting Bracket, (853)
Cover are sequentially assembled to the door frame.
854 Cover
852 Cover
851 Cover
165
11.9 Assembling Magazine Fence Ass’Y
961 110406-05995A Bracket, Cover 1

962 110508-43542A Cover; Magazine 1
963 110508-43932B Cover; Magazine 1
964 101563-00056B Pole; Fence; (DL) 1
965 101563-00055A Pole; Fence; (DR) 1
966 110958-04740 Support; Frame 1
967 460103-01710 Duct; Magazine 1
968 110505-00858 Cover, Duct; 1
969 110958-04740 Support; Frame 1
970 102301-02017 Door; Magazine; (R) 1
971 110302-02056 Bar; Frame 1
972 101563-00056B Pole; Fence; (DL) 1
973 102302-00435A Fence; Magazine 1
974 110302-02104 Bar; Frame(1) 1
975 102301-01833A Door; Magazine; (F) 1
976 101563-00067 Pole; Safety Fence (L) 1
977 101563-00068 Pole; Safety Fence (M) 1
978 102302-00521A Fence; ATC(1) 1
166
979 102302-00522A Fence; AAC(2) 1

980 101563-00069A Pole; Safety Fence (R) 1
981 110423-15314 Bracket; Fix 1
982 110302-02105 Bar; Frame (2) 1
983 101563-00083 Pole; Fence; (A) 1
984 110302-02284 Bar; Frame (1) 1
985 102302-00582 Bar; Frame (1) 1
986 150119-00993 Duct, Oil 1
987 150119-00994 Duct, Oil 1
988 220206-00148 Handle 1
989 110927-00318 Hinge, Door; Semi SG 1
1) Install Magazine Fence Ass’y

First work on the cover brackets (961, 962, 964) (including anchor work) and then work
counterclockwise as shown below.
1 2
3 4
167
11.10 Sealing Semi Splash Guard
1) Parts to be sealed when installing cover (Common requirements for all parts)
Bottom and sides of the cover
: mark the parts to be sealed
168
2) Parts to be sealed before installing cover (Common requirements for all parts)
Parts not welded: Bolting pockets, pluggable hole of connection gap, etc.
169
3) Bolting pocket cover assembly (Common requirements for all parts)

Pocket cover assembly area, gaps between pocket covers
Gap between covers
Cover assembly area
Refer_to_front_left
Refer_to_front_right
Refer_to_rear_left
Refer_to_rear_left
170
4) Packing assembly area

Column’s front & inner cover assembly
400606-02227
5) Assemble bonded seal

Counter bore for assembling column’s inner cover and AAC Guard assembly
Left Column_5Locations Right Column_5 Locations AAC Guard_4 Locations
171
6) Window assembly
Seal the connecting part between the window and sheet metal joint.
Front Cover (Opt.) Rear Cover (Opt.)
Main Door (Opt.) AAC Chip Cover
172
7) ATC Cover
ATC Door Guide joint, Column’s bottom cover joint
8) If AAC Cover or options are not selected

Assemble bonded seal when installing a hiding cover in place of AAC Door
173
Revision History
Revision History
Installation Manual DBM2540 (MD0036ISK204)
Version Year/Month Revision history Created by
S. Y Jung
01 2020. 04 Official draft (MD0036ISK204)
& Overseas CS
02
03
04
05
06
07
08
09
10
174

DBM2540 - MD0036ISE204 - English

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Installation Manual

DOOSAN Machine Tools MD0036ISK204

1. Preparation Before Machine Shipping ................................................................................ 3

1.1 Selection of Machine Installation site ............................................................................... 3

2.1 Main Transportation Unit Setup...................................................................................... 15

3. Temporary Installation of Machine .................................................................................... 38

3.1 Temporary Installation of Bed......................................................................................... 38

4. 2nd Grout Injection............................................................................................................. 45

4.1 Pre-Checking of Foundation Holes ................................................................................ 45

5. Assembling the Machine.................................................................................................... 50

5.1 Cooling unit, hydraulic unit, and other units.................................................................... 50

6.1 Turning On Main Power ................................................................................................. 63

7. Machine Accuracy Adjustment ......................................................................................... 66

7.1 Machine Leveling .......................................................................................................... 66

8. AAC(Auto Attachment Changer) ......................................................................................103

8.1 AAC Alignment Related M-Code & Keep Relay ............................................................103

9. ATC Adjustment ................................................................................................................118

9.1 Assembling the Tool Magazine ..................................................................................... 118

10. G120 (Five Face Automatic Offset) Auto Measurement................................................134

10.1 Preparations ...............................................................................................................134

11. Assembling the Cover.....................................................................................................140

11.1 Deploying Various Covers ..........................................................................................140

1. Preparation Before Machine Shipping

1.2 Machine Layout

1.3 Foundation Work

1.4 Foundation Drawing

1) Foundation Drawing (DBM2540)

2) Foundation Work (DBM2540)

3) Foundation Drawing (DBM2550)

4) Foundation Work (DBM2550)

5) Foundation Details (DBM2540 & 2550)

1.5 Preparations Before Shipping Machine

1) Preparation of Machine Unloading Workers

2) Machine Transport and Preparation of Installation Equipment

Model Unit Weight (kg)

Bed & Table Unit 22000

3) Preparation of Power and Pneumatic Air Source

5) Preparation of 2nd Grout for Installing the Machine

DBM25 Series is designed to be transported in parts, installed on-site by way of

② Cross / Ram Saddle / Column Base / Electric Cabinet / Operation Panel

④ Magazine & Fence

⑤ Attachment & 1 Aac (Opt.)

⑥ Side Chip Conv. Lift-Up Conv. Bucket – 1 unit

2.2 Unloading Machine Units

1) Precautions for Unloading

2) Unloading Large Units

(Unloading by using crane) (Unloading by using forklift)

(Unloading by using crane) (Unloading by using forklift)

2.3 Unit Packing List

Packing No. Model Packing Box Contents

1 DBM2540 Bed & Table Ass ’ Y, basic parts, TS27R (optional)

1) Table & Bed Unit

Packing No. No. Parts No. Definition Q’ty

1 10 - Main Bed & Table Ass ’ y 1

2) Column, Cross, Saddle, RAM, Electric cabinet Ass’y

If Z1100 (optional) is applied,

When shipping the lower Should be disassembled Should be disassembled

Packing No. No. Parts No. Definition Q’ty

2) Column Base Ass’y

Packing No. No. Parts No. Definition Q’ty

2 10 160101-01559A Base; Column L 1

Packing No. No. Parts No. Definition Q’ty