Doosan DBC 130 II User manual

Installation Manual
DBC 130
Ⅱ
Machine Tools

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DBC 130II DBC130II ISE41
Table of Contents
For enhanced performance, this installation manual is subject to change without notice
Table of Contents ..................................................................................................................1
1. Installation Site..................................................................................................................4
2. Foundation work ...............................................................................................................9
2.1 Foundation work timing and post checkpoints...............................................................9
2.2 Foundation work for installing the machine ...................................................................9
3. Transportation .................................................................................................................15
4. What's included...............................................................................................................16
4.1 Table Bed Ass’y..........................................................................................................16
4.2 Column Bed Ass’y......................................................................................................18
4.3 Column Body Ass’y ....................................................................................................20
4.4 Spindle Head Ass’y.....................................................................................................21
4.5 Duct Ass’y..................................................................................................................22
4.6 Coolant Tank, Chip Bucket, Chip Conveyor, TSC Ass’y, T/F(Option)............................23
4.7 Tool Magazine Ass’y (Option) .....................................................................................24
4.8 Semi Splash Guard – Operator Part (Option)..............................................................25
4.9 Semi Splash Guard – Magazine Part (Option).............................................................27
4.10 Semi Splash Guard – Table Part (Option)..................................................................28
4.11 List of tools related to the foundation work (1)...........................................................30
4.12 List of tools related to the foundation work (2)...........................................................31
4.13 BOLT KIT Shipping LIST...........................................................................................33
5. Installing the machine temporarily................................................................................36
5.1 Temporary installation of the column bed (Z-axis bed) assembly.................................36
5.2 Temporary installation of the table bed (X-axis bed) assembly.....................................39
5.3 Temporary Installation of ATC Base ............................................................................42
6. Second Round of Grout Injection..................................................................................44
6.1 Checkpoints before injecting grout..............................................................................44
6.2 Selection of Grout ......................................................................................................44
6.3 Blending the grout mixture..........................................................................................45
6.4 Injecting the grout mixture...........................................................................................46
6.5 Curing the surface of grout.........................................................................................47
7. Assembling the main unit...............................................................................................48
7.1 Installing the column...................................................................................................48
7.2 Installing the spindle head..........................................................................................50

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DBC 130II DBC130II ISE41
7.3 Installing the hydraulic power unit, electric cabinet, OP box and ducts ........................ 53
7.4 Wiring........................................................................................................................ 55
7.5 Connecting the hydraulic and air hoses...................................................................... 59
7.6 Connecting the tool magazine wires and hydraulic hoses........................................... 60
8. Removing the transit clamps......................................................................................... 61
9. Checking and fueling the oil tanks................................................................................ 62
9.1 Hydraulic tank............................................................................................................ 62
9.2 Oil Cooler Tank.......................................................................................................... 62
9.3 Table ......................................................................................................................... 62
9.4 Lub. Tank................................................................................................................... 62
9.5 Spindle Air Oil Tank.................................................................................................... 63
9.6 Air Service Unit Oiler Tank.......................................................................................... 63
9.7 Spindle Head Air Filter Unit Oiler Tank........................................................................ 63
10. Connecting the main power and air sources ............................................................. 64
10.1 Connect the main power source............................................................................... 64
10.2 Connecting the main air source................................................................................ 64
11. Power On ........................................................................................................................ 66
12. Checking the pressure on each unit........................................................................... 67
13. Assembling and adjusting the Y axis.......................................................................... 69
13.1 Installing the ball screw nut in the Y axis................................................................... 69
13.2 Installing the Y-axis taper gib and back plate gib....................................................... 69
13.3 Installing the reference gib....................................................................................... 70
13.4 Installing the ball screw nut...................................................................................... 70
14. Machine Leveling.......................................................................................................... 71
15. Precision Accuracy & Correction................................................................................ 77
15.1 Straightness of Z axis............................................................................................... 79
15.2 Straightness of X Axis .............................................................................................. 80
15.3 Straightness of Y Axis .............................................................................................. 81
15.4 Straightness of Pallet Deck ...................................................................................... 82
15.5 Squareness between coordinate axes...................................................................... 83
15.6 Parallelism of movement to X/Z axis, parallelism of pallet deck, and shaking of index
table................................................................................................................................ 86
15.7 Squareness in division of index table........................................................................ 89
15.8 Parallelism of the X-axis movement for the T-slot ..................................................... 90
15.9 Parallelism between center line of spindle and movement of Z-axis.......................... 92
15.10 Run-out on the spindle........................................................................................... 94
15.11 Movement of spindle in the Z-axis direction ............................................................ 94
16. Resetting the reference point for each axis............................................................... 95

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DBC 130II DBC130II ISE41
16.1 Resetting the reference point for the W axis (W-axis stroke : 700mm).......................95
16.2 Resetting the reference point for the X axis (X-axis stroke: 3000mm)........................96
16.3 Resetting the reference point for the Z axis (Z-axis stroke: 1600mm) ........................97
16.4 Resetting the reference point for the Y axis (Y-axis stroke: 2000mm) ........................99
17. Adjusting ATC..............................................................................................................100
17.1 ATC installation & leveling.......................................................................................100
17.2 Carriage Magazine Side Home Position Setting......................................................102
17.3 Setting the reference point for the tool magazine pot...............................................106
17.4 Fine-tuning the spindle side of the changer arm......................................................110
17.5 Setting Parameter #7 & Changer Movement...........................................................112
18. Installing the covers....................................................................................................113
18.1 Installing the table bed covers.................................................................................113
18.2 Installing the column bed covers.............................................................................114
18.3 Installing the column covers....................................................................................115
18.4 Installing the semi splash guard (in the table side) ..................................................116
18.5 Installing the semi splash guard (in the operator side).............................................117
18.6 Installing the semi splash guard (in the chip conveyor side) ....................................118
19. Installation Complete..................................................................................................119

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DBC 130II DBC130II ISE41
1. Installation Site
1) Do not install the machine in a place of a high temperature difference or in areas that are
exposed to dust or direct sunlight, and consider the ventilation condition. Besides, it is
recommended to select a place of less vibration. However, if it's inevitable, take
appropriate actions (reinforced foundation, reinforced ground, and dustproof screen, etc)
to prevent the machine from being affected by the vibration .
2) The minimum bearing power of soil that is required to install the machine is 10 tons/m².
3) A 20-ton crane with a lifting performance of 8m must be equipped at the installation site.
The installation personnel should take into consideration the dynamic relation between
crane and foundation.
▪If a crane meeting the above specification is not available, use alternatives such as a
car crane, large forklift, etc., for moving the machine.
4) When determining the installation site, refer to the machine layout diagram to secure
room for installing the assemblies (ATC, electric cabinet, hydraulic tank, chip conveyor,
etc) as well as enough room for repair (so that the doors are open/closed without
interruption). Besides, secure enough room between machines to facilitate the
installation work of the chip conveyor.
5) Refer to the layout diagram below. (For reference Only)
※The below diagram is a standard machine layout for reference.
The actual layout may
differ due to engineering changes or application of client specifications. Refer to the
layout diagram that is specific to the machine to install.
※
Ref 1) : Front View

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DBC 130II DBC130II ISE41
※Ref 2) : Right View
※Ref 3) : Top View

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DBC 130II DBC130II ISE41
※Ref 4) : Front view of machine to install semi splash guard on (Optional)
※Ref 5) : Right view of machine to install semi splash guard on (Optional)

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DBC 130II DBC130II ISE41
※Ref 6) : Top view of machine to install semi splash guard on (Optional)

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DBC 130II DBC130II ISE41
※Ref 7) : Top view of machine to install APC on (Optional)

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DBC 130II DBC130II ISE41
2. Foundation work
※
Foundation diagram: Use only the foundation diagram provided by the
salesperson.
- foundation diagram : “S/O NO._Serial No_drawing no”
- Example of foundation diagram: 201077848_MB0003-000084_BG6C21601C
☞(Note) The foundation diagrams illustrated in this manual are for reference only
2.1 Foundation work timing and post checkpoints
1) It is recommended to take at least a two-month schedule from completion of the
foundation work to completion of the installation.
▪It should take at least one month to cure the concreted surface.
2) After completion of the foundation work, measure each checkpoint on the foundation
and, if a problem is found, take an appropriate action (mostly repair) before the arrival of
the machine.
2.2 Foundation work for installing the machine
1) Foundation diagram
(Subject to change without notice for reasons of enhanced machinery or engineering
changes.)
※40 Tool Magazine

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DBC 130II DBC130II ISE41
※60 Tool Magazine

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DBC 130II DBC130II ISE41
※
APC (Option)
※Cross-sectional View
Section View A-A (Cross-section of Foundation)

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DBC 130II DBC130II ISE41
※Detailed Diagram
Section View B-B (Main Unit Bed)
Section View C-C (Kicker)
Section View D-D ( Center of Main
Unit Bed)
Section View E-E (APC)
Section View G-G (APC)
Section View F-F (APC)

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DBC 130II DBC130II ISE41
No. Item No. Definition Mat. / Spec. Q’ty Remark
1 B26491444 Nut BA 24×260 36
2 B26491204 Adjust Bush SM45C 36 Final-Set
3 B26491014 Adjust Bush SM45C 36 Pre-Set
4 B26491073A Anchor GC300 36
5 B26491143E Level Block GC300 36
6 B26491423A Level Plate GC300 36
8 B26491213A Hex. Bar(2) SM45C 1 MB36
9 B26491093B Hex. Bar SM45C 1 MB30
12 B26491334 Nut NA36 6
13 B26491313A Level Bolt SM45C 6 MB30
14 B26491513 Leveling Block GC45C 6
15 S2208862 Bolt, Hex. Socket Head BB 8×20 24
16 B26491363 Hex. Bar(3) SM45C 1 MB46
18 S4001331 Hex. Nut NA24 6 90 Tool Mag.
19 250205-00953 Plate SS400 6 90 Tool Mag.
20 B13593024A Foundation Collar SS400 6 90 Tool Mag.
21 S3520376 Set Screw BQ 6×8 18 90 Tool Mag.
22 B13593033B Bolt SM45C 6 90 Tool Mag.
23 S0035252 Bolt, Hex. Head BA S24×130 6
24 B26491053A Adjusting Block SS400 6
25 B26491044 Bracket SS400 6
27 457845 Disk Spring 56X28.5X3X4.3 24
28 B14491023 Level Plate GC300 12
29 R00296 Stud Bolt SB20X350L 12
30 B14491033 Adjust Bolt SM45C 12
31 182992 Nut SM45C 12
32 B14491044 Nut SM45C 12
34 110302-00731 Kicker Bar SS400 4
35 S0035551 Adjust Bolt SM45C 12
36 S4001331 Nut SM45C 12

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DBC 130II DBC130II ISE41
Note) 1) Reinforce the ground with stake driving, riprap piling and rebar reinforcement.
(bearing power of soil: at least 10 tons/m²)
2) Tolerance for each foundation checkpoint
▪Top view: ±10mm
▪Gap between holes: ±10mm
▪Cumulative gaps between holes : ±20mm
▪Size of foundation hole: ±10mm
3) It should take at least one month to cure the primary concreted surface.
4) Prepare the wiring between electric cabinet and main power
as well as air service
unit as appropriate for the work.
5) Use a wrinkle tube of larger than Ø300mm to inject mortar into the second mortar
surface in deeper than 400mm. Important: the tube must be removed after the
first foundation work.
6) The holes for the second mortar work should comply with the specifications in the
detailed diagram above.
7) When installing the machine temporarily, use the adjusting bolt on the level block
to make an approximate gap of 15mm.(ⓐ)
8) The
“
6” level plate should be installed 10mm~40mm under the ground. (the
bottom of the machine should be approximately 75mm high from the ground)
9) When the installation is completed, remove “2” B26491014 adjusting bush.
10) Refer to the standard layout to check the location of the main power supply pipe
and prepare the wiring and air service unit as necessary.

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DBC 130II DBC130II ISE41
3. Transportation
The boring machine can be dismantled into each unit to facilitate the transportation of the
machine to the plant.
Since each one of the units is heavy weighted and unbalanced, pay attention to keep every
unit balanced if using a forklift or crane for transporting purpose.
(1) When the machine is delivered on site, check if every one of the units are all included
in
the package based on the packing list.
(2) Use the crane or forklift to move the unit while keeping an eye on the balance.
(3) In this process, take caution lest that the wire rope or shackles should impact on the
unit, and adjust the length of the rope as appropriate to prevent it from being
unbalanced.
(4) If the rope is short, it may cause an interference with brackets or covers. This is why
you must pay special attention to the rope length.
Assembly Weight Unit Remark
1 Table Ass’y 17,000Kg Table Bed, Rotary Table, Rotary Base
2 Column Bed Ass’y 11,000Kg Column Bed, Column Base
3 Column BodyAss’y 6,000Kg Column Body
4 Spindle Head Ass’y 2,500Kg Spindle Head
5 ATC Ass’y 3,000Kg ATC, Tool Magazine, Tool Magazine Base
6 Others 3,500Kg Electric Cabinet, Hydraulic Unit, Oil
Cooler, Duct & Covers, Chip Conveyor
and Accessories
Total weight of machine 43,000Kg
The above list is for the standard equipment, and is subject to change without notice for
reasons of customer specifications or engineering changes.
※ Precautions for lifting up the assembly
1) Ensure that the front/rear sides of the table bed (X axis) and the left/right sides of the
column bed (Z axis) are fixed by the factory default brackets.
(2) Before lifting up the table bed and column bed units, hook wire ropes between eyebolts
in the sides of the bed and crane. To prevent the machine from being damaged, wrap
the contact points between ropes and machine with pieces of wood or cloth.
(3) When lifting up the column body, stretch the rope as appropriate for avoiding a possible
interference with the glass scale.
(4) In order to lift up the table bed and column bed units at once, you must use a crane
weighing at least 20 tons. (Required specifications: 20 tons of weight and 8m of tensile
height)

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DBC 130II DBC130II ISE41
4. What's included
4.1 Table Bed Ass’y
No. Item No. Definition Q’ty Packing
No.
Weight remark
1
160301-00136A TABLE BED ASSY 1
1 17 Ton
2
110961-00144D TRAY;(1) 1
8
110958-01660 SUPPORT,TRAY (1)
3
110961-00145D TRAY;(2) 1
8
110958-01660 SUPPORT,TRAY (2)
4
110961-00146C TRAY;(3) 1
8
5
900115-00582A CONVEYOR,CHIP; 1
8
6
110510-00428B COVER,SLIDE;(X4000)R 1
1
7
110510-00427B COVER,SLIDE;(X4000)L 1
1
8
110423-03265A
BRACKET,SLIDE
COVER;X-R
2
7
9
110423-03266A
BRACKET,SLIDE
COVER;X-L
2
7
10
110508-10529C COVER;TRAY,(1) 1
8
11
110508-10530C COVER;TRAY,(2) 1
8

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DBC 130II DBC130II ISE41
No. Item No. Definition Q’ty Packing
No.
Weight remark
12
110961-00183 COVER;CENTER 1
8
13
110508-11089C COVER,REAR; 1
8
14
110423-03095A BRACKET;TRAY 2
8
110958-01647ASUPPORT;TRAY (2)
14-1
110423-03095A BRACKET;TRAY 1
8
15
230104-01477 BUCKET;OIL 1
8
16
L56301092B STAND, FLOOR 3
8
17
150119-00381 PAN; OIL 1
8

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DBC 130II DBC130II ISE41
4.2 Column Bed Ass’y
No.
Item No. Definition Q’ty
Packing
No.
Weight
remark
1
160301-00144A COLUMN BED ASSY 12
11Ton
2
110510-00495 SLIDE COVER(FRONT) 12
3
110961-00150 TRAY(R) 18
4
110961-00153C TRAY(L) 18
5
101556-00002B REMOVER,CHIP(R) 18
6
101556-00348 REMOVER,CHIP(L) 18
7
110510-00020A SLIDE COVER(REAR) 1
2
8
250205-00868A BASE PLATE 18
110423-03229A BRACKET,FRAME (1)
9
110508-00986B BASE COVER(R) 18
10
110508-10915C BASE COVER(L) 18
11
110508-12561 COVER, CHIP(2) 18
12
150119-00100 PAN, OIL(R) 18
13
150119-00101 PAN, OIL(L) 18
14
110423-03780 BRACKET; TRAY 88
14-1
110423-03799 BRACKET; TRAY(2) 18
15
B26280544B COVER; GUIDE RAIL (1) 17
16
B26212163B BLOCK (U) 18