Machine Tools

Installation Manual
(DNM 400)
 DNM 400 DNM400ISE97

Table of Contents

1. Preparations before shipment ........................................................................................... 3

1.1 Installation Site ................................................................................................................ 3
1.2 Foundation Work ............................................................................................................. 5

2. Transportation ..................................................................................................................... 7
2.1 Using the crane ............................................................................................................... 7
2.2 Using the forklift ............................................................................................................... 8

3. What's included ................................................................................................................... 9

4. Checking and fueling the oil tanks.................................................................................. 11

4.1 Spindle Cooling Unit (Optional) ...................................................................................... 11
4.2 Spindle Bearing Lubrication Unit (DNM 400HS) ............................................................. 11
4.3 Lubrication Unit.............................................................................................................. 11

5. Removing the transit clamps ........................................................................................... 14

6. Connecting the main power and air sources ................................................................. 16

6.1 Connecting the main power source................................................................................ 16
6.2 Connecting the air source .............................................................................................. 17

7. Machine Leveling .............................................................................................................. 19

8. Static Accuracy Inspection & Correction ....................................................................... 22

8.1 Straightness of Pallet Deck ............................................................................................ 23
8.2 Squareness between X- and Y-axis Movements ............................................................ 24
8.3 Squareness between pallet deck and Z axis .................................................................. 24
8.4 Parallelism between pallet deck and X-/ Y-axis movements ........................................... 25
8.5 Squareness between pallet deck and main axis ............................................................ 26
8.6 Parallelism between center line of main spindle and Z axis ........................................... 26
8.7 Inspecting the parallelism between T slot and X-axis movement ................................... 27
8.8 Shaking inside the main spindle hole ............................................................................. 28
8.9 Z-directional displacement of the main spindle .............................................................. 28

9. Reference Point & Correction .......................................................................................... 29

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9.1 X-axis reference point and correction for the standard pallet ..........................................29
9.2 Y-axis reference point and correction for the standard pallet ..........................................29
9.3 X-/Y-axis reference point and correction for the center bush (optional) ...........................30
9.4 Z-axis reference point and correction .............................................................................31

10. ATC Change Position (Secondary Ref. Point) ............................................................. 32

10.1 Orientation ...................................................................................................................32
10.2 Secondary reference point ...........................................................................................33
10.3 Resetting the secondary reference point ......................................................................33

11. Installing the coolant tank.............................................................................................. 34

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1. Preparations before shipment

1.1 Installation Site
1) Do not install the machine in a place of a high temperature difference or in areas that are
exposed to dust or direct sunlight, and consider the ventilation condition. Besides, it is
recommended to select a place of less vibration. However, if it's inevitable, take caution
not to affect the machine with the vibration.
※ Reinforced foundation, reinforced ground, and dustproof screen
2) A 10-ton crane with a minimum lifting performance of 7m should be equipped in the
installation site. The installation personnel should take into consideration the dynamic
relation between crane and foundation.
※ If a crane meeting the above specification is not available, use alternatives such as
car crane, large forklift, etc., for moving the machine.
3) When determining the installation site, refer to the machine layout diagram to secure
room for installing the assemblies (chip conveyor or coolant tank, 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.
4) The ideal operation condition is between 30% and 75% in humidity at 20°C.
- The temperature difference should be within ±2°C for 24 hours (1 day).
- The temperature difference between floor and 5m high from the floor should be within
1°C.

※ Ref 1) : Front View of DNM 400 & 400HS

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※ Ref 2) : Right View of DNM 400 & 400HS

※ Ref 3) : Top View of DNM 400 & 400HS

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1.2 Foundation Work

It is recommended to perform the foundation work for the machine accuracy. This is true
especially if you have to use the machine for an extended time while keeping the machine
accurate.
※ If the following conditions are met, no foundation work is necessary in normal situations
or even a bolt is not necessary.
(1) The ground should endure a minimum load of 7000 kgf, and 1000 kgf at one
specific point. (bearing power of soil: at least 8 tons/m²)
(2) The concrete surface of the on-site floor should be at least 200mm thick.
(3) No gap is allowed between ground and concrete floor.

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 take an appropriate action (mostly repair) if a problem is found.

2) Foundation work for installing the machine

The below foundation diagram is a standard machine layout for reference. The actual
layout may differ depending on the machine. Refer to the layout diagram that is specific
※ Notes
① The minimum bearing power of soil is 8 tons/m²; reinforce the ground with stake
driving, riprap piling and rebar reinforcement. Once the machine is installed, a solid
foundation should be made so that no sinking and tilting should ever happen.
② The concrete surface of the on-site floor should be at least 200mm thick, and the
compression strength is at least 210Kg/cm².
③ At least one month of curing period is required; prepare the wiring between electric
cabinet and main power as well as air service unit as appropriate for the work.
④ Prepare oils, power source and air source before the machine arrives on the site.

3) Anchor Bolt
To fix the machine firmly on the floor,
install the anchor bolt on the floor. Refer to
the foundation diagram to locate the
places for the anchor bolts. Make holes for
the anchor bolts on the floor before the
machine arrives.
▪ Anchor Bolt Size: M20
Drilling Depth: 93mm

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▪ DNM 400 & 400HS Foundation Diagram

※ Tolerance for each checkpoint

Top View: ±10mm

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2. Transportation
2.1 Using the crane

▪ Hooking Detail
The lifting hooks and accessories are
not provided by default.
Make them prepared in your side, if
The lifting hook can endure necessary.
the minimum weight of

DNM 400 / 400HS DNM 500 / 500HS DNM 650 / 650HS

A 980㎜ 1160㎜ 1650㎜
B 380㎜ 410㎜ 410㎜

※ Weight of Equipment
When selecting a crane or forklift, refer to the following table. UOM: kg

Model Weight
DNM 400 / 400HS 5000
DNM 500 / 500HS 6500
DNM 650 / 650HS 8500

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Caution

A. Ensure that the lifting wire rope is secured firmly to the hook. Otherwise, the machine
may fall off during the lifting, causing a physical damage or even death. Special care
must be taken here.
B. Move the machine to the intended area, and put it down slowly in the right position.
C. Adjust the rope length as appropriate to keep the machine balanced.
D. If the rope is short, it may cause an interference with the main unit or covers. This is
why you must pay special attention to the rope length.

Warning

A. Use only a rope of at least 20mm in the normal diameter.

B. While lifting the machine, you must pay special attention to the balance.
C. Don't forget to protect the machine from any external impact.
D. Only the approved personnel should operate the forklift or crane and adjust the rope
length.
(At least two persons are needed for a visual assistance.)
E. Use only the rope that can endure the total weight of the lift.
F. Before lifting the machine, ensure that the rope, lifting device and crane have no
problem at all.
(Do NEVER use a rope, lifting device or crane if it has a problem.)
G. First, lift the machine a bit from the floor and check the balance before proceeding.
H. Ensure that there is no movable parts that can fall off inside the machine.

2.2 Using the forklift

A. Use only the forklift featuring an appropriate load capacity.
B. Insert the fork of the forklift into the lifting holes in the bottom of the machine base.
C. Lift up the machine while keeping it balanced.
D. Lower the machine slowly on the floor lest that it should be impacted on the floor.

Caution

If you lower the machine out of balance, it may break away from the level block.
To prevent this, moving the machine should be performed by a qualified forklift operator
and at least one assistant who can check the balance and other safety issues.

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3. What's included
Seq Picture Part No. Part Name Quantity Specification

1 STANDARD ACCESSORIES 1 AY
2 R80013C KIT. TOOL BOX 1 ST L31900021
R98003 BOX. TOOL 1 EA N02. PLASTIC

3 T6510029 SPANNER. SINGLE O.E 1EA MS50/WALTER

4 T6510060 SPANNER. DOUBLE ENDED 1EA MB 7X8

T6510062 1EA MB 8X10
T6510065 1EA MB 10X12
T6510069 1EA MB 12X14
T6510070 1EA MB 13X17
T6510072 1EA MB 17X19
T6510075 1EA MB 19X22
T6510077 1EA MB 21X23
T6510079 1EA MB 22X24
T6510081 1EA MB 24X27
5 R78278 SET. BALL HEX L-WRENCH 1ST MP1.5-
10/13609

6 T6550013 L-WRENCH 1EA MP12/SCM3

T6550015 1EA MP14/SCM3

7 T7050011 DRIVER. SCREW(-) 1EA 6X100L/32(-)

T7050021 DRIVER. SCREW(+) 1EA 6X100L/32(+)

8 R80037A GREASE GUN 1EA MODEL 12228

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Seq Picture Part No. Part Name Quantity Specification

9 R70200 KEY. HANDLE(DARK GRAY) 2EA K204-0112

10 C49070017 BOLT ASSY 1ST K204-0112

-SCREW. MACHINE

11 C72130113A BOLT. LEVEL 6EA

C72130123A BLOCK. LEVELING 6EA
C72130134A NUT. ADJUST 6EA

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4. Checking and fueling the oil tanks

4.1 Spindle Cooling Unit (Optional)
By factory default, DNM 400 is equipped with 12000-RPM unit; DNM 400HS is equipped
with 20000-RPM unit.
▪ Capacity: 12ℓ
▪ Type: FC10
▪ Remarks: Replace every 6 months, clean the filter every one month

유량계

4.2 Spindle Bearing Lubrication Unit (DNM 400HS)

For lubricating the built-in spindle bearing, a
separate lubrication unit has been installed.
▪ Capacity: 1.8ℓ
▪ Type: FC10
▪ Remarks: Refill every 50 hours

4.3 Lubrication Unit

▪ Capacity: 1.8ℓ
▪ Type: ISO VG68
▪ Remarks: Refill every 50 hours

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Note
Follow the instructions below for a proper lubrication.
(1) Use only the approved types of lubricant.
a) Otherwise, the lubrication unit may not work properly.
b) The lubricant used with coolant or the lubricant used with hydraulic fluid may
cause corrosion in the lubrication unit, resulting in deteriorated lubrication or
damaged slideway.
(2) Use only the approved types of coolant.
a) The coolant normally contains chemicals such as active agent. If you use an
improper kind of coolant, the chemicals of the coolant may affect the lubricant
adversely.
b) If you use other than recommended types of coolant, make sure that the
coolant shall not be mixed with the operating fluid, it has a good separability,
the coating shall not be peeled off, it shall not be rusted, and that the packing is
stable without expansion. If you encounter any problem using a particular
coolant, stop using the coolant whatsoever.
(3) Make it a rule to check the discharging status of the lubricant on a daily basis.
a) Use the ullage scale to check if the lubricant is supplied as appropriate.
b) By factory default, the machine has been removed of all remaining oil and
coolant in the tank. So you must refill the tank before operating the machine for
the first time.
(4) The replacement frequency is based on 8 hours of operation a day. If using out of
the frequency or using unrecommended types of oil, this may cause damage to the
machine.

▪ Oil Specifications

Manufacturer Shell
MOBIL TOTAL CALTEX Oiling points
Lubrication Type Product
VELOCITE TELLUS
ISO VG10 AZZOLA 10
No.6 C10
DTE 24 DROSERA RANDO HD- Shell Tellus Hyd. Power
ISO VG32
(NUTOH-32) ZS32 32 32 unit
DROSERA Way Shell Tonna Guide ways
ISO VG68 Vactra #2
MS68 lubricant 68 T 68 ball screws
Lithium soap type Power
Mobilux Multifax 2 or Shell Alvania
Multi-purpose chuck jaws
grease 2 Multifax Ep2 EP(LF) 2
grease & Turret

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Remark 1: We do not recommend you to use anything other than listed above. Since the
lubricant applying to the slideway contains extreme pressure additives, it may
cause unknown issues if responding chemically to other types of oil or coolant.
Remark 2: For fueling points and liters, refer to the user manual of each applicable model.
Remark 3: The lubricant used with coolant or the lubricant used with hydraulic fluid may
cause corrosion in the lubrication unit, resulting in defunctionalized lubrication
and damage to the slideway or the bolts.(IMPORTANT: The company shall not
take responsibility for any error caused by your using disapproved types of oil)
Remark 4: For oils applied to optional devices such as the special chuck or chip conveyor,
refer to the special instructions that ship with the optional device.
Remark 5: If you encounter a problem with the lubricant mixed with the coolant for the
slideway, prepare the oil skimmer before contacting us at our local office.

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5. Removing the transit clamps

Remove the transit clamps that are designed to prevent the axis from breaking away.
▪ Location of the transit clamps

①
②

NO Fix Part Number Type Location

1 X axis C72110113A Common Side of the table
2 Y axis C72110123A Common Front of the table
3 Z axis Common Over the table
Other Operation Panel Common Side of the OP

※ Checkpoints before operating the machine

(1) Are the lifting fixture and transit clamps all removed?
(2) Is the electrical phase correct?
(3) Are the air hoses connected properly?
(4) Are the air pressure and oil pressure supplied as appropriate to your settings?
(5) Is the lubricant supplied properly to all the intended points of the machine?
(6) Isn't there any missing part?

1) X-axis fixture

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2) Y-axis fixture

3) Z-axis fixture

4) OP fixture

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6. Connecting the main power and air sources

6.1 Connecting the main power source
※ Power Consumption
Item DNM400 DNM400HS

Power Voltage 380/440 V 200/220 V 380/440 V 200/220 V

Cable Thickness 16mm² 25mm² 25mm² 35mm²
Allowable Voltage Variation 10%
Apparent Power 30.9KVA 45.7KVA
Fusing Capacity 54.3A 93.8A 76.8A 132.6A

Warning

The machine may not operate properly if supplied with insufficient power, even causing a
risk of physical damage. So make sure to keep the proper supply of power by employing
necessary devices.

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※ Checking the main power connection

Before operating the machine, check the operation direction of the screw conveyor to
ensure that the power cable is connected properly. When done, manipulate the manual
switch as shown to check if the screw conveyor operates in the right direction.

Caution

1) Connect the earth wire to the PE (Protective Earth) terminal of the electric cabinet.
2) Do not make the power cable and the earth wire in serial connection. Otherwise,
this may cause a negative electrical impact on other connected devices or a failure
of the circuit breaker.

6.2 Connecting the air source

▪ Main Air Source
Pressure: 0.5 MPa or higher
Flux: 100 Nℓ/min (ANR) or higher
(use at least 0.75 KW compressor)

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▪ Air source for Air Curtain

Pressure: 0.1 MPa or higher

※ Compressor requirements
1) The minimum pressure is 0.5 MPa.
The operational pressure should be more than 40% higher from the minimum
requirement.

Note
If the discharge pressure of the compressor falls below the minimum requirement,
this may cause a failure of the air unit.

2) The recommended compressor is of the pressure-switch type.

3) Use only dehydrated clean air and, if the air contains moisture, make sure to install
an air dryer.

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7. Machine Leveling
1) Machine leveling
The precision on the parallelism for a machine is quite important as it can affect the
processing accuracy and life cycle of the machine significantly. Pay special attention to
the parallelism at the initial installation.

Model Number of bolts for leveling Note

DNM 400 & DNM 400HS 6EA Anchor bolt - prepared by customer

2) Instructions
① Return the Z axis to the reference point and move the X and Y axes to the center of
their respective stroke.
② Place the completed level on the table deck vertically.
③ Feed the Y axis in three divided strokes: both ends and center. Adjust the horizontal
parallelism to meet the feed level tolerance. (apply even force to each level bolt)
④ Feed the X axis in three divided strokes of both ends and center. Check and correct
the tilting if found.
⑤ Adjust the machine so that it is 65mm high from the ground. (avoid interference
with the coolant tank)
⑥ With the level bolt and nut tightened, adjust the parallelism so that it meets the
target below:
▪ Tolerance: 0.02mm// full stroke

Adjust the level bolt

Use the 4 level bolts that are marked in the figure above to
adjust the overall horizontal parallelism. Then, tighten the
other two level bolts to make the final adjustment.
Tighten the level nut

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※ Level Reference Point (use the leveled graplate or table)

① Place the level on the graplate and read one-end gradation of the water bubble of
the level.
② Turn the level by 180 degrees and read the gradation in the same direction.
③ With a plain screwdriver, adjust the reference point screw to set the level to an
intermediate gradation between initial gradation (before rotation, step ①) and
gradation after 180 degrees of rotation (step ②).
④ Repeat steps ① through ③ above until rotation in either direction comes up with the
same result.

Reference-
point
Adjusting
Screw

※ How to read the gradation

Negative (-) Positive (+)

① Feed the X axis in three divided strokes (220mm ≒ 762mm ÷ 3) and read the level
in each stroke.
② In the meantime, feed the Y axis in three divided strokes (140mm ≒ 435mm ÷ 3)
and read the level in each stroke.
③ The measurement may vary depending on your view position due to the distance
between gradation of the level and water bubble tube. So you must read the
gradation vertically at 90 degrees against the level.

X axis: 20
X axis 10 20 30
Z axis: 15
Z axis 15 25 30

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④ Feed the X axis in three divided strokes (220mm ≒ 762mm ÷ 3) and read the level
in each stroke.
⑤ In the meantime, feed the Y axis in three divided strokes (140mm ≒ 435mm ÷ 3)
and read the level in each stroke.
⑥ The measurement may vary depending on your view position due to the distance
between gradation of the level and water bubble tube. So you must read the
gradation vertically at 90 degrees against the level.

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8. Static Accuracy Inspection & Correction

※ V-MC Inspection Report Sample

V-MCT GEOMETRICAL TEST 2/4

NO TEST ITEM TOLERANCE READING

1 ▶SQUARENESS OF X-AXIS MOVEMENT TO Y-AXIS MOVEMENT

0.010/300 0.002

2 ▶SQUARENESS OF Z-AXIS MOVEMENT TO THE PALLET SURFACE PALLET#1

PALLET X-Z 0.010

0.015/300 PALLET#2

-
PALLET#1
Y-Z 0.012
0.015/300 PALLET#2
IN Y-Z PLANE
IN X-Z PLANE -
3 ▶PARALLELISM OF AXIAL MOVEMENTS TO THE PALLET SURFACE U P TO 5 0 0~ O VE R PALLET#1
50 0 1000 1 00 0
PALLET 0.014
0 . 02 0 . 03 0 .0 4 PALLET#2
X AXIS -
U P TO PALLET#1
5 0 0~
50 0 1 0 00 0.014
PALLET#2
0 . 02 0 . 03
X AXIS Y AXIS Y AXIS -
PALLET#1
4 ▶SQUARENESS OF THE SPINDLE CENTER TO THE PALLET SURFACE
Pallet X-Z 0.008
0.010/300 PALLET#2

-
PALLET#1

Y-Z 0.010
0.015/300 PALLET#2

-
5 ▶PARALLELISM OF Z-AXIS MOVEMENT TO THE SPINDLE CENTER
X-Z
0.008
0.010/300
Y-Z

Y-Z 0.012
0.015/300
X-Z

6 ▶PARALLELISM OF X-AXIS MOVEMENT TO THE REFERENCE T-SLOT PALLET#1

0.010/300 0.010
0.040/FULL PALLET#2
STROKE
-
M.DMF-Q7210-2(1990.4.23) A4(210×297mm) Doosan Infracore Co., Ltd.

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V-MCT GEOMETRICAL TEST 3/4

NO TEST ITEM TOLERANCE READING

7 ▶ RUN-OUT OF SPINDLE INTERNAL TAPER
A T S P IN DL E
N O SE 0.002
0 .0 0 5

AT 3 0 0
D IS T AN CE 0.007
0 .0 1 2

8 ▶ SPINDLE AXIAL MOVEMENT

0.003 0.001

8.1 Straightness of Pallet Deck

1) Measure
Place the straight edge on the pallet deck and
install the indicator on the block. Measure the
straightness on either ends and the center.
▪ Tolerance : X-Z: 0.015mm/500mm
Y-Z: below 0.040mm/front
2) Correct Straight
Edge
Correction is not possible as the straightness is
attributed to the physical pallet itself.
▪ If the difference is as significant as to require
correction, grind the deck again.

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8.2 Squareness between X- and Y-axis Movements

1) Measure
① Place the square horizontally on the pallet
deck.
ⓐ
② Install the indicator on the spindle head and ⓑ
put the gauge on the Y-axis side of the ⓒ
square.
ⓓ
③ While moving the X axis set either end of the
square to "0".
▪ To correct the parallelism, use the handle of a screwdriver to impact on any high
positions on the X axis as necessary.
④ Measure the Y-axis parallelism; the highest difference will be the measurement.
Set the parallelism between ⓐ and ⓑ to "0", against which the difference on
parallelism between ⓒ and ⓓ will be the measurement.
▪ Tolerance : 0.010mm/300mm

2) Correct
For this, use the key (C46021174) in the side
Key for
of the Y-axis LM guide. adjusting
Grind the key 1.8 times as much as the squareness
(2 EA)
measurement above.

8.3 Squareness between pallet deck and Z axis

▶X-Z
1) Measure
Place the square vertically (X axis) on the pallet
ⓐ
deck and move the indicator in the Z-axis
direction while measuring either ends of the
square (ⓐ, ⓑ). The greatest difference is the
measurement.
ⓑ
▪ Tolerance : 0.010mm / 300mm

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2) Correct
As this is for the squareness between pallet
and column, a slightest difference can be
corrected by the mechanical leveling.
If the squareness error is way beyond the
mechanical leveling, scrape the bed under the
column or insert a shim as wide as the error
between column and bed. However, the
squareness is well fit by factory default so the
mechanical leveling will do in most cases.

▶Y-Z
1) How to measure
Place the square vertically (Y axis) on the pallet
ⓐ
deck and move the indicator in the Z-axis
direction while measuring either ends of the
square (ⓐ, ⓑ). The greatest difference is the
measurement. ⓑ
▪ Tolerance : 0.015mm / 300mm

2) Correction
As this is for the squareness between pallet and column, a slightest difference can be
corrected by the mechanical leveling.
▪ If the squareness error is way beyond the mechanical leveling, scrape the bed under
the column or insert a shim as wide as the error between column and bed. However,
the squareness is well fit by factory default so the mechanical leveling will do in most
cases.

8.4 Parallelism between pallet deck and X-/ Y-axis movements

1) Measure
① Install the indicator on the spindle and
present the gauge to the table deck before
setting it to 0.
② Measure the X/Y-axis points in the right
figure and check if the measurements fall
below the tolerance.
▪ Tolerance :
X-axis direction: 0.003mm/ full stroke
Y-axis direction: 0.020mm/ full stroke

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2) Correct
For this, use the spacer (x4) that is designed
for adjusting the height of the X-axis L/M guide.
▪ Grind the space as much as the
Spacer for
measurement above on each of 4 corners. adjusting
height(4EA)

8.5 Squareness between pallet deck and main axis

1) How to measure
Install the indicator on the spindle and put the
gauge on a point about 150mm away from the
spindle center. While moving the spindle in the
X- and Y-axis direction, measure the difference
between highest and lowest value.
▪ Tolerance :
X-axis direction: 0.010mm / 300mm
Y-axis direction: 0.015mm / 300mm

2) Correction
In general, the squareness between spindle center and pallet deck is affected by several
factors: squareness between Z axis and pallet deck, parallelism between axial
movement and pallet deck, parallelism between spindle center and Z axis, and the
mechanical leveling condition. The squareness between spindle center and pallet deck
should be the last process after completing other precision work as mentioned above.

8.6 Parallelism between center line of main spindle and Z axis

▶ X – Z direction
1) Measure
Insert the test bar to the spindle, install the
indicator on the table, and present the gauge to 0 mm
the highest point of the test bar in the X-axis
direction. While moving the spindle, measure the
300 mm
runout on the spindle and stop moving the
spindle at the middle position between runout
highest and lowest points. Then move the Z axis
and measure the difference between mouth and
end of the test bar.
▪ Tolerance : 0.010mm / 300mm

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2) Correct Key for

This is to turn the spindle head itself. So use adjusting
squareness
the square keys (x2) on the L/M guide block of (2 EA)
the spindle head for adjusting the squareness.

▶ Y-Z direction
1) Measure 0 위치
Present the gauge to the highest point of the
test bar in the Y-axis direction. While moving
the spindle, measure the runout on the spindle 300위치
and stop moving the spindle at the middle
position between runout highest and lowest
points. Then move the Z axis and measure the
difference between mouth and end of the test
bar.
▪ Tolerance : 0.015mm / 300mm

2) Correct Spacer for

Use the height spacers (x4) on the L/M guide adjusting
height(4EA)
block of the spindle head for adjusting the
height.

8.7 Inspecting the parallelism between T slot and X-axis movement

1) How to measure
Install the indicator on the spindle, present the
gauge to one side of the T slot, and move the X
axis while measuring the parallelism. Where,
the parallelism is the measurement.
▪ Tolerance : 0.01mm / 300mm,
0.04mm / full stroke

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2) Correct
This is to turn the table itself. So use the square
Key for
keys (x2) on the L/M guide block of the table for adjusting
squareness
adjusting the squareness. (2 EA)
▪ Grind the key as much as the measurement
above.

8.8 Shaking inside the main spindle hole

1) How to measure Spindle Rotation
Insert the test bar into the spindle and present
the indicator to the mouth of the test bar, and to
a point 300mm away from the mouth. While
turning the spindle in a low speed, measure the 300mm
greatest shaking value.
▪ Tolerance : Mouth of the test bar: 0.005mm
300mm away: 0.012mm

2) Correction
As the taper side of the spindle is exposed to a high risk of scratch during the precision
work, remove the pull stud from the test bar or a new tool before applying minium or stamp
ink to the taper side, and use the sandpaper to grind the contact area of the taper.
※ Using the grinder is strictly prohibited. If the taper side is badly damaged, re-grind the
spindle itself.

8.9 Z-directional displacement of the main spindle

1) How to measure
Insert the test bar into the spindle, insert the
steel ball into the end center of the test bar,
and present the indicator to each of X and Y
highest point (or to the grinding section of the
test bar if applicable). While turning the spindle,
measure the greatest shaking value.
▪ Tolerance : 0.003mm

2) Correction
If the spindle moves in the Z-axis direction, this may be caused by a problem with the
spindle main bearing. If this is the case, replace the bearing.

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9. Reference Point & Correction

As this machine employs the absolute type of encoder, you don't need to adjust the dog;
simply change the parameter settings as necessary at the reference point.

9.1 X-axis reference point and correction for the standard pallet
As this machine employs the absolute type of encoder, you don't need to adjust the dog;
simply change the parameter settings as necessary at the reference point.

1) Return the X axis to the reference point

manually.
2) As shown, use the vernier calipers to measure
the distance between LM block and LM guide.
3) While feeding the X axis in Handle mode, 54㎜
adjust the distance to meet the standard.
※ Standard distance: 54mm

4) Change "Parameter No. 1815 #4(APZ)" for the X axis to 0, then back to 1.
5) When the alarm message of "P/S Alarm 000 Please Turn Off Power” is displayed, turn
off the machine and turn it back on in a moment.
6) Return the X axis to the reference point manually, and check the standard distance
again. Repeat the steps above until you get the satisfactory results.

9.2 Y-axis reference point and correction for the standard pallet
1) Return the Y axis to the reference point
manually.
2) As shown, use the vernier calipers to measure
the distance between LM block and LM guide.
56㎜
3) While feeding the X axis in Handle mode,
adjust the distance to meet the standard.
※ Standard distance: 56mm

4) Change "Parameter No. 1815 #4(APZ)" for the Y axis to 0, then back to 1.
5) When the alarm message of "P/S Alarm 000 Please Turn Off Power” is displayed, turn
off the machine and turn it back on in a moment.
6) Return the Y axis to the reference point manually, and check the standard distance
again. Repeat the steps above until you get the satisfactory results.

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9.3 X-/Y-axis reference point and correction for the center bush (optional)
As this machine employs the absolute type of encoder, you don't need to adjust the dog;
simply change the parameter settings as necessary at the reference point.

1) Return the X/Y axes to their respective

Y axis
reference point manually. direction
2) Feed the X/Y axes to their respective center of
the stroke.
X-axis
※ Distance from reference point to center: direction
X axis = 762mm/2
Y axis = 435mm/2
3) Install the indicator on the spindle. While
lowering the Z axis, measure the center bush in
each of X- and Y-axis directions.
4) Feed the X/Y axes in Handle mode so that they get as close to the center as possible.
Check the error on the monitor screen.
5) Return the X/Y axes to their respective reference point and enter the error in "Parameter
No.1850 Grid Shift". Check if X and Y values of "Parameter No.1815#4(APZ)" to 0,
respectively.
6) When the alarm message of "P/S Alarm 000 Please Turn Off Power” is displayed, turn
off the machine and turn it back on in a moment.
7) Return the X/Y axes to their respective reference point manually. Then, the X and Y
values of "Parameter No.1815#4(APZ)" switch back to 0, respectively.
8) Move the X and Y axes to their respective center and lower the Z axis for checking the
center again.
9) Repeat the steps above until you get the satisfactory results

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9.4 Z-axis reference point and correction

Work on the Z axis applies to both standard pallet and center bush (optional).

1) Return the Z axis to the reference point

manually.
2) Insert the test bar, place the block gauge
(approx. 100mm) down the bar and set the
indicator to 0.
3) In handle mode, move down the Z axis so that
Test Bar
the end of the test bar contacts on the indicator Block
(this will set the indicator to 0). Gauge
4) Use the below formula to calculate the
reference point error.
“0” Setting
(Test bar length + block gauge height) -150
▪ At Z0, the distance between top of the table
and spindle tool gauge line is 150mm.
5) Return the Z axis to the reference point and ent Table

er the error by adding or deducting the value of

"Parameter No.1850 Grid Shift". Check if the Z
value of "Parameter No.1815#4(APZ)" switches
back to 0.
6) When the alarm message of "P/S Alarm 000 Please Turn Off Power” is displayed, turn
off the machine and turn it back on in a moment.
7) Return the Z axis to the reference point manually. Check if the Z value of "Parameter
No.1815#4(APZ)" is changed to 1.
8) Repeat steps 2) through 7) above until you get the satisfactory results.

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10. ATC Change Position (Secondary Ref. Point)

※ Fixtures (centering fixtures)

① ② ③

10.1 Orientation
1) In MDI mode, instruct in the following order:
① G91 G30 Z0 ; (to the secondary reference point)
② M19 ; (Spindle Orientation)
③ M233 ; (Waiting Pot Down)

2) Select Changer in the OP and use the CW & CCW buttons to turn the changer arm to
the spindle side. Check if the gripper key aligns properly with the spindle key.

3) Change Parameter No. 4077 as appropriate to correct the orientation.

▪ Tolerance: 0.05mm/ full stroke
▪ Description of Parameter Value:
4069 on the basis of 360˚ for the spindle (90˚ = 1024)
0.08789° per pulse (effective range = ±4096)

4) Repeat the steps above until you get the satisfactory results.

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10.2 Secondary reference point

1) Remove the spindle key and insert
fixture ① instead.

2) In MDI mode, instruct in the following order:

① G91 G30 Z0 ;
(to the secondary reference point)
② M19 ; (Spindle Orientation)
③ M233 ; (Waiting Pot Down)

3) Push in fixture ② to the changer arm.

4) Select Changer in the OP and use the CW

button to turn the changer arm to the spindle
side. Use fixture ③ to check if fixture ① of the
spindle matches the center line with fixture ② of
the gripper.

10.3 Resetting the secondary reference point

1) Repeat steps 1) through 4) in "10.2 Secondary
reference point" above to move the changer
arm to the spindle position.
2) If the changer arm is off of the waiting pot and
of the spindle center in the same size and
same direction, loosen the changer arm bolts
(x4) to adjust the difference.
(Make adjustment based on the waiting pot.)

3) When centering on the changer arm is

completed, use the gap gauge to measure the
distance between arm and Z axis, which will be
set to the secondary reference point
(Parameter No.1241).
Change "Keep Relay 7.6" to 0. Now you can
move the axis.
※ Standard Distance
BT = 2mm, CAT = 3.18mm, DIN = 3.2mm

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11. Installing the coolant tank

※ When the leveling and precision works are completed, install the coolant tank.
1) Position of the coolant tank
① Refer to the marked point in the right picture and measure the heights on both
machine and coolant tank to check if there occurs any interference.
② Push in the coolant tank slowly to the front of the machine.

③ When done, tighten the bolt (marked in the

picture) until it contacts on the floor. Then, fix it
firmly.

2) Power connection to the coolant tank

When the coolant tank is positioned properly, plug in the power cable.

3) Connecting the coolant hoses

※ The number of hoses connecting to the pump
motor may differ depending on the number of
optional devices.

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4) Checking the operation

Use M codes listed below to check if the coolant works properly.

▪ Relevant Keep Relay Settings

Address Description
K0.7 Ignore COOLANT FILTER CHANGE ALARM (→1); do not ignore it (→0)
K5.2 Stop TSC when stopping supplying the coolant manually (→1); disabled
(→0)
K5.5 Enable the coolant pressure switch of TSC system unit including the tank
(→1); disabled (→0)
K5.6 Enable ECO TYPE TSC (→1); disabled (→0)
K9.2 Enable the tank-attached special coolant (TSC) (→1); disabled (→0)
K9.6 Enable the coolant supply manually in the state of DOOR INTERLOCK
(→1); disabled (→0)

▪ Relevant M codes
M-Code Meaning
M07 Through The Spindle Coolant On
M08 Flood Coolant On
M09 Coolant Off
M12 Shower Coolant On
M24 Chip Conveyor Run
M25 Chip Conveyor Stop
M126 Machine Flushing Coolant On For Spindle Head
M138 Base Coolant On
M139 Base Coolant Off
M140 ATC Pan Coolant Recovery On
M141 ATC Pan Coolant Recovery Off
M313 ATC Flow S/W Activating
M314 ATC Flow S/W Inactivating

※ Ensure that you have purchased all the necessary optional devices before
instructing any M code in the list above.

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Revision History
Installation Manual DNM 400

Version Year/Month Revision history Created by

01 2009. 07 Official draft (DNM400ISE97)

02

03

04

05

06

07

08

09

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