Doosan PUMA 480M Installation Manual
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Doosan PUMA 480M Installation Manual

Doosan PUMA 480M Installation Manual

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Machine Tools
Installation Manual
(PUMA 480LM)

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Summary of Contents for Doosan PUMA 480M

  • Page 1 Machine Tools Installation Manual (PUMA 480LM)

  • Page 3: Table Of Contents

    PUMA 480LM P48LMISE98 Table of Contents 1. Preparations before shipment ..................... 3 1.1 Installation Site ........................ 3 1.2 Foundation Work ......................5 2. Transportation ........................8 2.1 Using the crane ....................... 8 2.2 Using the forklift ....................... 9 3. What's included ........................10 4.
  • Page 4 PUMA 480LM P48LMISE98 10. Reference Point & Correction ..................31 11. Q-Setter Operation ......................33...

  • Page 5: Preparations Before Shipment

    PUMA 480LM P48LMISE98 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.
  • Page 6 PUMA 480LM P48LMISE98 Ref 2) : Right View ※ ※ Ref 3) : Top View...

  • Page 7: Foundation Work

    PUMA 480LM P48LMISE98 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.
  • Page 8 PUMA 480LM P48LMISE98 ※ Foundation Cross-sectional Diagram 1. These diagrams are just of the typical type. The thickness of the concrete surface depends on the ground conditions. -marked parts are not provided by factory default. Make preparations for yourself. ※ Notes 1) Reinforce the ground with stake driving, riprap piling and rebar reinforcement.
  • Page 9 PUMA 480LM P48LMISE98 5) The holes for the second mortar work should comply with the specifications in the detailed diagram above. 6) Prepare oils, power source and air source before the machine arrives on the site. 7) Adjust the height of the machine so that it is 5mm to 10mm high from the ground. To facilitate the work on the coolant tank, measure the height between coolant tank and ground beforehand.

  • Page 10: Transportation

    5. f 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. UOM: kg Approximate mass of machine PUMA 480M 8,450 kg PUMA 480LM 10,050 kg...

  • Page 11: Using The Forklift

    PUMA 480LM P48LMISE98 Warning 1. Use only a rope of at least 20mm in the normal diameter. 2. Adjust the angle formed by each wire line so that the ropes do not contact on the machine body. (The rope should not tilt beyond 40 degrees against the vertical line.) 3.

  • Page 12: What's Included

    PUMA 480LM P48LMISE98 3. What's included Picture Part No. Part Name Quantity Specification L73900017 Standard Accessories 1 Ay R80013c Kit. Tool Box 1 St L31900021 R98003 Box. Tool 1 Ea N02. Plastic T6510022 Spanner. Single Ended MS30 T6510060 Spanner. Double Ended MB 7X8 T6510062 MB 8X10...
  • Page 13 PUMA 480LM P48LMISE98 Picture Part No. Part Name Quantity Specification R70084 Key. Handle(Dark Gray) K204-0112 L08501183b Plate. Level Inspection 60deg/12st/25mm -12st L08520353b 45deg/10st/25mm -10st...

  • Page 14: Second Round Of Mortar Injection (Grouting)

    PUMA 480LM P48LMISE98 4. Second Round of Mortar Injection (Grouting) 4.1 Checkpoints before injecting mortar When the temporary installation is completed, inject mortar into the foundation holes for the machine before curing the surface. This process is very important because it affects the accuracy, strength and lifecycle of the machine and more.

  • Page 15: Injecting The Mortar Mixture

    PUMA 480LM P48LMISE98 4.3 Injecting the mortar mixture 1) Pour the mortar or grout mixture in a single direction from one side of the foundation hole so that the mixture can fill in the hole evenly. 2) Mortar compacting Use a pipe or long thin pole to keep stirring in the mortar mixture so that the mixture fills up the whole hole evenly without the buildup of air bubbles.

  • Page 16: Connecting The Main Power And Air Sources

    PUMA 480LM P48LMISE98 5. Connecting the main power and air sources 5.1 Connecting the main power source ※ Power Consumption Item Puma480LM Power Voltage 380/440 V, 50/60Hz 200/220 V, 50/60 Hz Cable Thickness 25mm² 70mm² Allowable Voltage Variation Apparent Power 58.1 KVA Warning The machine may not operate properly if supplied with insufficient power, even causing...

  • Page 17: Connecting The Air Source

    PUMA 480LM P48LMISE98 5.2 Connecting the air source ▪ Requirements Pressure: 0.5 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.

  • Page 18: Checking And Fueling The Oil Tanks

    PUMA 480LM P48LMISE98 6. Checking and fueling the oil tanks 6.1 Hydraulic Unit Hydraulic Unit 13ℓ ISO VG32 Refill every 6 months 6.2 Gear Box (2-step) Inlet Gear Box 6ℓ ISO VG32 Refill every 6 months...

  • Page 19: Lubrication Unit

    PUMA 480LM P48LMISE98 6.3 Lubrication Unit Lubricant Inlet & Manometer Lubricant Tank 1.8ℓ ISO VG68 Refill every 70 ~ 80 hours...
  • Page 20 PUMA 480LM P48LMISE98 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.
  • Page 21 PUMA 480LM P48LMISE98 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.

  • Page 22: Removing The Transit Clamps

    PUMA 480LM P48LMISE98 7. Removing the transit clamps Remove the transit clamps that are designed to prevent the axis from breaking away. Part Number Type Location X axis L32391023A Common Front Side Z axis L32391033A Common Rear Side OP Panel L33585523 Common Front Side...
  • Page 23 PUMA 480LM P48LMISE98 c) OP fixture d) Tail stock fixture 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?

  • Page 24: Machine Leveling

    Pay special attention to the parallelism at the initial installation. Model No. of Level Bolt Remark PUMA 480M Through the foundation bolt PUMA 480LM Through the foundation bolt PUMA 480XLM Through the foundation bolt...
  • Page 25 PUMA 480LM P48LMISE98 ① Measure the Z axis of Puma480LM at each of the three stokes (700mm ≒ 2155mm/3). ② 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.

  • Page 26: Precision Measurement & Correction

    PUMA 480LM P48LMISE98 9. Precision Measurement & Correction When the machine leveling is completed, perform the precision inspection on the machine in order to deal with the precision changes that may occur while in transportation or installation. This is performed to produce the optimal precision for the machine. 9.1 Runout on the spindle &...

  • Page 27: Parallelism Between Center Line Of Spindle And Z-Axis Movement

    PUMA 480LM P48LMISE98 9.2 Parallelism between center line of spindle and Z-axis movement In general, the parallelism should be measured using the test bar but it is rarely available on site. Use an on-site workpiece as an alternative to the test bar. ▪...
  • Page 28 PUMA 480LM P48LMISE98 When you get a satisfactory result, tighten up the head stock bolts. ⑤ Tension Bolt How to adjust the tension of gear box belt ※ If you need to adjust the accuracy on the spindle or adjust the tension of the gear box belt after an extended time of use, follow the instructions below: Danger -You must turn off the machine before adjusting the belt tension or replacing the belt.

  • Page 29: Parallelism Between Center Line Of Spindle And Z-Axis Movement

    PUMA 480LM P48LMISE98 9.3 Parallelism between center line of spindle and Z-axis movement In general, the parallelism should be measured using the test bar but it is rarely available on site. Use an on-site workpiece as an alternative to the test bar. 1) Install a 400mm workpiece in the chuck that “A”...

  • Page 30: Precision On The Tool Post

    PUMA 480LM P48LMISE98 How to use the adjusting bolt on the tail ※ stock body ⓐ Loosen the front tail stock gib bolt by two turns, and tighten the rear gib bolt. ▪ Since the tail stock gib is of the taper type that contacts the tail stock body tightly on the base, you should loosen the bolt slightly to make room for work.
  • Page 31 PUMA 480LM P48LMISE98 Adjusting Bolt For Push (x2) Adjusting Bolt For Pull (x2) 3) To measure the accuracy of the turret Operate the machine as shown to call the ① tool where the outer-diameter tool holder is attached. Install the indicator on the chuck and ②...
  • Page 32 PUMA 480LM P48LMISE98 Use the pin puller to remove the positioning ④ pins from the turret. ▪ P57210070 TAPER PIN TPB10X70 ▪ L33581363 FIXTURE Taper Pin FIXTURE Loosen the curvic coupling bolts slightly ⑤ from the turret. ▪ BB12 X 110 (S2216861) = 8EA With a plastic hammer or wood support, ⑥...
  • Page 33 PUMA 480LM P48LMISE98 10. Reference Point & Correction 2-M5 Tapping 2-Φ8 Drilling Material: Aluminum recommended (because of weight when carrying it) (Diagram of a centering fixture sample) 1) Insert the centering fixture into the spindle chuck and install the indicator short and firm. 2) Return the X axis to the reference point manually and instruct the tool number of a tool where the ID tool holder is attached.
  • Page 34 PUMA 480LM P48LMISE98 4) By rotating the spindle manually or rotating the C axis after converting three axes with each other in Handle mode, measure the concentricity on spindle and ID holder. 5) Move the X axis in Handle mode to set the gauge to 0 and check the height error. ※...
  • Page 35 PUMA 480LM P48LMISE98 11. Q-Setter Operation 1) Q-Setter related Keep Relay settings and M codes Keep Relay M Code Description K7.5 Enable Q-setter (→1), disabled (→0) Q- Setter Swing Arm Down Q- Setter Swing Arm Up 2) Check the Q-Setter operations of Swing Arm Up/Down ①...
  • Page 36 PUMA 480LM P48LMISE98 “A” “B” Measuring Section Fixing Bolt Adjusting Screw (1) Adjusting Screw (2) As in the left figure above, use the indicator to measure the parallelism on the ① measuring section from "A" to "B", and adjust the parallelism below 0.01mm for the saddle.
  • Page 37 PUMA 480LM P48LMISE98 12. Installing the coolant tank When the leveling and precision work are completed, install the coolant tank. At least two persons should be involved. Read through and follow the instructions below when installing the coolant tank using the crane or forklift. 1) Position of the coolant tank A collision between component parts may occur if you do not secure enough room for...
  • Page 38 PUMA 480LM P48LMISE98 ▪ Relevant Keep Relay Settings MEANING K0.4 Coolant Pressure Switch Is Used(→1), Or Not(→0) Spindle And Coolant Stop Running On FEED HOLD Or SINGLE BLOCK ALARM K3.0 (→1), Or Not(→0) K3.5 High Pressure Coolant Runs When Manual Coolant Switch Is On(→1), Or Not(→0) When M-Code Of Coolant On Is Ordered, M-Code Is finished By Motor(→1), Or K3.6 Internal Relay Operation(→0)
  • Page 39 PUMA 480LM P48LMISE98 Revision History Installation Manual PUMA 480LM Version Year/Month Revision history Created by 2009. 08 Official draft (P48LMISE98) Jeong, Sam Young...

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Puma 480lmPuma 480xlm

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