Doosan PUMA 480LM Installation Manual Download Page 22 | Manualshive

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PUMA 480LM

P48LMISE98

7. Removing the transit clamps

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

NO

Fix

Part Number

Type

Location

a

X axis

L32391023A

Common

Front Side

b

Z axis

L32391033A

Common

Rear Side

c

OP Panel

L33585523

Common

Front Side

d

Tail Stock

L32391043B

Common

Front Side

a) X-axis fixture

b) Z1-axis fixture

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Summary of Contents for PUMA 480LM

Page 1: ...Machine Tools Installation Manual PUMA 480LM ...

Page 2: ......

Page 3: ...13 4 4 Curing the surface of mortar 13 5 Connecting the main power and air sources 14 5 1 Connecting the main power source 14 5 2 Connecting the air source 15 6 Checking and fueling the oil tanks 16 6 1 Hydraulic Unit 16 6 2 Gear Box 2 step 16 6 3 Lubrication Unit 17 7 Removing the transit clamps 20 8 Machine Leveling 22 9 Precision Measurement Correction 24 9 1 Runout on the spindle nose 24 9 2 P...

Page 4: ...2 PUMA 480LM P48LMISE98 10 Reference Point Correction 31 11 Q Setter Operation 33 ...

Page 5: ...ld 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 etc as well as enough room for repair so that the ...

Page 6: ...4 PUMA 480LM P48LMISE98 Ref 2 Right View Ref 3 Top View ...

Page 7: ...timing and post checkpoints 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 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 installi...

Page 8: ...ring soil power of 3 tons m 3 Prepare the wiring between machine and main power source as appropriate beforehand 4 Use a wrinkle tube to inject mortar into the second mortar surface about 400mm deep Important the tube must be removed after the first foundation work Use the nonshrinking grout and comply with the mixture ratio as instructed by the manufacturer 1 These diagrams are just of the typica...

Page 9: ...s 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: ...e and ropes 3 Move the machine to the intended area and put it down slowly in the right position 4 Adjust the rope length as appropriate to keep the machine balanced 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 PUMA 480XLM 12 50...

Page 11: ...6 Use only the rope that can endure the total weight of the lift 7 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 8 First lift the machine a bit from the floor and check the balance before proceeding 9 Ensure that there is no movable parts that can fall off inside the machine 2 2 Using ...

Page 12: ... T6510060 T6510062 T6510065 T6510069 T6510070 T6510072 T6510075 T6510077 T6510079 T6510081 Spanner Double Ended 1ea 1ea 1ea 1ea 1ea 1ea 1ea 1ea 1ea 1ea MB 7X8 MB 8X10 MB 10X12 MB 12X14 MB 13X17 MB 17X19 MB 19X22 MB 21X23 MB 22X24 MB 24X27 5 R78278 Set Ball Hex L Wrench 1st MP1 5 10 13609 6 T6550013 T6550015 L Wrench 1ea 1ea MP12 SCM3 MP14 SCM3 7 T7050011 T7050021 Driver Screw Driver Screw 1ea 1ea ...

Page 13: ...80LM P48LMISE98 Seq Picture Part No Part Name Quantity Specification 9 R70084 Key Handle Dark Gray 2ea K204 0112 10 L08501183b 12st L08520353b 10st Plate Level Inspection 1ea 1ea 60deg 12st 25mm 45deg 10st 25mm ...

Page 14: ...xture 1 Mix grout and water appropriately for more than 2 minutes using a motorized hand mixer or a mechanical mixer in compliance with the instructions provided by the grout maker 2 A mixture of water and mortar should be injected completely in less than 30 minutes after the mixing Otherwise the mixture may get started with a chemical reaction 3 The temperature of the mixture is desirable between...

Page 15: ... is filled up with mortar Inject mortar into each foundation hole up to the bottom of the leveling plate The instructions and pictures above are extracted from DB130CX mortar injection instructions that can be applied to the current machine 4 4 Curing the surface of mortar 1 Keep supplying an adequate amount of water on the surface in the course of mortar curing 2 Make a generous schedule for the ...

Page 16: ...oper supply of power by employing necessary devices Checking the main power connection Before operating the machine check the pressure setting of the hydraulic tank to ensure that the power cable is connected properly After the main power is connected be sure to check if the pressure of the gauge is set to 40 bars as shown 1 Connect the earth wire to the PE Protective Earth terminal of the electri...

Page 17: ...rational pressure should be more than 40 higher from the minimum requirement 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 Note ...

Page 18: ...16 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 Gear Box 6ℓ ISO VG32 Refill every 6 months Inlet ...

Page 19: ...17 PUMA 480LM P48LMISE98 6 3 Lubrication Unit Lubricant Tank 1 8ℓ ISO VG68 Refill every 70 80 hours Lubricant Inlet Manometer ...

Page 20: ...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...

Page 21: ... 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 lu...

Page 22: ... that are designed to prevent the axis from breaking away NO Fix Part Number Type Location a X axis L32391023A Common Front Side b Z axis L32391033A Common Rear Side c OP Panel L33585523 Common Front Side d Tail Stock L32391043B Common Front Side a X axis fixture b Z1 axis fixture ...

Page 23: ... 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: ...trokes 700mm 2155mm 3 adjust the level as appropriate 3 With the level bolts and nuts tightened up adjust the level below the tolerance Tolerance 0 02mm per 1000mm Setting the reference point for the leveling Place the level in the center of the pallet and read one end gradation of the water bubble of the level Turn the level by 180 degrees and read the gradation in the same direction Turn the lev...

Page 25: ...ble tube So you must read the gradation vertically at 90 degrees against the level Precautions for the leveling work Apply force as evenly as possible to each level bolt If any one of the level blocks contacts on the bed unevenly it may cause an incorrect leveling in the end The last step of the leveling should be ended in the direction that the level bolt is tightened X axis Z axis 15 10 20 25 30...

Page 26: ...erformed to produce the optimal precision for the machine 9 1 Runout on the spindle nose Before attaching the chuck to the spindle ensure that no scratch occurs on the spindle or the nose 1 Precision work Install the level on a solid component such as bed or turret and measure on the spindle or nose Tolerance below 0 01 mm 2 Correct As the final accuracy is determined based on the chuck being atta...

Page 27: ... and Z axis movement Target below 0 005 mm 100 mm 1 Insert a workpiece made of soft metal such as aluminum in Φ50 L150 200 into the chuck and perform the rough cut then finishing cut 2 Use the micrometer to measure the overall length between two points A B If the difference between A and B is more than 0 01mm 100mm you must adjust the head stock 3 Adjusting the head stock Install the indicator on ...

Page 28: ... must turn off the machine before adjusting the belt tension or replacing the belt 1 Loosen the clamp bolt 2 on the motor base 2 Loosen the nuts 1 2 on the block 3 Use the bolt 1 to adjust the belt tension 4 Refer to the below table and check the bend δ of the belt at tension F 5 When you reach the target value tighten the clamp bolt 1 and nut 2 Model Belt Type No of Belts Total Tension Kgf Bend δ...

Page 29: ...he turret While moving the Z axis check the X axis deviations normally no deviation is allowed and set the end of the workpiece to 0 Close the hydraulic valve of the tail stock to lower the oil pressure to 0 This is to prevent the tail stock from being pushed back due to the oil pressure when loosening the tail stock bolts Use the L wrench to loosen the bolts 4 BB 20 70 on the tail stock body If B...

Page 30: ...pleted adjust the accuracy of the tool post based on the spindle 1 To measure the accuracy of the tool post body Install the indicator on the check or bed and present the gauge to the tool holder While moving the Z axis measure the parallelism If the measurement is more than 0 01mm for the whole stroke you should correct the accuracy 2 Precision work on the tool post body Remove the X axis sliding...

Page 31: ...ing the Z axis measure the parallelism If the measurement is more than 0 01mm for the whole stroke you should correct the accuracy 4 Correct Remove the tool and tool holder from the turret Mark the position if necessary To facilitate the work move to the Z axis position proper position for the measuring Remove L33582221C location disk at first Then loosen the coolant plug bolt Adjusting Bolt For P...

Page 32: ... turret BB12 X 110 S2216861 8EA With a plastic hammer or wood support impact on the turret head to make adjustment within the tolerance When done tighten up the bolts and perform the reaming of the pin hole again before inserting the taper pin Do the same on the hole for each of two spare taper pins Install the location disk according to the number FIXTURE Taper Pin Spare Taper Pin Hole ...

Page 33: ...oint manually and instruct the tool number of a tool where the ID tool holder is attached 3 Feed the axis to X0 and move it in Handle mode so that you can measure the inner diameter of the ID holder Set the gauge to 0 2 M5 Tapping 2 Φ8 Drilling 15 30 60 Φ20 60 Φ50 Φ80 Material Aluminum recommended because of weight when carrying it Diagram of a centering fixture sample Centering Fixture ...

Page 34: ... Since the error is the height error of the turret make correction of the adjusting plate according to the error 6 Return to the reference point and enter half of the X axis error step 5 above in Parameter No 1850 Grid Shift 7 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 8 Return the X axis to the reference point ma...

Page 35: ...orkpiece that you can measure the outer diameter of Insert the finishing tool into the turret and process the whole outer diameter side of the workpiece evenly When completed the X axis should not move at all With the micrometer measure the diameter of the completed workpiece Axial Direction X direction X direction Z direction Z direction Parameter No 5015 5016 5017 5018 4 Readjusting the sensor p...

Page 36: ...sensor surface should fall below 0 002mm for the Z axis movement of the saddle Repeat Swing Arm Up Down several times to check if the saddle stops at the same position If necessary use the adjusting screw 2 to make adjustment Check if the outer diameter tool is positioned at the middle of the sensor height Loosen 4 bolts in the marked area of the picture and grind or replace the height spacer as n...

Page 37: ...re enough room for work Take caution when installing the coolant tank Otherwise it may cause an accident 2 Power and hose connection for the coolant tank When the coolant tank is positioned properly supply power to the tank and connect the hoses The number of cables or hoses differs depending on the optional devices Check the numbering before proceeding 3 Checking the operation Use M codes listed ...

Page 38: ...oolant Is Valid Even Splash Guard Is Opened 1 Or Not 0 K4 2 When Low And High Coolant Are Used M7 Or M8 Command Is Available Without M9 1 Or Not 0 K6 4 Cool Jet Coolant Pump Is Used 1 Or Not 0 K51 2 Coolant Gun is Used 1 Or Not 0 F32i K12 2 K52 2 Coolant Flushing Motor Is Used 1 Or Not 0 F32i K13 2 Relevant M codes M CODE MEANING M07 High Pressure Coolant On M08 Coolant On M09 Coolant Off M63 Spin...

Page 39: ...37 PUMA 480LM P48LMISE98 Revision History Installation Manual PUMA 480LM Version Year Month Revision history Created by 01 2009 08 Official draft P48LMISE98 Jeong Sam Young 02 03 04 05 06 07 08 09 10 ...

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