Doosan PUMA 480M User manual

Machine Tools
Installation Manual
(PUMA 480LM)

1
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. Second Round of Mortar Injection (Grouting) .................................................................. 12
4.1 Checkpoints before injecting mortar ............................................................................... 12
4.2 Blending the mortar mixture ........................................................................................... 12
4.3 Injecting the mortar mixture ........................................................................................... 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 Parallelism between center line of spindle and Z-axis movement .................................. 25
9.3 Parallelism between center line of spindle and Z-axis movement .................................. 27
9.4 Precision on the tool post............................................................................................... 28

2
PUMA
480LM
P48LMISE98
10. Reference Point & Correction ..........................................................................................31
11. Q-Setter Operation ............................................................................................................33

3
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. However, if it's inevitable, take caution
not to affect the machine with the vibration.
Reinforc※ed foundation, reinforced ground, and dustproof screen
2) A 14-ton crane with a minimum lifting performance of 4m ~ 5m 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, 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 ºC.
- The temperature difference should be within ±2 ºC for 24 hours (1 day).
-
The temperature difference between floor and 5m high from the floor should be within 1
ºC.
Ref 1) : ※Front View

4
PUMA
480LM
P48LMISE98
Ref 2) : Right View※
※ Ref 3) : Top View

5
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.
▪ The ground should be strong and solid. (bearing power of soil: at least 3 tons/m²)
▪ The concrete surface of the on-site floor should be at least 200mm thick.
▪ No gap is allowed between ground and concrete floor.
1) Foundation work timing and post checkpoints
It is recommended to take at least a two①-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 ②checkpoint 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
to the machine to install.
※ Foundation Diagram of Puma480LM
※ Tolerance for each checkpoint
Top View: ±5mm Gap between holes: ±10mm
Cumulative gaps between holes : ±20mm Size of foundation hole: ±10mm

6
PUMA
480LM
P48LMISE98
※ Foundation Cross-sectional Diagram
※ Notes
1) 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 first curing period for the concrete surface should be at least one month with a
minimum bearing soil power of 3 tons/m².
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 typical type. The thickness of the concrete
surface depends on the ground conditions.
2. -marked parts are not provided
by factory default. Make preparations for
yourself.

7
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.

8
PUMA
480LM
P48LMISE98
2. Transportation
2.1 Using the crane
1. 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.
2. To prevent damage to the machine, insert soft padding between machine 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 12,500 kg
(including hydraulic unit, electric cabinet and CNC)
H
ydraulic unit
CNC device
Lifting hook
Front door
Front door
Caution

9
PUMA 480LM P48LMISE98
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. While lifting the machine, you must pay special attention to the balance.
4. Don't forget to protect the machine from any external impact.
5. 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.)
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 the forklift
1) Refer to the weight table and select a forklift that supports an appropriate load capacity.
2) Insert the fork of the forklift into the lifting holes in the bottom of the machine base.
3) Lift up the machine while keeping it balanced.
4) Lower the machine slowly on the floor lest that it should be impacted on the floor.
Warning

10
PUMA
480LM
P48LMISE98
3. What's included
Seq Picture Part No. Part Name Quantity Specification
1
L73900017
Standard Accessories 1 Ay
2
R80013c
R98003
Kit. Tool Box
Box. Tool
1 St
1 Ea
L31900021
N02. Plastic
3
T6510022
Spanner. Single Ended
1ea
MS30
4
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
6x100l/32(
-
)
6x100l/32(+)
8
R80050
Grease Gun
1ea
A
-
220

11
PUMA 480LM 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

12
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. For this reason, a correct,
well-ordered workflow is required for each process.
(1) Is the concrete surface of each foundation hole rough?
(2) Has foreign matter inside of each foundation hole been completely removed?
(3) Has each foundation hole been soaked up in water?
▪ Keep the concrete soaked in water for at least 12 hours before injecting mortar, and
drain the water right before the injection. This is to enhance the adhesiveness of the
injected mortar and to prevent the mortar from drying too quickly as well as to
improve the fluidity of the mortar.
4.2 Blending the mortar mixture
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 10ºC and 21 ºC when
grouting. (Do
NEVER perform the grouting at below 0 ºC)
4) When mixing grout, be sure to meet the specified mixing ratio of water (grout water
ratio). (the specified ratio of water is about 15% of the grout weight.)
※ If the amount of water goes over the specified level, it may result in the deteriorated
strength of grout and the buildup of air bubbles in the bottom of the level plate while
drying.
※ Changes in compression strength of grout according to water ratio (example)
Water
Ratio
Compression Strength (Kgf/cm²) 20˚C Flow
(30 min)(mm)
Initial
Hardening Time
(Min)
Day 1 Day 3 Day 7 28일
13% 490 700 830 13% 490 700
14% 440 660 815 14% 440 660
15% 340 640 800 15% 340 640
16% 320 550 630 16% 320 550
17% 290 480 550 17% 290 480

13
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.
▪ To make the work effective
and as intended, it
is recommended to use the vibrator designed
to compact the concrete while injecting
mortar. (recommended)
3) Clean up the floor when the hole 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 curing. (The longer the curing period is, the greater
the strength. Assign 3 ~ 5 days for grout curing, and 7 days or more for mortar. Allow
additional 2 or 3 days for the curing in the wintertime.)
3) It is recommended that the surface be covered with a wet cloth in order to slow down
moisture evaporation as well as to minimize the impact by the surrounding vibration.

14
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 10%
Apparent Power 58.1 KVA
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.
※ 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 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.
Warning
Caution

15
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.
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

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

17
PUMA 480LM P48LMISE98
6.3 Lubrication Unit
Lubricant Tank 1.8ℓ ISO VG68 Refill every 70 ~ 80 hours
Lubricant Inlet &
Manometer

18
PUMA
480LM
P48LMISE98
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 c
ause damage to the
machine.
▪ Oil Specifications
Manufacturer
Lubrication Type
MOBIL TOTAL CALTEX ESSO Oiling points
ISO VG32 DTE 24 DROSERA
ZS32
RANDO HD-
32
NUTOH-
32
Hyd. Power
unit
ISO VG68 Vactra #2 DROSERA
MS68
Way
lubricant 68 FIBIS K-53 Guide ways
Tail Stock
Lithium soap type
Multi-purpose
grease
Mobilux
grease 2 Multifax 2 or
Multifax Ep2
Power
chuck jaws
& Turret
Note