In - PUMA V400 Series (0409) PDF

INSTRUCTION MANUAL
MAINTENANCE & TECHNICAL DOCUMENTS
Before using this machine, fully understand the contents of this manual
to ensure proper operation.
Always keep this manual near the machine for immediate use.
PV40INE43(1st Edition)
Introduction
Introduction
Thank you for choosing the DAEWOO machine tool. We are proud to have you among our DAE-
WOO family of users.
Manuals contain concise information on the installation, setup, operation and maintenance of
your machine tool. To make the most of its outstanding performance over a long period, the
machine must be properly installed, and operating and maintenance procedures must be clearly
understood and carefully followed.
We provide the following manuals.
Item Description Coverage

Machine instruction manual – Specification, maintenance data
Machine operation manual – Basic operation
Machine manual Parts list – Machine parts designation
Electric diagram – Hardware diagram
Ladder diagram – Software diagram
Instruction manual – NC operation and programing
CNC manual
Maintenance manual – NC maintenance
– F.C.F, Parameter sheet, Chuck &
Appended data Extra documents
Cylinder manual
This manual was considered complete and accurate at the time of publication, however, due to
our desire to constantly improve the quality and specification of all our products, it is subject to
change or modification.
If you have any questions, please contact the nearest DAEWOO Technical/Service center.
DAEWOO HEAVY INDUSTRIES & MACHINERY LTD.

http://www.domss.com
http://www.pumasis.com
Address : A/S dept., Machine tool & F.A division
601-3, Namsan-Dong, Changwon,
Gyeongsangnam-Do, Korea 641-090
Tel. : 82-55-280-4483
Fax. : 82-55-281-6181
Introduction PV40INE43
Table of contents
Safety precautions
1. Safety precautions
2. General safety
3. Clothing and personal safety
4. Safety related to operation
5. Safety related to gripping workpiece and tooling
6. Safety related to maintenance
7. Safety related tothe workpiece
8. Safety equipment
9. Safety related to a chip conveyor
10. Safety nameplates
11. When door is open
12. Warning labels on the machine
13. Noise emission
Page
Section 1 Construction of machine ............................................................................. 1.1-1
1.1 Concept of axis ...................................................................................................... 1.1-1
1.2 Overview of machine ............................................................................................. 1.2-1
1.3 Construction of units .............................................................................................. 1.3-1
1.3.1 Headstock ....................................................................................................... 1.3-1
1.3.2 Chucking system............................................................................................. 1.3-1
1.3.3 C-axis (main & sub spindle) ............................................................................ 1.3-2
1.3.4 Carriage(X, Z-axis).......................................................................................... 1.3-2
1.3.5 Hydraulic power unit........................................................................................ 1.3-2
1.3.6 Coolant system ............................................................................................... 1.3-2
1.3.7 Lubrication system .......................................................................................... 1.3-2
1.3.8 Tool post.......................................................................................................... 1.3-2
1.3.9 Operation console............................................................................................ 1.3-3
Table of contents Page 0.1-1 PV40INE43

Table of contents
Page
1.3.10 Electrical cabinet ........................................................................................... 1.3-3
1.3.11 Foot switch .................................................................................................... 1.3-3
1.3.12 Pressure switch............................................................................................. 1.3-3
1.3.13 Self-lock cylinder for chuck ........................................................................... 1.3-3
1.3.14 Halogen lamp ................................................................................................ 1.3-3
1.3.15 Door interlock switch(Option) ........................................................................ 1.3-4
1.3.16 Safety glass................................................................................................... 1.3-4
1.3.17 Ball screws .................................................................................................... 1.3-4
1.3.18 Electrical Torque limiter ................................................................................. 1.3-4
1.3.19 Oil skimmer(option) ....................................................................................... 1.3-4
Section 2 Machine specifications ................................................................................ 2.1-1
2.1 Specification table .................................................................................................. 2.1-1
2.2 Dimensional drawings ............................................................................................ 2.2-1
Section 3 Handling and installation ............................................................................. 3.1-1
3.1 Guide to select a installation site(Environmental requirements) ............................ 3.1-1
3.1.1 Care in handling a precision machine ............................................................. 3.1-3
3.2 Foundation requirements ....................................................................................... 3.2-1
3.2.1 General precautions for building a new foundation......................................... 3.2-1
3.3 General procedure for installation .......................................................................... 3.3-1
3.3.1 Precautions for installation .............................................................................. 3.3-1
3.4 Leveling the machine ............................................................................................. 3.4-1
3.4.1 Leveling procedure.......................................................................................... 3.4-1
3.5. Foundation plan.................................................................................................... 3.5-1
3.6 Power requirements............................................................................................... 3.6-1
3.6.1 Inspection of cable connection........................................................................ 3.6-1
3.6.2 Electrical work ................................................................................................. 3.6-2

Table of contents
Page
3.7 Air source requirements ......................................................................................... 3.7-1
3.7.1 Air source ........................................................................................................ 3.7-1
3.7.2 Selection of compressor.................................................................................. 3.7-1
3.8 Lubricant oil required at installation........................................................................ 3.7-1
Section 4 Machine operation ........................................................................................ 4.1-1
4.1 Before starting operations ...................................................................................... 4.1-1
4.1.1 NC operation ................................................................................................... 4.1-1
4.2 Warming-up ........................................................................................................... 4.2-1
4.2.1 Purpose of warming-up ................................................................................... 4.2-1
4.2.2 Method of warming-up .................................................................................... 4.2-1
4.2.3 Tool offset........................................................................................................ 4.2-1
4.2.4 Setting of start point ........................................................................................ 4.2-3
4.2.5 Automatic operation ........................................................................................ 4.2-5
4.3 Safety function ....................................................................................................... 4.3-1
4.4 Machine operation ................................................................................................. 4.4-1
4.4.1 Hydraulic unit .................................................................................................. 4.4-1
4.4.2 Spindle speed-torque-power diagram ............................................................. 4.4-6
4.4.3 Hydraulic chuck............................................................................................... 4.4-7
4.4.4 Cutting soft top jaws of power chuck............................................................... 4.4-21
4.4.5 C-axis .............................................................................................................. 4.4-23
4.4.6 Cautions on operating the turret...................................................................... 4.4-24
4.4.7 After completion of a day's operation .............................................................. 4.4-25
Section 5 Inspection and maintenance ....................................................................... 5.0-1
5.1 Lubrication ............................................................................................................. 5.1-1
5.1.1 Spindle lubrication system .............................................................................. 5.1-4
5.1.2 Slideway lubrication system ............................................................................ 5.1-4
5.2 Cleaning coolant tank ............................................................................................ 5.2-1

Table of contents
Page
5.3 Tensioning belts ..................................................................................................... 5.3-1
5.3.1 Adjusting V-belt between the spindle and main motor .................................... 5.3-1
5.3.2 Adjusting timing belt for spindle motor of rotary tool and servo turret ............. 5.3-3
5.4 Troubleshooting for simple mechanical trouble...................................................... 5.4-1
5.4.1 Trouble with headstock ................................................................................... 5.4-1
5.4.2 Trouble with turret .......................................................................................... 5.4-2
5.4.3 Others ............................................................................................................ 5.4-7
5.5 General trouble shooting........................................................................................ 5.5-1
5.5.1 Headstock........................................................................................................ 5.5-1
5.5.2 Chuck .............................................................................................................. 5.5-2
5.5.3 Hydraulic unit .................................................................................................. 5.5-3
5.5.4 Lubrication unit................................................................................................ 5.5-4
5.5.5 Coolant unit ..................................................................................................... 5.5-5
5.5.6 Carriage(X, Z-axis).......................................................................................... 5.5-5
5.5.7 Turret............................................................................................................... 5.5-6
5.5.8 Air unit ............................................................................................................. 5.5-7
5.5.9 Q-setter ........................................................................................................... 5.5-7
Section 6 Technical data ............................................................................................... 6.1-1
6.1 Tooling system ....................................................................................................... 6.1-1
6.1.1 PUMA V400 ..................................................................................................... 6.1-1
6.1.2 PUMA V400M .................................................................................................. 6.1-2
6.2 Toolholder dimensions ........................................................................................... 6.2-1
6.3 Working range diagram.......................................................................................... 6.3-1
6.3.1 PUMA V400 ..................................................................................................... 6.3-1
6.3.2 PUMA V400M .................................................................................................. 6.3-3
6.4 Dimension of spindle nose ..................................................................................... 6.4-1
6.5 Hydraulic chuck and cylinder ................................................................................. 6.5-1
6.6 Hydraulic circuit diargram....................................................................................... 6.6-1

Safety precautions
1.Safety precautions
The machine is shipped with a variety of safety devices. However, careless handling of the
machine may lead to serious accidents.
All the items described must be carefully observed when operating the machine. Failure to
observe fundamental safety information can lead to serious operator injury or machine damage.
All operators must strictly follow the information.
[Symbols]
The following warning indications are used in this manual to draw attention to information of par-
ticular importance.
: Indicates an imminent hazard which, if not avoided, will result in death or serious
injury.
: Indicates hazards which, if not avoided, could result in death or serious injury.
: Indicates hazards which, if not avoided, could result in minor injuries or product
damage.
: Important information for machine operation.
Safety precautions Page 1 PV40INE43

Safety precautions
2. General Safety
1) There are high voltage terminals on the electrical control panel, transformer, motors, junction
boxes, and other equipment(with a battery warning mark attatched).
Do not touch any of them under any circumstances.
2) Make sure that all doors and covers are fitted before switching on the power. If any door or
cover is to be removed, first cut off and lock the main breaker.
1) Memorize the position of the EMERGENCY STOP button so that you can press it immediately
from any position.
2) Take care not to touch any of the switches accidentally while the machine is in operation.
3) Take care not to catch your fingers in the chuck.
4) Under no circumstances touch a rotating workpiece or the tool with your bare hands or any
other object.
5) To prevent incorrect operation of the machine, carefully check the position of the switches
before operation.
6) If in the slightest doubt a procedure, ask the person in charge.
7) Always switch off the power switch on the operation panel and switch off the main power
breaker before leaving the machine.
8) If more than one operator are using the machine, do not proceed to the next step without indi-
cating to the other operator(s) that you are about to do so.
9) Do not modify the machine in any way that will affect its safety.
Be absolutely certain to use the specified and standardizes parts as replacement or consum-
able parts so as to maintain the as-shipped machine specifications.
We take no responsibility for any personal accidents or machine trouble due to inobservance
of this warning.
1) If there is a power failure, switch off the main power breaker immediatly.
2) Do not subject the CNC unit, the operation panel, or the electrical control panel to stroke shocks.

Safety precautions
3) Do not change the parameter or other electrical setting values without good reason. If it
becomes necessary to change a values, first check that it is safe to do then make a note of the
original value so that it can be reset if necessary.
4) Do not paint, soil, damage, modify, or remove any of the safety nameplates. If the nameplates
become illegible or if the nameplate is lost, obtain a replacement by sending the part number
stamped at the bottom right-hand corner of the nameplate to DAEWOO and mount replace-
ment in the original position.
5) Do not open any doors or satety covers while the machine is in automatic operation.
6) Stop all machine operations before cleaning the machine or any of the peripheral equipment.
7) After a job has been completed, set up each part of the machine so that it is ready to be for the
next series of operations.
3. Clothing and Personal Safety
1) Tie back long hair, which could become entangled drive mechanisms.
2) Wear safety equipment(helmet, goggles, safety shoes, etc.) whenever possible.
3) Always wear a helmet if there are any overhead obstacles in the work area.
4) Always wear a protective mask when machining magnesium alloys.
5) Always use safety shoes with steel toecaps and oil-resistant soles.
6) Never wear loose or baggy clothing.
7) Always completely fasten buttons and hooks on the arms of clothing to avoid the danger of
entanglement in drive mechanisms.
8) Do not operate the machine while under the influence of drugs with powerful effects, unpre-
scribed drugs, or alcohol.
9) Do not operate the machine if you suffer from dizziness or fainting spells.
10) Always use gloves when loading or unloading workpiece or tools and when removing chips
from the work area to protect your hands from sharp edges and heat generated during
machining.

Safety precautions
4. Safety Related to Operation
1) Close all doors and covers of the CNC unit, operation panel, electrical control panel, and junc-
tion boxes to prevent damage from water, chips, and oil.
2) Check all electrical cables for damage to prevent accidents due to current leakage or electric
shock.
3) Do not handle coolant with bare hands since it is liable to cause irritation. Operators with aller-
gies should take special precautions.
4) Do not operate the machine during violent thunderstorms.
5) Check the safety covers regularly to make sure that they are properly fitted and that they are
not damaged. Repair or replace any damaged covers immediately.
6) Always obtain assistance in handling loads beyond your capacity.
7) Do not operate fork lifts or cranes or carry out slinging work unless you have undergone offi-
cially approved training.
8) When using fork lifts or cranes, make sure that there are no obstruction in the vicinity if these
machines.
9) Always use wire rope or slings of a standard suitable for the load to be supported.
10) Do not adjust the coolant nozzles while the machine is in operation.
11) Do not remove or otherwise interfere with safety devices such as stop dogs, limit switches, or
interlocks in order to increase axis travel.
12) Do not wipe the workpiece or cleae away chips with your hand or with a rag while the tool is
rotating; always stop the machine and use a brush.
13) Do not operate the machine with any of the safety covers removed.
14) Always wear gloves and use a brush to clean chips off the tool tips; never use bare hands.
15) Stop all machine operations before mounting or removing a tool.
16) Check slings, chains, hoists, and other lifting gear for defects before use. Repair or replace
defective fear immediately.

Safety precautions
1) Do not alllow chips to accumulate during heavy-duty since they become hot and may take fire.
2) Check that the spindle belts have the correct tension before operating the machine.
3) Warm up the spindle and all of the axis feed mechanisms before operation.(Operate the
machine in the automatic mode for 10 to 20 minutes at 1/3 to 1/2 maximum spindle speed or
maximum axis feed rate.)
Write the program for the warming-up operation so as execute the function of the full range of
machine components, If operation is to be performed at maximum spindle speed, pay meticu-
lous attention to the warming-up operation.
4) Do not operate the switches on the operation panel while wearing gloves as this could lead to
incorrect operation or other mistake.
5) When one series of operations has been completed, switch off the power switch on the CNC
operation panel, switch off the main power breaker, then switch off the factory power supply.

Safety precautions
5. Safety Related to Gripping Workpiece and Tooling
1) Do not operate a spindle on which accessories are mounted at above the rated speed. If the
chuck or the accessory being used is not a DAEWOO product, check the maximum safe oper-
ating speed with the manufacturer.
1) Always use tools suitable for the work and which conform to the machine specifications.
2) Replace tools quickly, since badly worn tools are a cause if accidents or damage.
3) Before starting the spindle, check that any part which are bolted or clamped to the chuck or the
steady rest are properly secured.
4) If the center hole on large bar workpiece is too small, the workpiece could come off when a
load is applied. Make sure that the hole is big enough and that it has the correct angle.
5) Take care not to catch your fingers in the chuck.
6) Always use the correct lifting gear for heavy chucks, steady rests, and workpieces.
7) Always close the front shield before starting the spindle the cutting operations.
8) The maximum spindle can be limited by inputting a G50 command with the spindle speed.
The G50 command helps to ensure safety in operation.
9) If the spindle must be rotated close to the maximum allowable spindle speed, observe the fol-
lowing points :
- Make sure that the workpiece clamped in the chunk is balanced.
- Apply the allowable maximum amount of pressure to grip the workpiece because centrifugal
force reduces the chuck gripping force.
The maximum allowable spindle speed and application pressure are indicated on the name
plate on the front shield and on the chuck body. The allowable maximum speed and the appli-
cable pressure ensure a chucking force that is more than one-third over the original chunk
gripping force with the standard soft-top jaw set in line with the periphery of the chuck body.
10) If special jaws(larger than standard soft-top jaws) are used, observe the following points :
- Lower the spindle speed because centrifugal force and lower efficiency reduce the chuck
gripping force.
- If the jaw tightening nut (jaw nut) is outside of the periphery of the chuck, only one tightening

Safety precautions
bolt is holding the jaws in place. This is a potentially dangerous condition. Jaw nuts always
be within the periphery of the chuck.
- Machine the jaws to the workpiece shape.
11) Securely tighten the bolts on the chuck body, the jaws, and the block to the specified torque.
1) Make sure that the tool length is such that the tool will not interface with fixtures or other
objects.
2) Perform a test operation after mounting a tool.
3) After machining soft jaws, check that they grip the workpiece correctly and that the chcuk
pressure is correct.
4) Since the tool holders can be mounted from the left or the right, check that the tool holder is
mounted facing the correct direction.
5) For safe chuck work
f : Centrifugal force
F0 F1
1. Set the chuck gripping force by ensuring sufficient factor of
(Cutting force)
safety(2 to 3 or over). Run the spindle within the allowable speed
R0 R1
range set at this time.

µX (F0 — f) x R0 > F1 x R1
N = (1000 x V) / (π x D)
N:
V:
Spindle speed
Cutting speed
2. In constant peripheral speed cutting, calculate the actual machin-
π: Circumference-to-diameter ratio, 3.14
D: Machining diameter
ing speed before designating G50 (max.speed limit function).
Must be
deep
3. Secure the jaw gripping depth as much as possible.
4. Before machining an unbalanced workpiece, carry out balancing
Clamping block Balance weight

of the workpiece weight by gradually changing the spindle speed.
T-slot Jig
5. Never attempt to install jigs using T-nut.

Be sure to fix the jigs with bolts.
Jaw
Cylinder Hollow chuck No chucks prepared by DAEWOO have T-groove.
6. When inserting a bar material into the hollow chuck, ensure that
the bar does not protrude from the rear end of the cylinder.
Chuck
Workpiece
7. Never use double chucking method.

Safety precautions
6. Safety Related to Maintenance
1) Always switch off the main power breaker and lock it before carrying out any maintenance
work. This will eliminate the possibility of the machinery being started inadvertently by some-
one else.
2) After the power has been switched off for a short while, check the voltage with a multimeter or
similar instrument to make sure that there is no residual voltage. Also discharge the capaci-
tors.
1) Maintenance work for electrical parts must be carried out by qualified personnel.
2) Do not remove or modify overtravel limit switches, interlock limit switches, proximity switches,
or other safety devices.
3) Even if the door of the power control panel is open, the power is not cut off. When working
inside the power control cabinet or repairing the machine, always switch off the main breaker
and attach a padlock(provided by customers).
4) When carrying out maintenance in high places, always use a suitable ladder or a service plat-
form and always wear a helmet.
5) Always switch off the main power breaker and lock it before replacing bulbs or other electrical
equipment and use products with the same specifications as the original.
6) Keep your fingers clear of belts and pulleys.
7) Do not start the machine until all of the covers removed for maintenance have been refitted.
8) Wipe up any water or oil spills immediately and keep the maintenance area and the workplace
clean and tidy at all times.
1) Maintenance work should be carried out by qualified personnel in accordance with the instruc-
tions of the person in charge.
2) Keep a stock of replacement parts.
3) Read the manuals thoroughly.
4) Do not use compressed air to clean the machine or to remove chips.

Safety precautions
5) Always use gloves when clearing away chips; never touch chips with bare hands.
6) Use only the specified grades of hydraulic oil, lubricating oil, and grease or their equivalents.
7) When changing a fuse, check that the new fuse has the correct rating.(Using a fuse with too
high a rating could result in damage to the equipment.)
8) Follow the instructions indicated on the instruction plate concerning the brands of oil to be
used, lubrication points, amount to be used, and oil change intervals.
9) Check the results of the maintenance work in the presence of the person in charge.
10) If one of the belts in a set has stretched beyond the prescribed limit, change the entire set.
11) Stop all machine operation before cleaning the machine or the surrounding area.
7. Safety Related to the Workplace
1) Immediately remove all water and oil spills from the floor and dry the floor to prevent acci-
dents.
2) Use strong service platforms only and make sure that nothing can slip off them.
3) Keep combustible material well away from the work area and any other place where there are
hot chips.
4) Always provide sufficient lighting in the work area.
5) Always provide sufficient working space and clear access to the machine and peripheral
equipment and store tools and other potential obstacles in a prescribed place away from the
machine.
6) Never place tools or other potentially dangerous object on top of the headstock, turret, or cov-
ers.
7) Make sure that the nominal cross-sectional area of the power supply cable between the fac-
tory power supply switch and the machine main power breaker is such as to enable a stable
supply for operation at the maximum output.
8) Protect all cables which will run along the floor from being damaged by chips, since this could
cause short-circuiting.

Safety precautions
8. Safety Equipment
1) This machine is provided with various safety devices to protect the operator and the machines.
The safety devices include interlock devices and emergency stop switches as well as doors
and covers.
Never cancel any of the devices.
Failure to observe this instruction could result in serious harm to a human life or body.
9. Safety Related to a Chip Conveyor
1) Before carrying out miantenance work or other jobs on the chip conveyor, make sure that the
power supply is turned off and that the conveyor itself is placed in the completely stopped sta-
tus. Failure to observe this precaution causes serious personal injury.
2) During the operation of the chip conveyor, keep hands away from and do not insert any region
of your body into any sections of the conveyor. Failure to observe this precaution causes seri-
ous bodily injury.
10. Safety Nameplates
1) Safety nameplates are mounted on the machine to secure the operators and the machine from
danger.
Do not remove or these nameplates. If a nameplates is damaged or becomes illegible, please
contact DAEWOO.
11. When door is open

1) You cannot command cycle start.(Except autodoor)
2) You cannot command to search tool.
3) Chip conveyor is stoped and coolant is off.

Safety precautions
12. Warning labels on the machine
Safety-related information, which must be strictly observed by all machine operators is given on
caution labels. These caution labels are attached to the machine.
DANGER
Hazardous voltages in this
enclosure can cause severe
injury or death.
Turn off all electric powers

before servicing.
Servicing by qualified
personnel only.
TURNING CENTER
MODEL : PUMA
SERIAL NO.:
WARNING POWER SOURCE :
RATED CAPACITY
AC200/220V,3 PE,50/60Hz
: kVA
Moving parts can cause LARGEST LOAD : kW
severe injury or death. FULL LOAD CURRENT : A
INTERRUPTION CAPACITY : A
Turn off all electric powers ELECTRIC DRAWING EDITION :
before approaching the MASS : kg
machine inside. MANUFACTURED : 200 . . MADE IN KOREA

Main overcurrent protection provided at machine supply terminals.
Do not operate with guards

removed.
601-3, Namsan-dong, Changwon, Korea
WARNING
L31681134F/ENGLISH
CAUTION
Prior to machine power-on, 1. During automatic operation, do not enter the machine's area of movement.
both the pump and the 2. Before entering the machine's area of movement for cleaning, inspection, or setup
Pump Reservoir change, turn off the main switch and make sure the entire situation is safe.
reservoir of the hydraulic
power unit must be filled up 3. Do not remove protective coveers, interlocks(mechanical or eletrical), or other
with the hydraulic oil through safety devices when using this machine. DAEWOO Heavy Industries Ltd.
oil inlets as indicated in will not be responsible for accidents resulting from unauthorized modification
instruction manual. of the machine's original safety devices.
4. Never touch a rotating or moving spindle, cutting tool, or workpiece with
your hand(or some makeshift device).
CAUTION
1. Operator and maintenance must carefully read, understand, and fully comply with
the instructions and safety precautions given in all machine related manuals
and machine attached warning/instruction plates-before installing, operating,
or performing maintenance on this machine.
2. Only qualified personnel should be allowed to operate this machine.
3. Always wear eye protectors, and safety shoes when working with this machine.
4. Always handle workpieces and cutting tools cafefully.
5. If two or more personnel must work together, use constant communication signals.
6. Unauthorized modification of the original parameters in the machine's
numerical control system is prohibited.
7. Do not remove or deface the warning/instruction stickers attached to this machine.
8. Always lubrication oil comply with lubrication chart.
LUBRICATION CHART
3
4
NO. Location Volme Recommended Oil Lubricating intervals

1 Chuck jaws Suitable amount Mobilux Grease 2 MOBIL Everyday when cleaning
2 Slideway lub. tank 1.5L 0.4GAL ISO VG68 120~150HR
3 Coolant tank 100L 26.4GAL Well-Cut B 30 Houton Replenish when needed
4 Hydraulic unit 50L 13.2GAL ISO VG32 Change every 6 months
DANGER
The elimination or alteration
of safety devices can cause
CAUTION
serious injury or death. 1. Do not rotate chuck and other workholding devices above their maximum speed
Do not eliminate or alter the limits.∗
door safety switch, guard, 2. Make sure rotating components have adequate and balanced gripping forces. ∗
parameter or keep relay. ∗ Refer to workholder manufacturer's specifications.
Hydraulic chuck max. permissible pressure and speed limits ;
WARNING NO.
1
CHUCK
HC10
bar(Kg/cm 2)
27
psi(lb/in 2 )
384
min -1(rpm)
3,000
CYLINDER
Y1530RE
Flying workpiece or jaw 2
could result in death or
serious injury. 3
4
Do not operate unless doors
are closed and interlocks Chuck number for this machine is : NO.
are being worked.
WARNING WARNING
Hot and sharp chips can Decreased gripping force due
cause injury. to an inadequate lubrication
can cause malfunction and/or
Do not touch the chips without serious accident such as
workpiece discharge.
wearing protective gloves.
Once a day, put grease into
all nipples of mater jaws as
Do not touch the chips when indicated in the instruction
the machine is being operated. manual.
CAUTION
To prevent the coolant from
penetrating into the tool
post assembly,all the holder
housing of turret disc must
be plugged by dummy holders

NOISE EMISSION
13. NOISE EMISSION
Values of aerial noise produced by the machine, according to section 1.7.4 (f) of ANNEX 1 of
98/37 EC DIRECTIVE :
Measuring position a b c d
Value of the continuous acoustic pressure level if

over 70 dBA dB(A) 80 80 80 81
(It should be mentioned if below 70 dBA.)
Maximum value of instantaneous acoustic pressure dB(C) <130 <130 <130 <130
dBC
Value of level of emitted acoustic power, if the dB(A)
continuous acoustic pressure level is over 85 dBA
Data collecting system :

The measuring position is as shown on drawing and is taken at 1600mm from the floor and
at 1000m from the machine.
Measuring conditions :
* Spindle rotation at maximum speed.
(not cutting)
d
c
a
b
Noise emission Page 12 PV40INE4

1. Construction of machine
1.1 Concept of axis
Concept of axis Page 1.1–1 PV40INE43

1.2 Overview of machine
ELECTRICAL
CABINET
DOOR INTER
LOCK SWITCH
OPERATOR'S
SAFETY GLASS
CONSOLE
Z-AXIS AC SERVO
MOTOR
TOOL POST
HYDRAULIC
CHUCK
HEAD STOCK
POSITION CODER
BED & BASE
FOOT SWITCH
Overview of machine Page 1.2–1 PV40INE43

1.3 Construction of units

1.3.1 Headstock
The headstock is a Meehanite casting that has
been normalized before machining. The head-
stock and rigid spindle with super precision
SPINDLE
bearing are manufactured in a temperature
controlled environment and assembled and
HEAD TIMING BELT tested in a clean room, virtually eliminating the

STOCK
possibility of thermal growth. The spindle is
V-BELT directly driven by AC spindle motor through the
V-ribved belt. The spindle speed is controlled
V-PULLEY POSITION
CODER at NC by the high resolution magnetic pulse
coder.
1.3.2 Chucking system

A chuck mounted on the spindle front end is
Hydeaulic connected to the rotary hydraulic cylinder
chuck
through draw bar. Advance of cylinder piston
to the chuck side allows chuck jaw to be opend
through wedge mechanism, and the retraction
Draw bar allows it to be closed. The rotary hydraulic cyl-
inder is composed of cylinder part, check valve
and rotary joint part. The check valve, even
Rotary hydraulic when supply oil pressure unusually drops due
cylinder
to pressure source trouble, etc., is fitted to
maintain constant pressure in the cylinder.
Chuck jaws must be formed to the configura-
tion of workpiece to be chucked. The chuck
has restrictrictions to the usage to maintain
safety, high accuracy and long service life, and
cautions for handling. Read the enclosed
Chuck Instruction Manual throughly, and follow
the instructions.
Construction of units Page 1.3–1 PV40INE43

1.3.3 C-axis (main & sub spindle)

The machine has drilling and milling functions in addition to turning functions. Spindle posi-
tion is detected by the Bz sensor.
The spindle can be positioned at any angular position(360°) in units of 0.001° by the sensor.
1.3.4 Carriage(X, Z-axis)

Z-axis ball screw with saddle is connected directly to the AC servo motor. The saddle
moves along on the Z-axis guide way of bed body.
X-axis servo motor is directly connected to the X-axis ball screw too. The tool post moves
along the carriage of X-axis, cross slide on saddle.
1.3.5 Hydraulic power unit

The hydraulic power unit is a main component to operate each units ; Hydraulic chuck &
Cylinder, Tool post, etc.
The hydraulic power unit supplies oil pressure to each unit.
The oil pressure is controlled by the solenoid valves provided for each unit.
1.3.6 Coolant system

The larger coolant tank and pump provide the necessary coolant volume for any cutting
conditions.
Coolant nozzles of turret are provided for each turret station for perfect coolant flow to any
type of tools.
1.3.7 Lubrication system

The reliable way lube system is previded in order to provent the wear of slideway surface
and smooth movement of X, Z-axis.
1.3.8 Tool post

The turret is hydraulically clamped to the turret base except when turning and the turret
position is indexed correctly due to high precision curvic coupling. When indexing, the tur-
ret is unclamped and rotated by the servo motor. When the encoder confirms it’s position,
servo motor stops and turret is clamped.

1.3.9 Operation console

The operation console is located on the right side for easy operation. A convenient tool
measure function automatically calculates and enters the offset amount.
Manual control of turret indexing and spindle are provided for easier set up. Digital alarm
systems provide diagonostic of both machine and control functions.
1.3.10 Electrical cabinet

Electrical cabinet includes all electric components in it ; NC unit, spindle & servo dirve
units, I/O parts, power supply, etc.
1.3.11 Foot switch

The foot operated pedal switch located at the front of the machine is designed for safety
requirements with protection cover. The switch body with a waterproof structure is made of
die-casting aluminum alloy.
Clamp and unclamp of chuck can be performed by the foot pedal switch respectively.
1.3.12 Pressure switch

The pressure switch is installed as a safety devices for hydraulic and pneumatic system. If the
hydraulic pneumatic pressure drops below the specified value, this switch would operate to stop
the machine operation with warning signal to protect personnel and the machine from hazards.
1.3.13 Self-lock cylinder for chuck

In order to eliminate the possibility of accidents to personnel and damage to the machine
due to interruption or loss of hydraulic pressure in the supply line to the cylinder, the self-
lock device for chuck is installed at the hydraulic rotary cylinder.
In the event of hydraulic loss, this interlock device automatically and instantly prevents loss of
the fluid within the cylinder body and maintains the gripping force of the workpiece on the chuck.
1.3.14 Halogen lamp

Installed inside the machine, the halogen lamp is an incandescent lamp of waterproof
structure. Its body is made of aluminium casting coated with a special film. Illuminating over
the inside of the machine, this lamp would assure optimum working condition by eliminating
eyestrain and fatigue.

1.3.15 Door interlock switch(Option)

Operating with a separate actuating key which is fixed on the movable front door, the door
interlock device is installed as one of safety devices at above the front door to ensure oper-
ator’s safety. If an attempt is made to start rotating the spindle, index the turret or feed an
axis while the front door is in the open, this device is automatically actuated to stop the
machine operations and display the alarm message on CRT.
1.3.16 Safety glass

This safety device is installed on splash guard in order to protect operator from hazards
while cutting conditions.
1.3.17 Ball screws

Both X and Z feature large diameter ball screws. These high precision ball screws provide
outstanding repeatability and allow for the fast rapid traverse rates.
each ball screws are supported on each end by thrust angular contact bearings. This dou-
ble pretensioned design eliminates thermal growth.
The high quality ball screws are centrally lubricated and are protected from chips and damage.
1.3.18 Electrical Torque limiter

All the linear motion axes are protected by the electrical torque limiter against the over load
torque which can lead the machine to be the malfunction. The alarm is occured and the
machine is directly stopped when the axis is under overload situation.
vertical Z-axis has braking device. This device would do its action that stops or holds the
linear motion of the carriage, when the current has been switched off in case of "Emer-
gency off" or through power failure.
1.3.19 Oil skimmer(option)

Belt-type oil skimmer which is basically composed of motor, wiper blade assembly, tail pul-
ley and skimmer belt is mounted on the coolant tank for removing lubricating oil from the
surface of the coolant liquid. The belt is operated to pick up lubricating oil from the mixture
in the coolant tank.
Lubricating oil is subsequently scraped off the both side of skimmer belt with wiper blade
and discharged into a collection container.
Oil skimmer by itself can achieve the desired level of coolant purity.

2. Machine specifications
2.1 Specification table
Specifications
Description Unit
PUMA V400 PUMA V400M
Swing over bed mm 610 610
Swing over saddle mm 500 500
Capacity Recom. turning diameter mm 305 305
Max. turning diameter mm 496 420
Max. turning length mm 461 400
X-axis travel mm 268(248+20) 268(210+58)
Travels
Z-axis travel mm 488 488
Spindle speed rpm 3,000 3,000
Spindle nose ASA A2#8 A2#8
Main Spindle Spindle bearing diameter mm 130 130
Spindle through hole diameter mm 90 90
Min. spindle indexing angle(C-axis) deg - 0.001
No. of tool stations st 8(12) 12
OD tool size mm 25 25
Turret Boring bar diameter mm 50 40
Indexing time sec 0.15 0.15
Rotary tool spindle speed rpm - 4,000
Feedrate Rapid traverse(X/Z-axis) m/min 20/20 20/20
Main spindle motor kW αP40 18.5/22 αP40 18.5/22
Rotary tool spindle motor kW - 3.7
Motors
Feed motor(X,Z-axis) kW X:3.0, Z:4.0 X:3.0, Z:4.0
Coolant pump motor kW 0.4 0.4
Power soruce Electric power supply kVA 40.3 44.7
Machine height mm 3,210 3,210
Machine dimension(Length) mm 1,455 1,455

Machine size
(width) mm 2,075 2,075
Machine mass kg 6,000 6,000
Specification table Page 2.1–1 PV40INE43

2.2 Dimensional drawings
1730.5
2075
600
(DOOR OPENED STATE)
(END POSITION OF Z-SLIDING COVER)

488
1190
3210
2798
125
2722
128
1795
1355
1016
5
375 65 360
1475 195 1460
1670 340 425
1865 1492.3 1000
Fig. 2-1 Dimensional drawings
Specification table Page 2.2–1 PV40INE43

3. Handling and installation

This section outlines the procedures for handling and installing your machine when it has to be
moved to a place area due to any change in your plant layout.
Most precautions noted may also apply to the initial installation of an machine at your plant.
3.1 Guide to select a installation site(Environmental requirements)

In order to ensure high machine accuracy and performance, the following points should be
considered with regard to the installation site.
Avoid the following places when choosing the installation site for the machine:
- Places subject to direct sunlight, near heat sources, or subject to excessive temperature
change
- Humid places
- Dusty places
- Places near vibration generating equipment
- Weak soil
(1) Foundation work is advised for sites where the subsoil is soft, to prevent the machine from
tilting or sinking after installation.
For details regarding foundations, refer to Fig. 3-4.
(2) The installation site should be as far as possible from vibration sources such as roads,
stamping/press equipment, or planer machine tools.
If nearby sources of vibration are unavoidable, prepare dampening pits around the foun-
dation to reduce the vibration effects.(during operation:Less than 0.5G)
(3) NC malfunctions could result from the proximity of high-frequency power generators, elec-
tric discharge machines, and electric welding machines, or when power is supplied from
the same distributor panel as these machines.
For wiring details, consult our service engineer dispatched to assist with installation.
(4) The ideal operating environment calls for an ambient temperature of 20°C, with humidity
between 40 and 75%.
Guide to select a installation site Page 3.1–1 PV40INE43

(5) Keeping the ambient temperature at a constant level is an essential factor for accurate
machining.
(6) In order to maintain static machine accuracy within guaranteed values, the machine instal-
lation site should be located so that it is unaffected by air currents within the factory.
Although air-conditioning is not required, the optimal ambient temperature range is 17°C
to 25°C.(63°F to 77°F)
Allowable temperature range during machine operation: 0°C to 40°C(32°F to 104°F)
(7) To maintain static machine accuracy at levels even higher than the standard guaranteed
values :
a) Keep the ambient temperature variance for 24 hours (1 day) within ±2°C(3.6°F).
b) Ambient temperature variances from floor level to a height of about 5 meters(16.4ft)
should be held within 1°C(1.8°F).

3.1.1 Care in handling a precision machine

The tarning center lathe consists essentially of four major components : the machine, the elec-
tric control box, the hydraulic power unit and the CNC unit. This turning center is built in one
unit and it can be easily moved without separating it into consisting units.
Lifting and moving machine :

There are three different methods for moving the entire machine to any desired location; by an
overhead crane, moving by a forklift truck and using lifting hooks supplied together with the
machine and by rolls over which the machine is pushed by manual labor.
(1) Machine lifting
Unit : mm
Frame
Wire rope
(1500x4ea)
Wire rope
(2400x4ea)
2400
1150
Lifting Fixture
705
1575
Fig. 3-1 Machine lifting

6,000kg

Procedure :
a) Move the saddle below ;
b) Disconnect the cables and hoses from the coolant tank and others.
c) Pull out the coolant tank.
d) Fix the lifting hooks at the predetermined positions.
e) Move the machine by the crane as above drawing of cables and the lifting fixture.
(2) Precautions for lifting

: (1) The cables should have a nominal diameter of 20 mm(0.79 in.)or larger.
(2) Change an angle formed by each cable line so that cables will not contact the
finished surfaces of the machine.(The cables may not form an angle larger
than 40 degrees to the perpendicular line.)
(3) Check for balance and be very careful when lifting the machine.
(4) Use extra care to lower the machine gently onto the floor; NEVER APPLY
SHOCKS TO THE MACHINE WHEN PLACING IT ON THE FLOOR.
MACHINE MASS
PUMA V400/400M 6,000kg
(Including the hydraulic power unit, the electrical control box and CNC unit.)
(3) Moving by a forklift truck

: (1) As the machine mass is approximately 6,000kg use the truck with a sufficient
capacity.
(2) Close the front splash guards and all doors.
(3) Put the forks of forklift into lifting caves located in the bottom of machine base.
(4) Lift the load slowly, keeping it as horizontal as possible.
(5) When placing the load on the floor, care to lower it gently so as not to hit the
floor.
(4) Rolling
: Be careful that the machine does not tip over on any side so that the machine
base may not strike the ground.

3.2 Foundation requirements

3.2.1 General precautions for building a new foundation
: If the following conditions are satisfied, no foundation work is required for general
machining activities, and foundation bolts are not necessary.
- The subsoil must be solid.
- The concrete floor thickness must be approximately 200mm.
- There must be no gap between the floor and the subsoil.
For long-maintained accuracy and where sub-soil or ground under the floor is not
strong enough, a new concrete foundation should be set up in accordance with
the Foundation Plan attached to this Manual.(Fig. 3-4)
(1) Foundation requirements vary depending on the characteristics of the sub-soil.
Under any soil conditions, it is important that sub-soil should be well com-
pacted to keep the foundation from unsettling once the machine has been
installed.
(2) Where sub-soil is too soft, it is necessary to drive concrete piles into the sub-
soil.
(3) The Foundation Plan attached to this Manual is prepared for laying a typical
concrete foundation specifically for the machine. The concrete thickness or
depth should be determined in terms of the ground condition in each case.
Foundation requirements Page 3.2–1 PV40INE43

3.3 General procedure for installation

(1) Place leveling plates, 150x80x50 mm(5.91x3.15x1.97 in.) over individual foundation bolt-
holes.
Refer to the Foundation Plan(Fig. 3-4).
(2) Place foundation washers(furnished together with the machine) on the leveling plates and
then place the machine on them.
(3) Pass foundation bolts through the hole in the leveling plate and a center bore through the
built-in leveling bolts assembly.
Secure each foundation bolt carefully, using a washer and a nut on its upper end.
(4) Use wedge pieces, shims, or leveling blocks under the machine base to level the machine
approximately.
(5) Pour mortar into the foundation bolt holes and allow it to set.
(6) After the mixture has become hard enough, remove the shims or leveling blocks from under
the machine base, and level the machine within the specified limits.
3.3.1 Precautions for installation

(1) Keep the underside of the leveling plates free from any oily substance.
(2) With leveling bolts resting on level plates, the bottom surfaces of the machine base casting
should be about 5 to 10 mm(0.20 to 0.40 in.) above concrete floor level.
(3) Fill the foundation bolt holes with mortar so as to reach the underside of the respective lev-
eling plates. Be sure to compact the mortar thoroughly.
NA Nut Base
Leveling bolt
Hex nut
45
60
(0.20 to 0.40 in.)
5 to 10mm
Level plate
Foundation Bolt
100
The part names shown in are not supplied as standard equipment.

Fig. 3-2 Precautions for installation
General procedure for installation Page 3.3–1 PV40INE43

3.4 Leveling the machine

3.4.1 Leveling procedure
(1) Measure the machine level at the chuck the X and Y-axis directions.
’A’
VIEW ’A’
Fig. 3-3 Leveling procedure
(2) Readings are taken on both longitudinal and transverse directions while both leveling bolts
and the foundation bolt nuts are tightened firmly.
Tolerance : 0.02mm per 1000mm(0.00025in./ft)

Accuracy of level : 1grad. = 0.01mm per 1000mm(0.000125 in./ft)
Leveling the machine Page 3.4–1 PV40INE43

Foundation bolt
29
R7
Base
R7
Nut
35
Leveling bolt
180
Hex nut
Foundation plan
140
CONCRETE FOR FOUNDATION
(1985X1750)
45 60
MACHINE BASE
A A
10
220
(1475X1460) Level plate

3.5. Foundation plan
1750
400
1150
1460
360
150
195
150
275
375 100
CENTER OF SPINDLE
45 1385
255 1475 255 SECTION A-A
1985
Page 3.5–1
Fig. 3-4 Foundation plan
Note 1 : This foundation plan is typical.
Mortar
Concrete thickness is determined in accordance
Concrete with sub-soil conditions.
Note 2 : Customers should have on hand the parts for
600
installation of machine.
Rubble 1) Foundation bolt. M16 4pcs.
2) Nut and washer for above. M16 4pcs.each
200
3) Leveling plate 150x80x50t mm 4pcs.

(5.91x3.15x1.97t in.)
Concrete pillor 2000 These parts are available as options.
(for soft subsoil)
Unit : mm(in).
PV40INE43
3.6 Power requirements

Fusing capacity: 125 A min.
POWER SUPPLY
3/N/PE
50/60HZ 200V ~ 220V
OVER 40KVA
L1 L2 L3 N PE
2
22mm
L1 L2 L3 N PE
-XT1
-WCO1 22mm2
-Q1 PE100
125A
1L1 1L2 1L3
Fig. 3-5 Power requirements
Power source : 3-phase 200/220V, 50/60Hz

Main motor 18.5/22kW
Apparent power 50kVA
Power requirements 25.475 kW (PUMA V400) 29.73 kW (PUMA V400M)
3.6.1 Inspection of cable connection

The operator can check correctness of cable connection by reading the pressure gauge
whether it indicates the specified pressure level.
Confirm that the pressure gauge indicates the set pressure [3.92 MPa{40kgf/cm2(568.9 psi}].
When it indicates the specified pressure level, the electrical connection is correct.
Power requirements Page 3.6–1 PV40INE43

3.6.2 Electrical work

: (1) Connect the ground to the external protector connection terminal(PE) located
inside the control box.
(2) Do not connect the power cord and the grounding wire in serial ; if attempted,
it will give adverse affect to other equipment or cause malfunctioning of the
leak breaker, etc.
(3) When a leak breaker is used, select the one meeting the following rating.
- For inverter circuit use
- Sensitive current of 55 mA or more
- Middle-sensitivity high-speed inverter type
(4) If more than one machine tool is connected to the same single power source,
the value of “inductance of power source” for each machine is obtained by
dividing the value in the table by the number of machine tools to be con-
nected.
(5) Wiring inductance in 50m(164.05ft) cable is approximately 12µH when gen-
eral KIV cable is used.
(6) The momentary voltage variation ratio is calculated in the manner as
explained below.
If the “excessive voltage variation ratio” warning function which functions if
power source inductance is higher than the allowable limit does not give
warning signal and if the momentary voltage variation ratio is lower than the
value indicated in the table above, then it is assumed that the power source
inductance is lower than the limit.
(7) For further information on the momentary voltage variation ratio and power
source inductance, please contact your local DAEWOO service representa-
tive.
Power requirements Page 3.6–2 PV40INE43

3.7 Air source requirements

3.7.1 Air source
Pressure : 0.5MPa(5kgf/cm2/71.2PSI) or higher
Discharge : 100Nl/min(3.53ft3/min) (ANR) or larger
(Use a 0.75 kW(1HP) compressor or equivalent.)
3.7.2 Selection of compressor

A. The minimum required discharge pressure of a compressor is 0.5MPa(5kgf/cm2, 71.2PSI).
When selecting a compressor, allow approximately 40% margin.
B. Required discharge volume is 100Nl/min(3.53ft3/min) (ANR). With this volume, an air gun
can be used at the same time as the air blast.
C. There are three compressor operation types; manual unloader, automatic unloader, and
pressure switch types.
The compressor should be a pressure switch type for this machine model.
D. The compressor should be 1 HP(0.75kW) in size. For details, contact a compressor maker.
3.8 Lubricant oil required at installation

The user is responsible for supplying the lubricant oil specified in Section 6 of this manual
(5-1 Lubrication Chart and Lubricating Oil Specification).

(For optional specification systems, contact your DAEWOO representative regarding the
appropriate lubricant oil.)
Air source requirements Page 3.7–1 PV40INE43

4. Machine operation
4.1 Before starting operations
This section deals mainly with the operating procedures of your turning center under manual con-
trol. So the information given here is essential to every operator, whether you are new to a turn-
ing center or an “old professional”.
Follow these three points :
(1) Actually operae the turning center by yourself in reference to this Instruction Manual and the
operating Manual.
(2) Learn the symbols for the numerical control terms.
(3) After you have a general idea of how your turning center operates, read this manual repeat-
edly and also the Programming Manual of NC unit maker.
: Bring the machine to a complete
before operations such as setup or
adjustments inside the chip guard
are carried out.
Also turn off and lock-out the main
switch before you attempt to work
inside the machine at the rear side
of the machine.
4.1.1 NC operation
Before you begin to operate the machine automatically, make it a rule to check the following
points against a process sheet, a program manuscript, or any other chart giving detailed
machining instructions :
(1) Setting of hydraulic power chuck jaws and their gripping pressure
(2) Installation and arrangement of individual cutting tools with respect to their operating
sequence
(3) Setting of tool offsets
Before starting operations Page 4.1–1 PV40INE43

(4) Setting of zero offsets
(5) Setting of feedrate override to 100%
(6) Setting of soft-wired limit positions for each axis
(7) Positioning of the turret to the turret indexing position
(8) Positioning of tailstock or sub-spindle.
All essential information on the setup and check-up procedures is described in the sections
that follow.
Before starting operations Page 4.1–2 PV40INE43

4.2 Warming-up
4.2.1 Purpose of warming-up
When the machine is operated again after standstill for a long time or after various troubles,
the warming-up of the machine is necessary for the stability of lubrication, fluid temperature
and precision and for the machine life. When starting operation in the morning, operator
should perform the machine warming-up.
For the warming-up, auto-operation by means of program is more desirable than manual
operation.
4.2.2 Method of warming-up
1) Period : unloaded operation for more than 15 minutes.(longer in winter)
2) Spindle speed : approximately 500 rpm.
3) Traverse : proper execution of cutting feedrate and rapid traverse in turn.
4) Check the turret indexing function by program.
5) Check the condition of lubrication, hydraulic and coolant during the warming-up.
4.2.3 Tool offset

For appropriate dimension and reference position of each cutting tool, see maintenance sec-
tion of this manual. Install tool and holder on the position other than reference position. It is
very difficult to align cutting points of each tool to specified reference position in order to
attach tool on holder. Tool tip worn during cycle causes larger work diameter than specified.
NC program is executed, assuming that every cutting tool has been correctly installed,
because variable factors such as installation position and reference position shall be cor-
rected. The corrected difference refers to tool offset value. Tool offset shall be made before
first machining, after first cutting, and during cycle, because tool wear amount must be con-
sidered even if installed as specified first.
NC system has tool offset function that corrects tool error automatically when each tool is
indexed into cutting position. Each tool position difference can be offset by manual switch as
in the figure below.
As in the figure, tool tip is placed in the following coordinate point for reference point.
Warming-up Page 4.2–1 PV40INE43

X-axis : +56mm(diameter) Z-axis : –20mm

Offset value of tool position is –56.00mm on Actual tool
position
Actual cutting tool
X-axes and +20.00mm in Z-axes, as in the fig-
ure above. If tool is correctly installed on refer-
ence point, offset value is "0" on both axes.
(ł 56)
28
Reference tool
20
Ref. tool
position
X axis : +56mm on work diameters
Z axis : -20mm
In case of machining without tool offset, tool
will move along dot line as in the figure below.
After tool offset value is input, tool moves

20
along correct program routine indicated full
line. Tool offset is made automatically when
28
tool (T-groove plate) moves by inputting
desired offset value for each cutting tool of
tool(T-groove plate).
Tool line without offset
For measurement and input of tool offset, refer
Tool line offset at X=-56,000 and
to instruction manual of NC unit.
Z=20,000
* Tool offset check

1. After first offset value is input into NC, make first cutting operation and measure machin-
ing area dimension.
2. In case of error, make tool offset again for correction.
3. In case of dimension error due to tool wear, measure actual machining dimension of
work and add the error to offset value.

4.2.4 Setting of start point

1) Start point for initial machining
If the start point of tool post is changed according to work configuration, non-machining
time can be reduced. When work or machining process has been changed, the start point
for machine reference point shall be changed.
(1) Setting of X-axis start point

Setting procedure of start point is as follows.
A) As in the left figure, machine the outside diameter of work at manual cycle using ref-
erence tool.
B) Move tool away from work only at Z-axis direction and measure machining area with
micrometer.
Then assume that measured value is 102.880mm.
C) Turn off machine lock switch and move tool so that the position on CRT display is the
same with start point (Coordinate point G50) of program.
(2) Setting of Z-axis start point

A) Rotating spindle, contact reference tool on the sectional surface of work.
B) Adjust Z-axis coordinate point of CRT to "0" at the area where tool contacts the sec-
tional surface of work.
C) In case the cutting of work face is 2mm and Z of G59 is 200mm, move tool 198mm at
"+Z" direction, referring to the position value of CRT.
The point is start point of Z-axis.

2) Resetting of starting position after power failure.
To prepare for such case that the power source is unexpectedly disconnected during oper-
ation or power failure occurs, it is recommended to check and record the relation between
the zero position and starting position.
When setting of zero position for X and Z axis is completed, follow the procedure described
below.
(1) Return the tool to the zero position for X and Z axis.
(2) Record the numerical values for X and Z axis which are displayed on the position dis-
play unit at that time.
(3) Return the tool to the starting positions for X and Z axis and continue the machining
operation.
(4) Suppose that the power source is disconnected or power failure occurs.
(5) Turn the power source on.
(6) Return the tool to the zero positions of X and Z axis.
(7) Reset the display on the position display unit to 0 for both of X and Z axis.
(8) Move the tool in “–” direction for both of X and Z axis until the values recorded as above
are displayed.
Thus, the tool is returned to the starting position.
When, however, time elapses after power failure, machining dimensions may become
different because of thermal displacement etc. of the machine.
The above procedures can be also adapted to each of axes, X and Z-axis.

4.2.5 Automatic operation

When tool setting, setting of starting position and tape checks are all completed, automatic
operation is to be started by setting the tape or memorizing the tape on the numerical control
unit. Prior to automatic operation, however, be sure to check for the following points.
(1) Check the set value of feedrate.
Override switch. Normally, it is recommended to set it to 100%.
(2) Check the set value of spindle speed override switch. Normally, it is recommended to set
it to 100%.
(3) Check the dry run toggle switch is OFF.
If lamp is ON, turn OFF the toggle switch, and lamp is turned OFF.
(4) Set the machine lock/display lock toggle switch to the neutral position.
(5) Check whether that the optional block skip toggle switch is set to the ON position or OFF
position.
Usually, set this switch to OFF when cutting the first workpiece and keep it ON when cut-
ting the second and subsequent workpieces.
(6) Check whether the optional stop toggle switch is set to the ON or OFF position. Usually,
set this switch to ON when cutting the first workpiece and keep it turn OFF when cutting
the second the subsequent workpieces.

4.3 Safety function
In this machine, there are safety functions to protect the machine or operator from the mistake
of operation.
A. Travel limit
1) Over travel
This region is set up by TRAVEL LIMIT function of NC, and the end point is stroke end of
each axis.
2) Emergency stop
If the axis passes beyond the OT range, the switch for EMERGENCY is operated and the
machine becomes the emergency stop state.
B. Level check of lubrication oil
If the oil is reduced under the set level, the machine becomes the ALARM state.
C. Pressure check
If the pressure of pneumatic, hydraulic and lubrication line drop less than the set value, the
machine become the ALARM state.
D. Setting time check
If the time for each motion exceeds its setting time, the machine becomes the ALARM state.
E. Safety door switch
The front door opening is detected and locked by CE certified safety switch. All automatic
operations are only eflective at the door-closed status.
F. Front door
Front door window has double panel construction, tempered glass and polycarbonate. And
the sheet metal located in the lower of window has double panel construction.
Safety function Page 4.3–1 PV40INE43

4.4 Machine operation

4.4.1 Hydraulic unit
OIL COCK
EYE BOLT AIR BREATHER
OIL LEVER GAGE 2-DARIN PORT
SECTION FILTER
PRESSURE GAGE
PRESS ADJUSTMENT
T PORT
PRESSURE SWITCH OIL TANK
FLOW REGULATOR
TANK DRAIN PORT
MOTOR & PUMP
OIL COOLER
POWER UNIT BASE
Fig. 4-1 Hydraulic unit
: Normally it is not necessary to refill the oil in the pump. But, when replacing the
pump, you must supply the oil at the pump through the oil case inlet port before
operation.
Oil specification ISO VG32
(1) Pressure indication
Pressure setting for the hydraulic unit should be :
Pressure setting 3.92 MPa{40 kgf/cm2 (568.8 psi)}
Machine operation Page 4.4–1 PV40INE43

(2) Adjustment of hydraulic pressure
The following outlines the methods of setting individual functional units for operating pres-
sure. Since the pressure lines for the turret(s) have been adjusted at our factory before
shipment, they will not require readjustments, during the initial installation and subsequent
normal service of the machine.
When readjustment is to be made by your plant personnel, extreme caution must be taken in
accordance with the instructions given here to avert any mechanical trouble in the drive lines.
Any necessary adjustment must be made only by authorized personnel, and under all
operating conditions, careless tampering must be avoided.
a) System pressure adjustment(Adjustment is not usually required.)
Pressure decrease Pressure increase
Fig. 4-2 System pressure adjusting valve
b) Hydraulic pressure for power chuck. Refer to section 4, 4.4.3 - (4).
c) Hydraulic pressure for C-axis spindle clamp
Refer to section 4, 4.4.10 - (2).
Fig. 4-3 Adjustment of hydraulic pressure

(3) Hydraulic oil
Oil Specification ISO VG32

Volume 13 ℓ (2.9gal)
Oil Change Interval Change after first month of operation and every 6
months thereafter.
: Clean the suction strainer, the air breather and the tank when changing the oil.
Check the pressure for respective actuators.
Since use of clogged cartridge filter allows “dirty” oil to be circulated through the
system leading to serious trouble, it is necessary to clean the filters following the
procedure indicated below. ;
a) Oil tank
1) Loosen machine screws(M5 x10L) of
the tank cover.
2) Remove the tank cover upwards.
3) Detach and clean the suction strainer.
4) Discharge the oil of the tank through
the drain port.
5) Clean inside the tank.

6) Reassemble them in the reverse order.

b) Air breather Cap

Filter
Using an air blow device, remove the (10µm)
clogged foreign materials on the filter
and strainer of the air breather.
Strainer
(30µm)
c) Radiator
Remove foreign materials around the
pin of core using air or steam. Air blow

or steam
Be careful of infilteration of foreign mate-
rials inside core.
d) Fan motor
Pin
Clean body of fan and casing
Core
Fan
Fan
: 1. Do not use air blow.
2. After cleaning, recheck the con-
dition of radiator Dust, Oil
Air blow

e) Disassembly of radiator
1. Take out the radiator from rotor pack.
2. Loosen the hex socket head(M5x12L).
3. Loosen machine screws(M4x50L).
4. Detach the fan motor body and finger guide from radiator.
2-M5x12L
Core Arrow mark
Fan motor body
Machine screw
(4-M4x52L)

4.4.2 Spindle speed-torque-power diagram

- PUMA V400/V400M
40
PUMA V400/V400M (FANUC ALPHA P40)
30
MAIN SPINDLE POWER-TORQUE DIAGRAM 22 kW S3 30min.
High-speed winding (Standard) 20
18.5kW CONT.
10
m
N.
0
5 73 m
T= N.
OUTPUT (kW)
4
61
T=
1
20 288 1725 3000
SPINDLE SPEED (rpm)
40
PUMA V400/V400M (FANUC ALPHA P40) (Low-speed winding)
MAIN SPINDLE POWER-TORQUE DIAGRAM (22kW S3 15min.) 22 kW S3 30min.
Low & High speed winding (Option) 20
18.5kW CONT.
(13kW CONT.)
m
10 N.
0 m
=7
3 N.
) T 4
m 61
N. T=
5 1
05
OUTPUT (kW)
=1 m
)
(T N.
2 1
=6
(T
1
20 200 288 1725 3000
SPINDLE SPEED (rpm)
1115 3000
8
PUMA V400M (FANUC ALPHA 2) 5.5kW(15min)
MILLLING SPINDLE POWER-TORQUE DIAGRAM 5
4
3
2
m
1.5kW(Cont.)
N.
N. 47
T=
OUTPUT(kW)
1
.6
33
T=
100 425 1000 4000
TOOL SPEED(rpm)

4.4.3 Hydraulic chuck

(1) Construction
The construction of hydraulic chuck is shown below.
Soft jaw
Plug Chuck(Foot switch)
Jaw nut
Mounting bolt
Chuck adaptor Draw bolt
Draw bar
Fig. 4-4 Construction of hydraulic chuck
(2) Installation of hydraulic chuck

Procedure :
a) Press the power ON button on the operation panel to turn on the machine control circuit,
and depress the CHUCK foot switch pedal. This causes the draw tube in the spindle
bore to move forward
b) Fasten the draw tube in the spindle with the chuck. Use the fixture of draw tube
furnished with the machine.
c) Secure the chuck body onto the spindle end, using mounting bolts.
d) Adjust the draw tube so that the outer ends of the master jaws become flush with the
peripheral surface of the chuck body when the top jaws are in the OPEN condition.
The individual chuck jaws can be moved in the “opening” direction as the draw tube is
turned in the counterclockwise direction. Removal of the hydraulic chuck from the spindle is
the reverse of installation in steps from c) to b).

(3) Chuck grip confirmation

To ensure your safety in using the chuck grip confirmation unit, read the following informa-
tion carefully to understand the function and construction of the unit and observe the
instructions.
Hydraulic chuck
Proximity switch
Draw bar
Dog
bolt
Hydraulic rotary cylinder Proximity switch
Proximity switch plate
Fig. 4-5 chuck cylinder
Position of the dog moving with the hydraulic rotary cylinder piston is detected by the prox-
imity switches to confirm the chuck jaw position.(option)

(4) Adjustment of oil pressure for hydraulic chuck

The gripping pressure of the chuck jaws is dependent upon the working pressure of
hydraulic fluid which is determined by the setting of the chuck pressure adjusting valve
installed at the front of the machine.
A clockwise turn of the valve knob
increases the working oil pressure directed
into the chuck cylinder and counterclock- Pressure
decrease
wise turn decreases it. Pressure
increase
The allowable maximum pressure is indi-
cated in the table below. Adjust the pres-
sure meeting the types of chuck.
(5) Maximum permissible spindle speeds and
oil pressure setting
Maximum permissible spindle speed varies
depending on types of chuck and cylinder
to be used.
See the table below :
No. Chuck Types and spec Max setting pressure Max spindle speed Type of Cylinder
1 Solid type HC-12 2.65{27(383.9)} 3000 Y1530RE
MPa{kgf/cm2(psi)} Min-1{rpm}
: This table indicates the permissible spindle speed for standard chuck. If a chuck
other than those indicated above is used, follow the instruction on the name plate
at the front cover of the machine.
: DANGER BY DISCHARGE OF CHUCK OR WORKPIECE.
Do not exceed recommanded speed of chuck related with max. permissible input
force. Never start the machine with door open.
Do not exceed max. permissible input force reduce the hydraulic pressure by
more than 50%.
(6) How to set maximum spindle speed
The maximum spindle speed, which is limited due to chuck specifications, influence of

centrifugal force on chuck gripping force, imbalance of the workpiece, etc. can be set by
program.
Format :
G50 SOOOO··············· To be specified in a block without other command
Specify the required maximum spindle speed.
Programmed maximum spindle speed is effective until another spindle speed is designated.
(7) Adjusting proximity switch longitudinal position(option)

a) For solid cylinder
Loosen the screws clamping the two proximity switch plates to slide them with the prox-
imity switch to determine the position. After determining the position, tighten the proxim-
ity switch plate clamp screws.
Proximity switch plate
Proximity switch
Proximity switch
bolt Dog
Fig. 4-6 Adjusting proximity switch position(for solid cylinder)

: The proximity switch position is adjusted to provide the required clearance to the
dog(1 mm(0.04 in.)) before shipment. Thus, adjustment is not required usually.
Clearance
[1mm(0.04 in)]
PX1
Dog
Proximity switch
Clearance
[1mm(0.04 in)]
PX2
Dog
Proximity switch
Fig. 4-7 Clearance between proximity switch and dog

(8) Setting proximity switches

a) OD chucking
Set the proximity switches at the positions as indicated below :
· Proximity switch(PX1) : Piston advance end
· Proximity switch(PX1) OFF : Chuck gripping position
· Proximity switch(PX2) : Over clamp/alarm
PX1
PX2
Chuck side
PX1
Piston advance end(jaw close end)
Chuck gripping position

PX2
Piston retract end(jaw open end)
Fig. 4-8 Setting proximity switches(OD chucking)

b) ID chucking
Set the proximity switches at the positions as indicated below :
· Proximity switch(PX1) : Over clamp/alarm
· Proximity switch(PX2) OFF : Chuck gripping position
· Proximity switch(PX2) : Piston retract end
PX1
Piston advance end(jaw close end)
Chuck gripping position

PX2
Piston retract end(jaw open end)
Fig. 4-9 Setting proximity switches(ID chucking)
Note : According to the OD/ID chucking, the proximity switch to be set at the chuck grip-
ping position differs.
: Always actually clamp the workpiece to set the proximity switch at the chuck grip-
ping position.

(9) Confirmation signals

a) Signal input status display
Whether or not the proximity switches are set correctly and corresponding signals are
input can be checked by the check data display CRT screen.
For the procedure to display the CHECK DATA screen, refer to Operation Manual of NC
unit.
* For example : FANUC 18iT A
B
D
C
E
E
Fig. 4-10 CHECK DATA screen

b) Checking input signals

When the proximity switches are set in the correct position, the signals change as indi-
cated below according to the chuck status.
F 18iT
Chuck inward X1007.2 0

(ID chucking) X1007.3 1
Chuck outward X1007.2 1

(OD chucking) X1007.3 0
c) Operation completion confirmation delay timer

There may be cases in which the chuck open/close is not completed even if the corre-
sponding signal is input. For such cases, timer function can be used to delay the confir-
mation of the chuck operation after the input of the signal.
The timer is set using the following parameters.
F 18iT
Chuck clamp/unclamp *ref 1
*ref 1 T06(No.4):3000
delay timer(STD : 3sec)
ID K8 #6 “0”
Chucking direction select
OD K8 #6 “1”
Proximity switch select K7 #6 “1”

Ref. 1
Chucking clamp/unclamp delay timer, 3 sec means that the next step can be executed after 3
second of the chuck clamp or unclamp command. This setting value is decided under the con-
ditions of 20 bar chucking pressure and spare thime for safety. For increasing the productivity,
it is possible to change the delay timer if the workpiece diameter is uniform and the chucking
stroke is short. You must measure the chuck clamp/unclamp time and set the chuck clamp/
unclamp delay timer adding minimum 50% spare time when change the chuck clamp/
unclamp delay timer.
Especially, in the case of using the chuck at a pressure lower than 20 bar, you must measure
the chuck clamp/unclamp time and set the chuck clamp/unclamp delay timer considering min-
imum 50% spare time.
Flying workpiece under the running condition of incomplete chucking can cause series injury
or death if the chuck clamp/unclamp delay timer is short.

(10) Hydraulic chuck clamping force characteristics diagram
Work piece
a b a=b
H
Chuck
G: Mass center of top jow

G’
m: Mass of top jow(one jaw)

r r : Distance up to chuck center
H : Gripping force center height
G
Chuck
Fig. 4-11 Special jaw
N-12(KITAIGAWA) HC-12(SAMCHULLY)
156 156
140 4.1K 140 4.1K
120 N 120 N
34.2 34.2
100 KN 100 KN
26.3 26.3
80 KN 80 KN
18.4 18.4
60 KN 60 KN
40 10.5KN 40 10.5KN
20 20
0 500 1000 1500 2000 2500 3000 0 500 1000 1500 2000 2500 3000

(11) Standard soft jaws
PITCH 1.5 60¢“

Serration, P=1.5
0.17
50
39 30
1 H7 +0.043
0
6
50
2- 15-DRILL, THRU
23 C’BORE, DP30
(opposite side) 108
109

: (12) General precaution for using power chucks

In order to insure maximum safety in operation, the following points call for your spe-
cial notice :
a) Select the right chuck that matches the machine's capacity.
b) Workpieces should be clamped in the chuck without imbalance. Selection of cutting
conditions must be made referring to (10) “Power Chuck Clamping Force Charac-
teristics Diagram” since chuck jaw gripping force varies depending on the spindle
speed.
The maximum spindle speed and maximum allowable pressure limit(maximum set-
ting) are indicated on the instruction plate attached to the front of the left cover.
The maximum spindle speed refers to the speed at which the chuck can be turned,
with its gripping force maintained more than one-third of its rating, while the outer
ends of the individual top jaws are positioned evenly with the peripheral surface of
the body.
c) When soft top jaws larger than standard ones provided with the machine are pre-
pared by the customer and used with the chuck, keep in mind that developing cen-
trifugal force and decreasing efficiency may reduce the actual gripping force. Be
sure to reduce the spindle speed accordingly.
d) Where jaw nuts shown below go beyond the peripheral surface of the body, only
one bolt secures the corresponding jaw and a very dangerous condition is created.
Always locate the jaw nuts within the periphery of the body as shown below. It is a
good and safe practice to use soft top jaws that are made to fit the actual work con-
figuration.
Hard jaw
Jaw nut
Hard jaw
Jaw nut
Incorret Corret
e) Before starting spindle rotation, be sure to close the front door.

(13) Change of chuck gripping direction-ID/OD gripping

Gripping direction of the power chuck-ID gripping and OD gripping-can be changed by
the parameter.
The change of gripping direction may be made only while the spindle stops.
(14) Greasing
The chuck has grease nipples either on
the chuck front face or on its periphery.
Apply grease to the nipples every day.
Since chips and foreign matter accumu-
late on the jaw moving surfaces on the
chuck, clean them every day and lubricate
them with the mobilux grease 2.
WARNING
Decreased gripping force due
to an inadequate lubrication
can cause malfunction and/or
serious accident such as
workpiece discharge.
Once a day, put grease into
all nipples of mater jaws as
indicated in the instruction
manual.

4.4.4 Cutting soft top jaws of power chuck

There are three different methods applied in cutting soft top jaws of chuck jaws for chucking a
particular lot of parts.
- by pulse feed handwheel
- by auto or memory
- by manual data input(MDI)
They are all basically the same operations, and it is advisable to use the tape or the manual
data input when a good finish on the chucking surfaces of the jaws is essential.
Now let's explain the steps necessary to produce the top jaws for chucking the diameter of
70mm(2.75 in.) with a depth of 15mm(0.6 in.) by use of the manual data input.
(0.59)
15
B
A
'“70(2.76)
'“50(1.97)
Ring
Fig. 4-12 Cutting soft top jaws
(1) Procedure
a) Grip a ring of proper diameter in the chuck.
ø50 mm(2 in.) ring for instance
b) Locate the tool tip point at point A and set the zero offset value so that the actual position
of X-axis is equivalent to the ring diameter ; 50 mm(2 in.) in this case.
Actual position : X=50.000 mm
(Z=0.6000 in.)

c) Locate the tool tip point at point B and set the zero offset value so that the actual position
of Z-axis is equivalent to the required chucking depth of length ; 15 mm(0.6 in.) in this
case.
Actual position : X=15.000 mm
(Z=0.6000 in.)
d) Proceed with cutting by entering the following commands block by block.
In the example, the depth of cut is 5 mm(0.2 in.) and the feedrate is 0.1 mm/rev(0.004
ipr). The spindle speed must be selected to suit the operation.
G50 SOOO
G00 X 60 Z 18 SOOO (M41) M03
G01 Z 0.1 F 0.1
G00 X 58 Z 18
X 69.6
G01 Z 0.1
G00 X 67 Z 18
X 70
G01 Z0
X 48
G00 Z500 M05

4.4.5 C-axis
(1) Selection of C-axis
Selection of C-axis can be accomplished by means of a manual push button switch or M
code. The main spindle as C-axis consists of 3-axis drive unit, the high resolution magnetic
pulse code, preamplifier and disc clamping device with brake.
* When the main spindle with C-axis unit is selected as 2-axis mode, the disc brake is
released and the main spindle is driven by the spindle motor.
* When the main spindle is selected as C-axis, the main spindle as C-axis is controlled by
3-axis drive unit. Appropriate brake is to be applied by C-axis clamping device to prevent
spindle backlash.
(2) Clamp and unclamp of spindle
1) Clamping(High)
The high clamping pressure of spindle is allowed beyond 3.92MPa{40kgf/cm2(568.9psi)} , Since
the perssure have been set at our factory before shipment, they will not require readjustments.
Pressure setting 3.92 Mpa{40 kgf/cm2 (568.9 psi)}

2) Clamping(Low)
The low clamping pressure of spindle is adjusted before shipment. So readjustment is
not usually required.
Pressure setting 0.49 MPa{5 kgf/cm2 (71.1 psi)}
If the pressure is higher than setting value. A stick-slip may occur.
Pressure Pressure
decrease increase
3) Unclamping
When selecting the spindle unclamp M code at MDI or Auto mode, the clamping pres-
sure of spindle is intercepted, the disc brake is released HIGH lamp and LOW lamp is
extinguished and spindle is unclamped.
4.4.6 Cautions on operating the turret

: When indexing the turret, retract it to a position where rotating of the turret does
not cause interference between the tools in the turret and the workpiece or
chuck.
For 0.5 seconds after the completion of turret indexing, the turret may not be
clamped securely. Therefore, do not start machining within this period.

4.4.7 After completion of a day's operation

(1) Press the power OFF button on the MDI/CRT panel.
OFF
(2) Turn the main switch on the control box to OFF.

(3) Clean the machine and keep the surrounding area neat and in order.

5. Inspection and maintenance

This section deals with the maintenance requirements which must be met by every user in order
to insure excellent, trouble-free performance and prolonged life.
It also outlines some basic steps to pinpoint possible causes of trouble, together with trouble-
shooting hints, if your machine is found out of order in any way, or in need of readjustment or
repair.
To insure a maximum productive time with a minimum of downtime, the machine must be period-
ically inspected and carefully serviced.
A periodical inspection schedule is presented below. In addition to the regular maintenance items
given here. There are some maintenance items which should be checked according to the actual
condition of the machine, as described in this section.
<Periodical Inspection Schedule>
Frequency
No. Inspection Inspection item Number of months
Daily Weekly
1 6 12
Arranging the machine periphery in oder, cleaning
1 General O
the machine and its periphery(especially, the floor)
-Checking the chuck unit and its periphery to scan O
for chips
Headstock -Checking for secure mounting of the top jaws O
2
-Checking for smooth clamping/unclamping of chuck O
-Greasing the chuck jaw O
-Removing any chips from the coolant collector O
-Checking for secure mounting of the cutting tools O
and the holder
3 Tool post
-Checking the turrets and the cutting tools to scan O
for chips
-Checking the wipers for abnormalities such as O
Guideway damage
4
and wipers -Checking for unusual operating sounds during tail- O
stock or sub-spindle movement
Inspection and maintenance Page 5.0–1 PV40INE43

Frequency
No. Inspection Inspection item Number of months
Daily Weekly
1 6 12
-Checking the oil levels, and if necessary, refilling O
Lubrication
5 -Checking the oiling filters O
unit
-Checking for oil leakage and for damaged piping O
-Checking for appropriate pressure O
-Checking the oil levels, and if necessary, refilling O
Hydraulic
6 -Checking the strainers O
power unit
-Replacing the hydraulic oil O
-Checking for oil leakage and for damaged piping O
-Checking the coolant levels, and if necessary, refill- O
ing
-Checking the degree of dirtiness of the filters and O
7 Coolant unit
cleaning
-Checking the degree of dirtiness of the coolant and O
if necessary, replacing
8 Air unit -Checking the element and if necessary, replacing O
-Checking the nameplates for abnormalities such as O
Name damage or missing
9
plates -Please order our nearest service center, if neces- O
sary
-Cleaning the sensor section and removing any O
Q-setter chips
10
(option) -Checking for sounds of reaction during sensor con- O
tact
Electrical -Checking if the door is fully closed O
11 control -Checking the electrical components for dirt and dis- O
cabinet coloration and checking for loose terminal screws
-Checking for loose connector/terminals between O
12 Connectors
units
13 Foundation -Checking and adjusting the bed level using a level O
Inspection and maintenance Page 5.0–2 PV40INE43

5.1 Lubrication
: The machine should be completely and correctly lubricated in strict adherence to
the directions in the Lubrication Chart in the following page.
(1) Always use the specified lubricating oil.

a) If the oil other than specified is used, the lubrication unit might fail to operate normally.
b) Lubricating oil used in common with coolant or lubricating oil used in common with hydrau-
lic oil might cause corrosion of lubrication unit or mixing of oils to result in lubrication failure,
which, in turn, leads to damages on the slideway surfaces.
(2) For coolant, use the specified coolant.

a) Coolant usually contains chemical additives such as activator, If improper coolant is used,
lubricating oil will be affected by chemicals and therefore, use the specified coolant so far
as possible.
b) If coolant which is not our recommendation is to be used, check to be sure that it will not
cause any following problems.
Mixing with lubricating oil, possible parting, peel of paint, rusting, and swelling of packings.
If a problem is found during the use of the coolant, avoid the use of such coolant.
(3) Amount of lubricating oil and its discharge condition must be checked everyday.
a) Whether or not lubricating oil is properly supplied can be checked by checking oil level in
the tank. For normal oil consumption amount, refer to 5-1 in this section.
b) Prior to shipment of the machine from our plant, the oil and the coolant tanks are flushed
out and must therefore be refilled during the initial installation of the machine.
Lubrication Page 5.1–1 PV40INE43

Lubrication chart
1 4
2 3
Fig. 5-1 Lubrication chart
No Oiling points Quantity Recommended oil Lubricating intervals

Suitable
1 Chuck jaws Mobilux Grease 2 MOBIL Every when cleaning
amount
Slideway lubation 1.5 liter
2 ISO VG68 70~80 hours
tank (0.4 gal)
120 liter
3 Coolant tank Well-Cut B 30 Houton Replenish when needed
(31.7 gal)
10 liter
4 Hydraulic unit ISO VG32 Change every 6 months
(2.7 gal)
10.5 liter
5 Pneumatic oiler ISO VG68 Replenish when needed
(0.14 gal)
6 Gears for milling tool Suitable amount Mobilux Grease 2 MOBIL Every 6 months
*1 Refer to Table 5-1 on next page for similar oil of other makers.

Table 5-1 Lubricating oil specifications
Suppliers
MOBIL TOTAL CALTEX ESSO Oiling points
Type of lubrication
Hyd. power
ISO VG 32 DTE 24 DROSERA ZS32 RANDO HD-32 NUTOH-32
unit
ISO VG 68 Vactra #2 DROSERAMS 68 Way lubricant 68 FIBIS K-53 Guide ways
Lithium soap type Multifax 2 or Power chuck
Mobilux grease 2
Multi-purpose grease Multifax Ep 2 jaws & Turret
Note 1 : As for service point or amount of lubricating oil of the machine, refer to the Instruction
Manual of respective machine models.
Note 2 : Lubricating oil used in common with coolant or lubricating oil used in common with
hydraulic oil might cause corrosion of lubrication unit or turbidness of oils to result in
lubrication failure, which, in turn, leads to damages on the slideway surface or ball
screw. (We are not responsible for the troubles caused by using the lubricating oil which
is not our recommendation.)
Note 3 : As for oil replenishment for the optional accessories such as special chucks or chip con-
veyor, refer to the Special Instruction Manual supplied with individual accessories.
Note 4 : When slideway lubricating oil mixed with coolant and some trouble appears, contact
your local DAEWOO representatives. They have optional accessories such as oil skim-
mer.

5.1.1 Spindle lubrication system

All the spindle bearings are lubricated by packed high quality grease, requiring no further
greasing.
5.1.2 Slideway lubrication system

(1) The pump starts running and delivers the oil quantities premetered in the piston distributor
to the lubrication points of the machine. As soon as the operating pressure is reached in
the centralized lubrication system(12kg/cm2), pressure switch is on for 15 seconds as set
in the times. Afterwards, the pump motor will be switched off, the interval time preselected
in the time will run down.
The lubrication cycle is completed.
(2) After the pressure in the system has been released, the metering chambers of the piston
distributors are refilled.
Further lubrication cycles will be repeated in accordance with the interval time set.(10 min-
utes)
(3) Intermediate lubrication is possible by pressing push button.
(4) In case of critically low oil level, the alarm lamp will light via the connected float switch.

Oil specification ISO VG 68

Amount 1.5 liter(0.4 gal)
Oil Change Interval Replenish as required.
Low lubrication level alarm detected by the level switch occurs in
approx. 70~80 hour operation. Check oil level every day and replen-
ish lubricating oil before the alarm occurs.
: Check oil level before starting day's operation.

To forcibly deliver lubricating oil, follow the steps below :
(1) Press the alarm RESET button on the operation panel.
(2) Press the PUSH button.
This delivers lubricating oil.
Repeat the above indicated steps several times.
The centralized lubricating oil tank is accessible by opening the oil filter port
cover. The lubricating oil is fed to the saddle slideway, the cross-slide slide-
way, the X- and Z-axis drive ball screws.
Oil
pressure gage
Push
button Oil strainer
Reservoir
Float
switch
Pressure
switch
Fig. 5-2 Lubrication pump unit

5.2 Cleaning coolant tank
Oil level gauge
Drain plug
Strainer
Chip box
Clean box
Fig. 5-3 Cleaning coolant tank
(1) Procedure to clean the coolant tank

a) The coolant tank should be cleaned out periodically.
b) Flush out the tank completely to remove the coolant remaining in the tank through the drain
hole provided.
c) Remove chips in the coolant tank and chip boxes.
d) Clean inside the coolant tank.
e) Assemble the drain plug, the chip box and clean boxes.
f) Refill coolant inside the coolant tank with checking the oil level gauge not to leak.
Cleaning coolant tank Page 5.2-1 PV40INE43

5.3 Tensioning belts

: As a safety precaution, always turn OFF the machine when adjusting the belt ten-
sion or when replacing the belt.
5.3.1 Adjusting V-belt between the spindle and main motor

When the V-belts are worn or loosen after using for a long period, it is advisable to tension
them or replace them with new ones.
Tensioning the V-belts must be performed 3 months after initial installation, there after every 6
months.
Spindle pully
V-belt
Clamping bolt(1)
F
Adjusting bolt(2)
Spindle motor
Motor pully
Fig. 5-4 V-blet adjusting of spindle motor
Tensioning belts Page 5.3–1 PV40INE43

Adjust the belt tension as below procedure ;

(1) Loosen slightly the clamping bolts (1) of motor bracket.
(2) Loosen the adjusting bolt (2).
(3) Secure the adjusting bolt (2).
(4) Check the amount of deflection value (δ) of V-belt with tension (F1) as above table.
Total deflection force (kgf) Amount of deflection

Type of belt Type and maker
Min Re-tension Max(new) δ mm(in.)
V-ribbed belt 5V-1000-9PSC/MITSUBOSHI 21.12 26.03 30.93 14.80
(5) Secure bolts (1).

5.3.2 Adjusting timing belt for spindle motor of rotary tool and servo turret
When the timing belt is worn or loosen after using for a long period, it is advisable to tension
them or replace them with new ones.
Tensioning the timing belt must be performed 3 months after initial installation, thereafter
every 6 months.
Fig. 5-5 Timing blet adjusting for the spindle motor of rotary tool
Adjust the belt tension as below procedure ;

(1) Loosen the nut (1) with the adjusting screw (2).
(2) Secure the adjusting screw (2) slowly.
(3) Check the amount of deflection value (d) of timing belt with tension (F1) as above table.
(4) After getting the set value, secure the nut (1).
Type Type and No. of Width of Total deflection of Amount of deflection

of belt maker belt belt force F1 {kgf(lbf)} d mm(in.)
Timing belt
600-5GT-30/Unitta 1 25.0 1.3 2.24
(T/P servo drive)
Timing belt
615-5GT-25/Unitta 1 25.0 1.3 2.42
(Rotary tool)

5.4 Troubleshooting for simple mechanical trouble

5.4.1 Trouble with headstock
(1) No spindle rotation
Is the power chuck closed?
(2) No chuck jaw movement
Is the oil pressure set to the required level?
NO
YES Adjust the chuck pressure.
(See Section 4, 4.4.3 - (4).)
Is the draw tube connected properly between the hydraulic rotary cylinder
and the hydraulic chuck?
NO
YES Adjust the draw tube setting.
(See Section 4, 4.4.3 - (2 ).)
Do the master jaws move normally?
NO
Remove chips and apply machine oil.
Troubleshooting for simple mechanical trouble Page 5.4–1 PV40INE43

5.4.2 Trouble with turret

(1) No turret indexing
Is the turret located at the turret indexing position?
NO
YES Locate the turret to the turret indexing position manually.
Have chips accumulated under the turret?
YES
NO Remove chips.
Is the turret unclamped?
NO
Check in the operation panel.
(2) Weak turret clamping pressure
Is the oil pressure set to the required level?
NO
Adjust the system pressure.
(See Section 4, 4.4.1 - (2).)

(3) After collision of turret

a) Checking after turret collision
Misalignment of the turret or the headstock might be caused when the turret is struck
against the workpiece or the chuck in rapid feed due to operation error or programming
error, or when an abnormally heavy load is imposed on the turret due to axis feed with
damaged inserts. The procedure to check the alignment of the turret and the headstock
is explained below.
1) Checking turret alignment
Checking turret inclination Checking turret offset
Micro
indicator
inside
base
Bar
(2.36) (0.76)
Micro
20
indicator
60
Bar
ON
OFF
Dial Offset
indicator
X-axis
direction
Fig. 5-6 Fig. 5-7
Set the dial indicator as illustrat ed in Fig. Mount the inside base holder on the tur-
5-6 and feed the X-axis with the pulse ret as illustrated in Fig. 5-7. Check the
handle to check the inclination of the center position of the hole on the inside
toolholder mounting surface on the tur- base holder using the micro indicatior set
ret. If the inclination is larger than 0.005 in the chuck to check the offset or mis-
mm(0.0002 in.) it must be corrected. The alignment of the hole on the inside base
procedure to make corrections is holder from the spindle center. Alignment
explained in Item b). of the spindle center and the inside base
holder hole center in the X-axis direction
must be adjusted by the micro indicator.
If offset amount is larger than 0.05
mm(0.002 in.), make corrections as
explained in Item c).

2) Accuracy inspection of headstock

Finish a test piece indicated in Fig. 5-8 below in the MDI mode operation to check the
cylindricity. If the measured cylindricity is larger than 0.018 mm/225 mm(0.0007 in./8.86
in.), adjustment of the headstock is necessary. This adjustment should be carried out in
combination with the adjustment for offset in Fig. 5-7.
70(2.76)
to 100(3.94)
150 mm(5.91in)
Cutting conditions
Material : mild steel(S45C, JIS) or cast iron (FC, JIS)
Depth or cut : Ø0.2 mm(Ø0.008 in.)
Feedrate : 0.1mm/rev(0.004 ipr)
Fig. 5-8 Accuracy inspection of headstock

3) Headstock accuracy
Accuracy adjustment should be carried out in the following order.
Correcting inclination of turret
Correcting headstock accuracy
Correcting turret offset
b) Correcting turret inclination(Parallelism of Z-axis turret surface)

If the turret inclination amount measured as per Fig. 5-9 is larger than 0.005
mm(0.0002 in.), adjustment should be made in the manner indicated below(Refer to
Fig. 5-9.) :
1) Loosen light the nuts (4) & (5) on adjusting block.

2) After loosening the turret clamping screws (3) satisfactorily, check turret surface
inclination as in Fig. 5-6 adjusting the parallelism of the turret surface with two set
screw (2), (3) in A or B direction.
3) When the inclination of the turret is adjusted within the allowable range, secure the
turret clamping screw (3) and nut (4) & (5).
Set screw(1) Set screw(2) Set screw(2) Set screw(1)

Nut(5) Nut(5)
Nut(4) Nut(4)
Clamping screw(3)
A B
Fig. 5-9 Correcting turret inclination
c) Correcting turret offset

If the offset measuerd as per Fig. 5-7 is larger than 0.05mm(0.002 in.), make corrections
following the steps below :
1) Press the power [OFF] button to turn off the power supply to the NC and then, turn off
the main switch.
2) After removing the bolt(3), loosen the bolt(4).
3) Using the fixture(5), remove the taper pin(7).
4) Adjust turret offset within 0.05mm, refer to Fig. 5-10 while tapping the turret with a soft-
head hammer.
5) Reream the taper pin hole with a taper reamer(Ø8) and drive the taper pin.

6) After the two pins have been driven into the turrer head, secure the turret head clamping
screws tight.
7) If steps 1) through 7) cannot eliminate offset, proceed to the steps below.
8) After removing the bolt(1), detach the location disc(2).
9) After detaching the side cover(8) and coolant hose(9), remove the set screw(10).
10) After removing the bolt(11), detach the distributor(13) and shaft(23).
11) After removing the bolt(4), detach the turret(18) with a jib crane.
12) After removing the bolt(15), detach the flange clamp(16) and the coupling1(17).
13) Detach the coupling2(19).
14) Loosen the bolt(20) and finish the taper pin holes(22) with a taper reamer and drive the
taper pins(TPB10x32) into the taper pin holes.
15) Reassemble the tool post in reverse order of steps 1) to 14).
16) Be sure the all O-rings have been placed in position.
17) Turn on the power.
18) In the manual mode, check turret indexing operations by pressing the TOOL INDEX key.
19) Measure the offset amount again as illustrated in Fig. 5-7.
(21)(22) Pin
(19) Coupling(2)
(17) Coupling(1)
(4) Bolt
(3) Plug
(16) Flange
clamp
(15) Bolt
(1) Bolt
(11) Bolt (10) Set screw
(14) Bolt
(2) Disc location (8) Side cover
(13) Distributor
(12) Tap (9) Coolant hose
(23) Shaft
(5) Fixture
(6) Set screw
(7) Taper pin
(20) Bolt
(18) Turret
Fig. 5-10 Correcting turret offset

5.4.3 Others
(1) No lubricating oil flow to X-/Z-axis slideways and tool post.
Lubricating oil is not consumed in one to two days.
YES
Lubrication pump is faulty.
YES
NO Adjust centralized lubrication unit.
See 5.1.2 in this section.
The distributing valve is not moving.
YES
Replace.
(2) No coolant supply
The coolant pump motor is not rotating.
YES
NO Check if the overload relay
in the control box is tripped.
The strainer is clogged.
YES
NO Clean the strainer.
See 5.2
The coolant in the coolant tank is filled to the specified level.
NO
Replenish the coolant.

(3) No pressure building-up of hydraulic power unit
The hydraulic power unit pump motor is operating.
NO
YES Check if the overload relay
is tripped.
The filter is clogged.
YES
NO Clean the filter.
See Section 4, 4.1
The hydraulic oil in the tank is filled to the specified level.
NO
Replenish the hydraulic oil.

6 . Technical data
6. Technical data
6.1 Tooling system
6.1.1 PUMA V400
Unit : mm
Boring Bar Sleeves

12-H50 25-H50
16-H50 32-H50
Boring Bar 20-H50 40-H50 O.D Tool Clamper
Extended O.D Tool

50 Boring Bar I.D Tool Holder O.D Tool Holder 25
(H50)
12st Turret
(STANDARD)
Drill Sockets
MT#1
MT#2
MT#3
Drill MT#4 Face Tool Holder
U-Drill Sleeves
20
U-Drill 25
32
40 U-Drill Cap 8st Turret
(OPTION)
Fig. 6-1. Tooling system
Tooling system Page 6.1–1 PV40INE43

Tooling system
Boring Bar Boring Bar Sleeves
10-H40 20-H40
12-H40 25-H40
16-H40 32-H40 I.D Tool Holder
(H40)
6.1.2 PUMA V400M
Straight Milling Head Collet Adapter

40
Drill Drill Socket

MT#1-H40
MT#2-H40
MT#3-H40
Angular Milling Head Milling Arbor Adapter Collet(ER32)
3,4,5,6,7,8,9,10
11,12,13,14,15,16
17,18,19,20
U-Drill Sleeves U-Drill Cap
Page 6.1–2
U-Drill 20-H40
25-H40
32-H40 Dummy Plug Weldon Adapter(ID20)
Fig. 6-2. Tooling system

40 12st Turret
(BMT 65P)
O.D Tool
Holder
Face Tool Holder
6 . Technical data
O.D Tool
25 O.D Tool
25
PV40INE43
6 . Technical data
6.2 Tool interference diagram

(1) PUMA V400 12 Stations (Std.)
Fig. 6-3 Tool interference diagram
(2) PUMA V400 8 Stations (Opt.)
Tool interference diagram Page 6.2–1 PV40INE43

6 . Technical data
(3) PUMA V400M
Tool interference diagram Page 6.2–2 PV40INE43

6 . Technical data
6.3 Working range diagram

6.3.1 PUMA V400
(1) OD tool holder range
Unit : mm
7
30
40
20 228 20
268
488
623
HC-12 128
106
(2) Extended OD tool holder range
Unit : mm
7
40 70
110
90
268
488
623
HC-12
128
106
Working range diagram Page 6.3–1 PV40INE43

6 . Technical data
(3) ID tool holder range
Unit : mm
22
20
268 72
488
588
HC-12
128
78
106

6 . Technical data
6.3.2 PUMA V400M

(1) OD tool holder range
Unit : mm
3033
35 75
110
58 190 20
268
488
588
525
HC-12
128
67
106
(2) ID tool holder range
Unit : mm
22
20
268
488
588
HC-12
128
78
106

6 . Technical data
(3) Straight milling unit
Unit : mm
6
268 58
488
588
HC-12
155
128
106
(4) Angle milling unit
Unit : mm
28
20
268 72
488
588
HC-12
128
72
106

6 . Technical data
6.4 Dimension of spindle nose

(1) Standard spindle(JIS-A2-8)
6.4
80
TAPER 1/20
1 29 16
Fig. 6-6 Dimension of spindle nose(JIS-A2-8)
Dimension of spindle nose Page 6.4–1 PV40INE43

6 . Technical data
6.5 Hydraulic chuck and cylinder
304
54
HC-12
100
128
6
28
MAX.135
MIN.105
5
40
M20X2.5
90
45
671
548
M30X3.5
1016
31
MIN.26
MIN.56
43
4
20
Y1530RE
269
76
Fig. 6-7 Hydraulic chuck and cylinder
Hydraulic chuck and cylinder Page 6.5–1 PV40INE43

D1VW1CNYPF D1VW1CNYPF
(R30367) (R30367)
Ø2.6 ORIFICE Ø2.6 ORIFICE
(L32336024) (L32336024) D1VW1CNYPF D1VW1CNYPF D1VW1ENYPF
(R30367) (R30367) (R30368)
Ø2.6 ORIFICE Ø2.6 ORIFICE D1VW1CNYPF
DUAL CHUCKING BLOCK (L32336024) (L32336024) (R30367)
D1VW1CNYPF
(L15351362B) Ø2.6 ORIFICE (R30367)
(L32336024)
MPRV-3-PP MPRV-3-PP MPRV-3-PP MPRV-3-PP MPRV-3-PP
-07-K-N -07-K-N -07-K-N -07-K-N -07-K-N
(R30483A) (R30483A) (R30483A) (R30483A) (R30483A)
4-BB5x110 4-BB5x110 4-BB5x70 4-BB5x70 4-BB5x70 4-BB5x30 4-BB5x30
(R00022) (R00022) (R00021) (R00021) (R00021) (S2203761) (S2203761)
(HIGH) (LOW) (LOW) (HIGH)
Hydraulic circuit diagram

MAIN MAIN MAIN C-AXIS
CHUCK CHUCK CHUCK SPINDLE CLAMP TOOL POST
PV400 (2V);L32331221A PV400 (2V);L32331221A PV400M MANIFOLD(4V);L32331241A MANIFOLD(2V);L51331011

PV400M (4V);L32331241A
DUAL CHUCKING(OPT) C-AXIS

MAIN CHUCK MAIN CHUCK TOOL POST
SPINDLE CLAMP
6.6 Hydraulic circuit diagram
B PT1/4 B
B A B A B A A A
Dr CL UN
SET
5-25 bar Dr Dr
SET SET SET

20 bar 20 bar 5 bar
a a
Page 6.6–1
a a
b b
a a
b
b b
b b
PT BA PT BA PT BA PT BA PT BA PT BA PT BA PT BA PT BA PT BA
T T T
Fig. 6-8 Hydraulic circuit diagram

P P P
(HIGH) (LOW) (LOW) (HIGH)
PUMA V400 PUMA V400M
6 . Technical data
P T1 T2 DR
Rc3/8 Rc1/2 Rc1/2 Rc3/4
SET
40 bar
1.5kWx4P
HOSE HOSE
HOSE
Rc3/8
PV40INE43

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INSTRUCTION MANUAL

MAINTENANCE & TECHNICAL DOCUMENTS

WOO family of users.

understood and carefully followed.

We provide the following manuals.

Item Description Coverage

DAEWOO HEAVY INDUSTRIES & MACHINERY LTD.

Address : A/S dept., Machine tool & F.A division

601-3, Namsan-Dong, Changwon,

Gyeongsangnam-Do, Korea 641-090

3. Clothing and personal safety

4. Safety related to operation

5. Safety related to gripping workpiece and tooling

6. Safety related to maintenance

7. Safety related tothe workpiece

9. Safety related to a chip conveyor

10. Safety nameplates

11. When door is open

12. Warning labels on the machine

13. Noise emission

Section 1 Construction of machine ............................................................................. 1.1-1

1.1 Concept of axis ...................................................................................................... 1.1-1

1.2 Overview of machine ............................................................................................. 1.2-1

1.3 Construction of units .............................................................................................. 1.3-1

1.3.1 Headstock ....................................................................................................... 1.3-1

1.3.2 Chucking system............................................................................................. 1.3-1

1.3.3 C-axis (main & sub spindle) ............................................................................ 1.3-2

1.3.4 Carriage(X, Z-axis).......................................................................................... 1.3-2

1.3.5 Hydraulic power unit........................................................................................ 1.3-2

1.3.6 Coolant system ............................................................................................... 1.3-2

1.3.7 Lubrication system .......................................................................................... 1.3-2

1.3.8 Tool post.......................................................................................................... 1.3-2

1.3.9 Operation console............................................................................................ 1.3-3

Table of contents Page 0.1-1 PV40INE43

1.3.10 Electrical cabinet ........................................................................................... 1.3-3

1.3.11 Foot switch .................................................................................................... 1.3-3

1.3.12 Pressure switch............................................................................................. 1.3-3

1.3.13 Self-lock cylinder for chuck ........................................................................... 1.3-3

1.3.14 Halogen lamp ................................................................................................ 1.3-3

1.3.15 Door interlock switch(Option) ........................................................................ 1.3-4

1.3.16 Safety glass................................................................................................... 1.3-4

1.3.17 Ball screws .................................................................................................... 1.3-4

1.3.18 Electrical Torque limiter ................................................................................. 1.3-4

1.3.19 Oil skimmer(option) ....................................................................................... 1.3-4

Section 2 Machine specifications ................................................................................ 2.1-1

2.1 Specification table .................................................................................................. 2.1-1

2.2 Dimensional drawings ............................................................................................ 2.2-1

Section 3 Handling and installation ............................................................................. 3.1-1

3.1 Guide to select a installation site(Environmental requirements) ............................ 3.1-1

3.1.1 Care in handling a precision machine ............................................................. 3.1-3

3.2 Foundation requirements ....................................................................................... 3.2-1

3.2.1 General precautions for building a new foundation......................................... 3.2-1

3.3 General procedure for installation .......................................................................... 3.3-1

3.3.1 Precautions for installation .............................................................................. 3.3-1

3.4 Leveling the machine ............................................................................................. 3.4-1

3.4.1 Leveling procedure.......................................................................................... 3.4-1

3.5. Foundation plan.................................................................................................... 3.5-1

3.6 Power requirements............................................................................................... 3.6-1

3.6.1 Inspection of cable connection........................................................................ 3.6-1

3.6.2 Electrical work ................................................................................................. 3.6-2

Table of contents Page 0.1-2 PV40INE43

3.7 Air source requirements ......................................................................................... 3.7-1

3.7.1 Air source ........................................................................................................ 3.7-1