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MH-SERIES SIGMA-5 POSITIONER MANUALMH95, MH185, MH505, MH1605, and MH3105

Upon receipt of the product and prior to initial operation, read these instructions thoroughly and retain for future reference.

Part Number: 162068-1CDRevision: 0

MOTOMAN INSTRUCTIONS

MOTOMAN INSTRUCTIONSDX100 INSTRUCTIONSDX100OPERATOR’S MANUALDX100 MAINTENANCE MANUAL

The DX100 operator’s manual above corresponds to specific usage. Be sure to use the appropriate manual.

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MH-SERIES POSITIONER

MANDATORY

General items related to safety are listed in Section 2 of the DX100 Controller Manual. To ensure correct and safe operation, carefully read the DX100 Controller Manual before reading this manual.

CAUTION

• The drawings and photos in this manual are representative examples, and differences may exist between them and the delivered product.

• YASKAWA may modify this model without notice when necessary due to product improvements, modifications, or changes in specifications.

• If such a modification is made, the manual number will also be revised.

• If your copy of the manual is damaged or lost, contact a YASKAWA representative to order a new copy. The representatives are listed on the back cover. Be sure to tell the representative the manual number listed on the front cover.

• YASKAWA is not responsible for incidents arising from unauthorized modification of its products. Unauthorized modification voids the products warranty.

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Notes for Safe OperationRead this manual carefully before installation, operation, maintenance, or inspection of the MH-SERIES POSITIONER.

In this manual, the Notes for Safe Operation are classified as “WARNING,” “CAUTION,” “MANDATORY,” or “PROHIBITED.”

Even items described as “CAUTION” may result in a serious accident in some situations. At any rate, be sure to follow these important items.

WARNINGIndicates a potentially hazardous situation which, if not avoided, could result in death or serious injury to personnel.

CAUTIONIndicates a potentially hazardous situation which, if not avoided, could result in minor or moderate injury to personnel and damage to equipment. It may also be used to alert against unsafe practices.

MANDATORYAlways be sure to follow explicitly the items listed under this heading.

PROHIBITEDMust never be performed.

NOTETo ensure safe and efficient operation at all times, be sure to follow all instructions, even if not designated as “CAUTION” and “WARNING.”

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WARNING

• Before operating the MH-SERIES POSITIONER, check that servo power is turned OFF by pressing the EMERGENCY STOP buttons on the operator station or Programming Pendant (refer to Figure 1). When servo power is turned OFF, the SERVO ON LED on the Programming Pendant is turned OFF.

Injury or damage to machinery may result if the Emergency Stop circuit cannot stop the positioner during an emergency. The positioner should not be used if the EMERGENCY STOP buttons do not function.

Figure 1: EMERGENCY STOP Button

• Release the EMERGENCY STOP button (refer to Figure 2). Once this button is released, clear the cell of all items which could interfere with the operation of the positioner then, turn servo power ON.

Injury may result from unintentional or unexpected positioner motion.

Figure 2 : Release of EMERGENCY STOP Button

TURN

• Observe the following precautions when performing teaching operations within the working envelope of the positioner:

– View the positioner from the front whenever possible.

– Always follow the predetermined operating procedure.

– Ensure that there is a safe place to retreat to in case of emergency.

Improper or unintended manipulator operation may result in injury.

• Confirm that no person is present in the working envelope of the positioner and that you are in a safe location before:

– Turning on the power for the DX100 controller.

– Moving the positioner with the Programming Pendant.

– Running the system in the check mode.

– Performing automatic operations.

Injury may result if anyone enters the working envelope of the positioner during operation. Always press an EMERGENCY STOP button immediately if there is a problem. The EMERGENCY STOP buttons are located on the operator station and on the Programming Pendant.

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Definition of Terms Used Often in This ManualThe positioner usually consists of the controller, the Programming Pendant, and supply cables.

In this manual, the equipment is designated as follows:

CAUTION

• Perform the following inspection procedures prior to conducting positioner teaching. If problems are found, repair them immediately and be sure that all other necessary processing has been performed.

– Check for problems in positioner movement.

– Check for damage to insulation and sheathing of external wires.

• Always return the Programming Pendant to the hook on the cabinet of the DX100 controller after use.

• The Programming Pendant can be damaged if it is left in the work area, on the floor, or near fixtures.

• Read and understand the Explanation of Warning Labels in the DX100 Controller Manual before operating the MH-SERIES POSITIONER.

Equipment Manual Designation

DX100 controller DX100

DX100 Programming Pendant Programming Pendant

Cable between the positioner and the controller

Power cables

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MH-SERIES POSITIONER Table of Contents

1 Introduction ..................................................................................................................................... 1-1

1.1 About this Document ......................................................................................................... 1-1

1.2 System Overview............................................................................................................... 1-2

1.3 System Layout ................................................................................................................... 1-2

1.3.1 System Layout...................................................................................................... 1-4

1.4 Customer Support Information........................................................................................... 1-7

2 Safety.............................................................................................................................................. 2-1

2.1 Introduction........................................................................................................................ 2-1

2.2 General Safeguarding Tips................................................................................................ 2-1

2.3 Mechanical Safety Devices................................................................................................ 2-2

2.4 Installation Safety .............................................................................................................. 2-2

2.5 Programming, Operation, and Maintenance Safety........................................................... 2-3

3 Equipment Description.................................................................................................................... 3-1

3.1 General Information........................................................................................................... 3-1

3.2 MH-Series SIGMA-5 Positioner Assembly – Type I .......................................................... 3-1

3.2.1 MH-Series SIGMA-5 Positioner Type I – Specifications....................................... 3-2

3.3 MH-Series SIGMA-5 Positioner Assembly – Type II ......................................................... 3-3

3.3.1 MH3105-Series SIGMA-5 Positioner, Type II – Specifications............................. 3-4

3.4 *MotoMount™.................................................................................................................... 3-5

4 Installation....................................................................................................................................... 4-1

4.1 Materials Required............................................................................................................. 4-1

4.1.1 Customer-Supplied Items..................................................................................... 4-1

4.1.2 List of Tools .......................................................................................................... 4-1

4.2 Installing the MH-Series SIGMA-5 Positioner – Type I...................................................... 4-2

4.2.1 Site Preparation.................................................................................................... 4-2

4.2.2 Unpacking ............................................................................................................ 4-2

4.2.3 Headstock Assembly Mounting Hole Pattern – MH95/185/505/1605................... 4-3

4.2.4 Column Assembly Mounting – Type I Assembly .................................................. 4-5

4.2.5 Connecting the Cables ......................................................................................... 4-7

4.2.6 Home Position ...................................................................................................... 4-7

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4.3 Installing the MH-Series SIGMA-5 Positioner – Type II .....................................................4-8

4.3.1 Site Preparation.................................................................................................... 4-8

4.3.2 Unpacking.............................................................................................................4-8

4.3.3 Unbolting the Drive Assembly Floor Mounting – Type II....................................... 4-9

4.3.4 Connecting the Cables .......................................................................................4-11

4.3.5 Home Position ....................................................................................................4-11

4.4 Tailstock Column Installation ........................................................................................... 4-12

4.4.1 Type I Installation................................................................................................ 4-12

4.4.2 Type II Installation............................................................................................... 4-13

4.4.3 Leveling the Tailstock ......................................................................................... 4-14

4.4.4 Tooling Fixture Installation (initial) ...................................................................... 4-17

4.4.5 Tooling Fixture Installation (regular) ................................................................... 4-18

4.4.6 Final Alignment Check........................................................................................ 4-18

4.4.7 Tooling Fixture Removal..................................................................................... 4-21

4.5 MotoMount Installation..................................................................................................... 4-22

4.5.1 Preparation ......................................................................................................... 4-22

4.5.2 Unpack and Assemble........................................................................................ 4-22

4.5.3 Securing MotoMount Drive Components onto Faceplate ...................................4-24

4.5.4 Retrofitting Tailstock Assembly........................................................................... 4-24

4.6 MotoMount HD Adjustments ............................................................................................ 4-25

4.6.1 Allowable Misalignment ...................................................................................... 4-25

4.6.2 Tooling Fixture Installation – MotoMount HD...................................................... 4-26

4.6.3 Tooling Fixture Removal..................................................................................... 4-26

4.6.4 Variable Tooling Size Accommodations .............................................................4-27

4.7 Conducting a Safety/Operation Check.............................................................................4-27

5 Tooling Recommendations .............................................................................................................5-1

5.1 Headstock Only – Tooling Recommendations...................................................................5-1

5.1.1 Customer-supplied Tooling Fixture....................................................................... 5-2

5.2 Headstock/Tailstock with MotoMount ................................................................................5-5

5.2.1 Customer-supplied Tooling Fixtures ..................................................................... 5-5

5.2.2 Multiple Tooling Fixtures....................................................................................... 5-5

5.2.3 Specifications........................................................................................................ 5-5

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MH-SERIES POSITIONER Table of Contents

6 Maintenance ................................................................................................................................... 6-1

6.1 Spare Parts........................................................................................................................ 6-1

6.2 Servomotor ........................................................................................................................ 6-1

6.3 Weld Ground Brush Replacement – Type I ....................................................................... 6-2

6.3.1 MH95/185/505/1605............................................................................................. 6-2

6.4 Weld Ground Brush Replacement – Type II ...................................................................... 6-5

6.4.1 MH3105................................................................................................................ 6-5

6.5 Reset Headstock To Home Position.................................................................................. 6-7

6.5.1 Homing ................................................................................................................. 6-7

6.6 Maintenance Schedule .................................................................................................... 6-11

6.6.1 MH-Series SIGMA-5 Positioner.......................................................................... 6-11

6.6.2 MotoMount ......................................................................................................... 6-11

6.7 Troubleshooting............................................................................................................... 6-12

6.7.1 MH-Series SIGMA-5 Positioner.......................................................................... 6-12

6.7.2 MotoMount ......................................................................................................... 6-12

A Performance Charts .......................................................................................................................A-1

A.1 MH-Series Positioner Assemblies .....................................................................................A-1

A.1.1 MH95 ...................................................................................................................A-1

A.1.2 MH185 .................................................................................................................A-2

A.1.3 MH505 .................................................................................................................A-3

A.1.4 MH1605 ...............................................................................................................A-4

A.1.5 MH3105 ...............................................................................................................A-5

B Illustrated Parts list .........................................................................................................................B-1

B.1 Introduction .......................................................................................................................B-1

B.1.1 Contents...............................................................................................................B-1

B.1.2 Parts List ..............................................................................................................B-1

B.1.3 Symbols and Abbreviations..................................................................................B-2

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1 Introduction1.1 About this Document

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1 Introduction

1.1 About this Document

This manual provides the following information:

CHAPTER 1 – INTRODUCTIONProvides general information about the MH-SERIES POSITIONER system and components and customer support contact information.

CHAPTER 2 – SAFETYProvides general safety information regarding installation, maintenance, and operation.

CHAPTER 3 – DESCRIPTION OF EQUIPMENTProvides a description of the major components.

CHAPTER 4 – INSTALLATION This chapter provides installation procedures.

CHAPTER 5 – TOOLING RECOMMENDATIONSThis chapter provides guidelines for customer-supplied tooling design.

CHAPTER 6 – MAINTENANCEThis chapter provides preventive maintenance requirements for certain components MH-SERIES POSITIONER.

APPENDIX A – PERFORMANCE CHARTSThis appendix provides performance charts for each of the MH-SERIES POSITIONER.

APPENDIX B – ILLUSTRATED PARTS LISTThis appendix contains the Illustrated Parts List (IPL). The IPL provides detailed views (with part numbers).

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1 Introduction1.2 System Overview

1.2 System Overview

The MH-SERIES POSITIONER Assembly is available in four basic mechanical configurations:

• The Drive Assembly

• The Drive Assembly with MotoMount

• The Headstock Positioner Assembly

• The Headstock and Tailstock Positioner Assembly

These assemblies are combined with the appropriate single or multiple external axis control packages to provide a complete positioner kit.

1.3 System Layout

The two major components of a typical headstock and tailstock positioner assembly (MHT) are;

• MHT System Layout Type I (Fig. 1-1)

• MHT System Layout Type II (Fig. 1-2)

WARNING

Do not use a MotoMount™ with stand-alone headstock (no tailstock) applications. Use of a stand-along application will result in uncontrolled tooling motion.

NOTEThe warranty is void if the Yaskawa drive or headstock assembly is integrated with other than a Yaskawa tailstock or MotoMount system.

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1 Introduction1.3 System Layout

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Fig. 1-1: MHT System Layout - Type I

Fig. 1-2: MHT System Layout - Type II

DRIVEASSEMBLY

MotoMount™ASSEMBLY (HS)

AC SERVOMOTOR

MotoMount™ASSEMBLY (TS)

TAILSTOCKCOLUMN

STANDARDTOOL RADIUS

LEVELINGSCREW, TYP

HEADSTOCKCOLUMN

MotoMount™ HEADSTOCKASSEMBLY

STANDARDTOOL RADIUS

FORKLIFTPOCKETS

HOUSING

MotoMount™ TAILSTOCKASSEMBLY

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1.3.1 System Layout

The modular drive assembly provides precision-controlled rotary motion and can be mounted in any orientation that the welding, material handling, or dispensing application might require. The standard configuration utilizes an AC servo motor, a high ratio gear reducer with integral output bearing, faceplate, and a cast iron housing. It also includes dual integral position switches and weld ground brushes.

1.3.1.1 Drive Assembly with MotoMount

The Drive Assembly combined with the MotoMount compliant tool mounting system provides headstock and tailstock components for applications requiring custom headstock and tailstock supporting structures. MotoMount is a modular accessory for MHT positioners that provides improved repeatability as compared to hard-mounted tooling systems.

Fig. 1-3: Drive Assembly and MotoMount Assembly

Drive Assembly

MotoMount

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1.3.1.2 Headstock Assembly

The Headstock Assembly integrates the drive assembly with a column that is designed to be floor-mounted or mounted to a machine base, as required for use in cantilevered (stand-alone) applications. The standard configuration provides connectors in the column for motor control and safety circuits. Leveling bolts are included. The user must provide suitable anchor bolts.

Fig. 1-4: Headstock Assembly

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1.3.1.3 Positioner Assembly (headstock and tailstock)

The positioner assembly integrates the headstock with a tailstock column and the MotoMount compliant tool mounting system. This system is designed to be floor-mounted or mounted to a machine base. Span between the headstock and tailstock is determined by the application. The standard configuration provides a 815-mm tooling sweep radius.

Fig. 1-5: Positioner Assembly (headstock and tailstock)

NOTEIf integrating the Yaskawa drive or headstock assembly with other than Yaskawa tailstock or the MotoMount system voids the warranty

TailStock Assembly

HeadStock Assembly

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1 Introduction1.4 Customer Support Information

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1.4 Customer Support Information

If you need assistance with any aspect of your MH-SERIES POSITIONER system, please contact Yaskawa Motoman Customer Support at the following 24-hour telephone number:

For routine technical inquiries, you can also contact Yaskawa Motoman Customer Support at the following e-mail address:

When using e-mail to contact Yaskawa Motoman Customer Support, please provide a detailed description of your issue, along with complete contact information. Please allow approximately 24 to 36 hours for a response to your inquiry.

Please have the following information ready before calling:

[email protected]

NOTEPlease use e-mail for routine inquiries only. If an urgent or emergency need for service, replacement parts, or information, contact Yaskawa Motoman Customer Support at the telephone number shown above.

• System MH-SERIES POSITIONER

• Robots

• Software Version Access this information on the Programming Pendant’s LCD display screen by selecting {MAIN MENU} - {SYSTEM INFO} - {VERSION}

• Robot Serial Number Located on the robot data plate

• Robot Sales Order Number Located on the DX100 controller data plate

(937) 847-3200

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2 Safety2.1 Introduction

2 Safety

2.1 Introduction

It is the purchaser’s responsibility to ensure that all local, county, state, and national codes, regulations, rules, or laws relating to safety and safe operating conditions for each installation are met and followed.

We suggest that you obtain and review a copy of the ANSI/RIA National Safety Standard for Industrial Robots and Robot Systems (ANSI/RIA R15.06-1999). You can obtain this document from the Robotic Industries Association (RIA) at the following address:

Robotic Industries Association900 Victors WayP.O. Box 3724

Ann Arbor, Michigan 48106TEL: (734) 994-6088FAX: (734) 994-3338

www.roboticsonline.com

Ultimately, well-trained personnel are the best safeguard against accidents and damage that can result from improper operation of the robot system. The customer is responsible for providing adequately trained personnel to operate, program, and maintain the robot cell. NEVER ALLOW UNTRAINED PERSONNEL TO OPERATE, PROGRAM, OR REPAIR THE ROBOT SYSTEM!

We recommend approved Motoman training courses for all personnel involved with the operation, programming, or repair of the robot system. This training is designed to familiarize personnel with the safe and correct operation of the robot system.

2.2 General Safeguarding Tips

All operators, programmers, plant and tooling engineers, maintenance personnel, supervisors, and anyone working near the robot must become familiar with the operation of this equipment. All personnel involved with the operation of the equipment must understand potential dangers of operation. General safeguarding tips are as follows:

• Improper operation can result in personal injury and/or damage to the equipment. Only trained personnel familiar with the operation of this robot, the operator's manuals, the system equipment, and options and accessories should be permitted to operate this robot system.

• Do not enter the robot cell while it is in automatic operation. Programmers must have the teach pendant when they enter the robot cell.

• Improper connections can damage the robot. All connections must be made within the standard voltage and current ratings of the robot I/O (Inputs and Outputs).

• The robot must be placed in Emergency Stop (E-Stop) mode whenever it is not in use.

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2 Safety2.3 Mechanical Safety Devices

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• In accordance with ANSI/RIA R15.06-1999, section 4.2.5, Sources of Energy, use lockout/tagout procedures during equipment maintenance. Refer also to Section 1910.147 (29CFR, Part 1910), Occupational Safety and Health Standards for General Industry (OSHA).

2.3 Mechanical Safety Devices

The safe operation of the robot, positioner, auxiliary equipment, and system is ultimately the user's responsibility. The conditions under which the equipment will be operated safely should be reviewed by the user. The user must be aware of the various national codes, ANSI/RIA R15.06-1999 safety standards, and other local codes that may pertain to the installation and use of industrial equipment. Additional safety measures for personnel and equipment may be required depending on system installation, operation, and/or location. The following safety equipment is provided as standard:

• Safety fences and barriers

• Light curtains and/or safety mats

• Door interlocks

• Emergency stop palm buttons located on operator station, robot controller, and programming pendant

Check all safety equipment frequently for proper operation. Repair or replace any non-functioning safety equipment immediately.

2.4 Installation Safety

Safe installation is essential for protection of people and equipment. The following suggestions are intended to supplement, but not replace, existing federal, local, and state laws and regulations. Additional safety measures for personnel and equipment may be required depending on system installation, operation, and/or location. Installation tips are as follows:

• Be sure that only qualified personnel familiar with national codes, local codes, and ANSI/RIA R15.06-1999 safety standards are permitted to install the equipment.

• Identify the work envelope of each robot with floor markings, signs, and barriers.

• Position all controllers outside the robot work envelope.

• Whenever possible, install safety fences to protect against unauthorized entry into the work envelope.

• Eliminate areas where personnel might get trapped between a moving robot and other equipment (pinch points).

• Provide sufficient room inside the workcell to permit safe teaching and maintenance procedures.

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2 Safety2.5 Programming, Operation, and Maintenance Safety

2.5 Programming, Operation, and Maintenance Safety

All operators, programmers, plant and tooling engineers, maintenance personnel, supervisors, and anyone working near the robot must become familiar with the operation of this equipment. Improper operation can result in personal injury and/or damage to the equipment. Only trained personnel familiar with the operation, manuals, electrical design, and equipment interconnections of this robot should be permitted to program, operate, and maintain the system. All personnel involved with the operation of the equipment must understand potential dangers of operation.

• Inspect the robot and work envelope to be sure no potentially hazardous conditions exist. Be sure the area is clean and free of water, oil, debris, etc.

• Be sure that all safeguards are in place. Check all safety equipment for proper operation. Repair or replace any non-functioning safety equipment immediately.

• Do not enter the robot cell while it is in automatic operation. Be sure that only the person holding the programming pendant enters the workcell.

• Check the E-Stop button on the programming pendant for proper operation before programming. The robot must be placed in Emergency Stop (E-Stop) mode whenever it is not in use.

• Back up all programs and jobs onto suitable media before program changes are made. To avoid loss of information, programs, or jobs, a backup must always be made before any service procedures are done and before any changes are made to options, accessories, or equipment.

• Any modifications to PART 1, System Section, of the robot controller concurrent I/O program can cause severe personal injury or death, as well as damage to the robot! Do not make any modifications to PART 1, System Section. Making any changes without the written permission of Motoman will VOID YOUR WARRANTY!

• Some operations require standard passwords and some require special passwords. Special passwords are for Motoman use only. YOUR WARRANTY WILL BE VOID if you use these special passwords.

• The robot controller allows modifications of PART 2, User Section, of the concurrent I/O program and modifications to controller parameters for maximum robot performance. Great care must be taken when making these modifications. All modifications made to the controller will change the way the robot operates and can cause severe personal injury or death, as well as damage the robot and other parts of the system. Double-check all modifications under every mode of robot operation to ensure that you have not created hazards or dangerous situations.

• Check and test any new or modified program at low speed for at least one full cycle.

• This equipment has multiple sources of electrical supply. Electrical interconnections are made between the controller and other equipment. Disconnect and lockout/tagout all electrical circuits before making any modifications or connections.

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2 Safety2.5 Programming, Operation, and Maintenance Safety

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• Do not perform any maintenance procedures before reading and understanding the proper procedures in the appropriate manual.

• Use proper replacement parts.

• Improper connections can damage the robot. All connections must be made within the standard voltage and current ratings of the robot I/O (Inputs and Outputs).

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3 Equipment Description3.1 General Information

3 Equipment Description

3.1 General Information

The MH-Series SIGMA-5 Positioner drive assembly consist of an AC servo motor and gear reducer with an integral output bearing mounted in a cast iron housing.Weld ground brushes and position switches are included as standard features. Drive assembly provides programmable motion about the central axis, and endless rotation can be purchased as an option. Holes in the faceplate provide for mounting MotoMount drive components or parts fixtures in stand-alone (cantilevered) applications.

3.2 MH-Series SIGMA-5 Positioner Assembly – Type I

The design of the four available drive assemblies is very similar; size is the primary difference. The flexibility of the Type I drive assembly allows for any mounting orientation including vertical (typical), horizontal, or other.The Type I drive assembly positioners (Figure 3-1) are available in four different models:

• MH95

• MH185

• MH505

• MH1605

Fig. 3-6: MH-Series SIGMA-5 Positioner Manual Drive Assembly — Type I

SERVOMOTOR,SIGMA-5

CASTING

FACEPLATE,TOOLING

IN-POSITIONSWITCH,2-PLACES

HOMING PIN(ZERO ADJ)HOLE

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3 Equipment Description3.2 MH-Series SIGMA-5 Positioner Assembly – Type I

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3.2.1 MH-Series SIGMA-5 Positioner Type I – Specifications

See Table 3-1 for Type I, MH-Series SIGMA-5 Positioner drive assembly

specifications.

* External axis default settings

CAUTION

Operating outside the standard setup, without Yaskawa approval may change E-Stop performance and void warranty.

Table 3-1: MH-Series SIGMA-5 Positioner Type I Specifications

SERIES COMPONENT MH95 MH185 MH505 MH1605

Drive Assy PN 158238-1 158238-2 158482-1 161825-1

Axis Type* Rotation Rotation Rotation Rotation

Rated Load kgf 95 185 505 1605

Max MHT Load @ CG Off Center

kgf@mm 550@30 550@50 1075@80 3000@95

Headstock Speed rpm 23.8 12.4 9.8 10.8

180 Degree Sweep Time sec 1.56 2.72 3.36 3.28

Rated CG Off Center mm 152 152 152 152

Rated CG Overhang mm 500 250 331 0

Load @ 500 mm CG Overhang

kgf 75 75 168 500

Rated Inertia kg*m2 20 47 105 678

Rated Holding Torque Nm 156 268 746 2826

Rated Weld Current (Std/Optional)

Amps 400/800 400/800 800/1200 800/1600

Allowable Thrust kgf 400 400 800 2000

Motor Power kW 0.450 0.450 1.300 3.7

Motor PN, YEC* SGMRV-05ANA-YR11

SGMRV-05ANA-YR11

SGMRV-13ANA-YR11

SGMRV-37ANA-YR11

Motor Speed* rpm 2500 2000 1500 2000

Rated Acceleration Time* sec 0.3 0.3 0.3 0.5

Motor PN, Motoman 156009-1 156009-1 156009-3 156009-6

Reducer RV-20E-105-1B RV-20E-161-1B RV-80E-153-1B RV-320E-185

Total Reduction Ratio* R 105 161 153 185

Repeatability mm/mm 0.00003 0.00004 0.00003 0.00003

Tail Stock Through Hole mm 45 45 45 45

Drive Assy Weight kgf/lbs 59.5/131 59.5/131 99.5/219 358/789

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3 Equipment Description3.3 MH-Series SIGMA-5 Positioner Assembly – Type II

3.3 MH-Series SIGMA-5 Positioner Assembly – Type II

The MH3105 head stock utilizes a Type II drive assembly similar to that used in the MSR505, MSR1005, and MotoSweep O 20/50 products.

Fig. 3-7: MH3105 Series SIGMA-5 Positioner Drive Assembly - Type II

HOUSING

FACEPLATE

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3 Equipment Description3.3 MH-Series SIGMA-5 Positioner Assembly – Type II

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3.3.1 MH3105-Series SIGMA-5 Positioner, Type II – Specifications

See Table 3-2 for Type II, MH-Series SIGMA-5 Positioner drive assembly specifications.

* External axis default settings

CAUTION

Operating outside the standard setup, without Yaskawa approval may change E-Stop performance and void warranty.

Table 3-2: MH-Series SIGMA-5 Positioner Type II Specifications

SERIES COMPONENT MH 3105

Drive Assy PN 162733-3

Axis Type* Rotation

Rated Load kgf 3105

Max MHT Load @ CG Off Center kgf@mm 6300@90

Headstock Speed rpm 6.7

180 Degree Sweep Time sec 4.95

Rated CG Off Center mm 152

Rated CG Overhang mm 58

Load @ 500 mm CG Overhang kgf 1400

Rated Inertia kg*m2 3058

Rated Holding Torque Nm 4622

Rated Weld Current Amps 1200

Allowable Thrust kgf 3000

Motor Power Kw 4.4

Motor PN, YEC* SGMRV-44ANA-YR11

Motor Speed* rpm 2000

Rated Acceleration Time* sec 0.3

Motor PN, Motoman 156009-7

Reducer RV-320C

Total Reduction Ratio* R 11575/39 (296.795)

Repeatability mm/mm 0.00004

Repeatability w/MotoMount mm/mm 0.000055

E-Stop Response sec TBD

E-Stop Response deg TBD

Face Plate Through Hole mm 110

Tail Stock Through Hole mm 45

Drive Assy Weight kgf/lbs 918/2022

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3 Equipment Description3.4 * MotoMount™

3.4 *MotoMount™

MotoMount (see Fig. 3-8) is a flexible tool fixture mounting system which improves tool repeatability and reduces loads on the headstock/tailstock bearing systems. MotoMount accommodates combined headstock/tailstock/tooling misalignment up to two degrees.

MotoMount is required for use with all Motoman MHT-series (headstock/tailstock) positioners. The MotoMount drive components are mounted onto the headstock faceplate, while the tailstock components replace earlier tailstock designs.

MotoMount is also available in a Heavy Duty (HD) configuration (see Figure 3-9). MotoMount HD is used on the1605/3105 drive assemblies.

MH95/MH185/MH505 drive assemblies use the standard MotoMount.

CAUTION

Do not use MotoMount with stand-alone (no tailstock) applications. Use in a stand-alone application will result in uncontrollable tooling fixture motion.

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3 Equipment Description3.4 * MotoMount™

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Fig. 3-8: MotoMount Layout

Fig. 3-9: MotoMount HD Layout

FACEPLATE

WELD GROUNDCABLE

TAILSTOCKTOOLINGADAPTER

DRIVEBUSHING

TAILSTOCKCOLUMN

FACEPLATE

WELD GROUNDCABLE

AUXILARYMOUNTINGHOLES

AUXILARYMOUNTINGHOLES

PRIMARYMOUNTINGHOLES

TAILSTOCKTOOLINGADAPTER

DRIVEBUSHING

BEARING

TAILSTOCKCOLUMN

LOCATING PIN

PRIMARYMOUNTINGHOLES

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4 Installation4.1 Materials Required

4 Installation

Installation of the MH-Series SIGMA-5 Positioner Manual positioner and MotoMount should be performed by personnel who are familiar with this Yaskawa Motoman product.

Follow established safety procedures at all times throughout the installation process. Failure to use safe work practices can result in damage to the equipment and injury to the workers.

4.1 Materials Required

This section identifies customer-supplied items and tools required to complete installation.

4.1.1 Customer-Supplied Items

• Servo motion control unit

• Incoming power supply

• Two earth ground cables with two earth ground stakes

4.1.2 List of Tools

CAUTION

Installation of MotoMount and the MH-Series SIGMA-5 Positioner is not a task for the novice. These components are not fragile, but should still be handled with care. Rough handling can damage electronic components.

Table 4-3: Tools

• Safety glasses

• Level

• Adjustable wrench set

• Hammer drill with appropriate concrete bits

• Forklift and/or overhead crane

• Open-end wrench set

• Wrench sets (standard and metric)

• Chalk String

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4 Installation4.2 Installing the MH-Series SIGMA-5 Positioner – Type I

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4.2 Installing the MH-Series SIGMA-5 Positioner – Type I

4.2.1 Site Preparation

Mount each MH-Series SIGMA-5 Positioner system on a machine base or a reinforced concrete factory floor suitable to withstand the static and dynamic forces.

4.2.2 Unpacking

The headstock and optional tailstock are shipped on a shipping skid. To

unpack the equipment, proceed as follows:

1. Carefully remove protective plastic wrapping from equipment.

2. Inspect equipment for shipping damage.

3. Unbolt the equipment from the shipping skid (see Fig. 4-10).

Fig. 4-10: Unbolting the Drive Assembly

4. Attach a lifting device to the eye bolts on top of the housing and lift the equipment from the shipping skid.

5. Place the equipment in a position using the layout prints.

WARNING

See the specification tables for drive assembly weight. Make sure that the lifing device is capable of handling the weight or injury to personnel can result.

NOTE Notify shipping contractor if there is any shipping damage.

NOTE Make sure there is adequate room on all sides of the positioner for parts fixtures.

SHIPPING SKID

SHIPPING BOLT

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4.2.3 Headstock Assembly Mounting Hole Pattern – MH95/185/505/1605

The headstock assembly may be mounted to the column assembly (see Section 4.2.4) or mounted to a customer-supplied machine base. For custom orientation auxiliary mounting holes are provided on top of the drive assembly housing, and may be used in addition to the base mounting holes. Table 4-4 shows mounting specifications for positioners.

The following figures show the mounting hole patterns;• Fig. 4-11 shows the mounting hole pattern for the MH95/185.

• Fig. 4-12: shows the mounting hole pattern for the MH505.

• Fig. 4-13 shows the mounting hole pattern for the MH1605.

Fig. 4-11: MH95/185 Mounting Hole Pattern

Table 4-4: Mounting Specifications for Positioners

Drive Assembly Bolt Size, Grade SHC Tightening Torque (N•m/lbf-ft.)

MH95 M10 44/32

MH185 M10 44/32

MH505 M10 44/32

MH1605 M16 162/122

260.0

52.5

20

104.5

320.0O

140.060.0

12.5

273

SWITCHES & BRACKETS NOT SHOWNFOR CLARITY

2X M10 X 1.5 THRU HOLESFOR ADDITIONAL MOUNTINGSUPPORT AS REQUIRED FOR SPECIFIC APPLICATIONS.

4X Ø 11.0 THRU+ 0.5- 0.0

52.5

2X Ø 10.0 THRU+ 0.015- 0.0

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Fig. 4-12: MH505 Mounting Hole Pattern

Fig. 4-13: MH1605 Mounting Hole Pattern

63.1

56.9

133.1

313

180.1

20 350.0

70.0 210.0Ø400.0

76.2

SWITCHES & BRACKETS NOT SHOWN FOR CLARITY

2X M10 x 1.5 THRU HOLES FOR ADDITIONAL MOUNTING SUPPORT AS REQUIRED FOR SPECIFIC APPLICATIONS

+0.5-0.04X Ø11.0 THRU

+0.018-0.02X Ø12.0 THRU

560

25 510

207

100.0

75150

150300

72.1160 240.0

350

G

6X CLEARANCE FOR M16 SCREWS

4X M16 THRU HOLES FOR AUXILIARY MOUNTING SUPPORT AS REQUIRED FOR SPECIFIC APPLICATIONS.

+0.018-0.02X Ø16.0 THRU

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4.2.4 Column Assembly Mounting – Type I Assembly

4.2.4.1 Hole Patterns

The column assembly for the MH-SERIES POSITIONER may be mounted to the floor or on a base. For accurate placement information, review the hole pattern in Figure 4-14 and the specifications in Table 4-5.

Fig. 4-14: Column-Mounting Hole Pattern - Type I

4.2.4.2 Installing the Type I Headstock Column Assembly

Refer to the system layout drawings to ensure set up location. To install the headstock, refer to Figure 4-11 and proceed as follows:1. Set the column assembly in desired position.

2. Use the leveling bolt holes as a guide and transfer the hole locations to the concrete.

3. Remove column assembly.

4. Install the anchors per the manufacture’s instructions.

5. Install a leveling shim at each anchor location and reset the column assembly.

6. Screw each leveling bolt down until it just contacts the leveling shim and hand tighten the anchor bolts or nuts.

Table 4-5: Mounting Hole Specifications

Drive Assembly Dynamic Rating per Anchor

A B C

MHT95/185 1360 kgf 300 250 M10

MHT505 1360 kgf 300 250 M10

MHT1600 3400 kgf 700 420 M12

NOTEDue to the variations in floor construction and preferences, this manual will not specify anchoring systems beyond dynamic rating requirements as listed in Table 4-5.

A

B

C-LAG BOLTCLEARENCE

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4.2.4.3 Leveling the Type I Headstock

The headstock must be leveled in two directions (see Figure 4-15): • Parallel to the faceplate

• Perpendicular to the faceplate

Since it only takes three points to define a plane, use only three of the four leveling bolts to level the system. It is important to consistently use the same three leveling bolts throughout each process. The fourth leveling bolt is used as an anchor only.

Before proceeding, make sure that the headstock is in the proper place. Make sure leveling bolt, lock-nut, and leveling shim are installed in each column base hole.

To level the headstock assembly axially, proceed as follows:1. Place a level on top of the housing, perpendicular to the faceplate.

2. Use the two leveling bolts beneath the faceplate (A and B), and a third beneath the motor (C) to level axially. If the faceplate side needs adjustment, A and B must be turned equally.

To level the headstock assembly cross-axially, proceed as follows:1. Place a level on top of the housing, parallel to the faceplate.

2. Use the same three leveling bolts used above and adjust them until the level is balanced, adjusting B and C equally.

3. Repeat the axial and cross-axial leveling steps until level readings are achieved both ways.

4. Drive the fourth leveling bolt down to the leveling shim.

5. Check level axial and cross-axial again. When level, tighten the anchor system (customer supplied) to the specified torque.

6. Tighten the four lock-nuts to the column base.

Fig. 4-15: Leveling Hardware

LEVELING SHIM

LEVELING BOLT

LOCK NUT

HEADSTOCKCOLUMN

FACEPLATE

COLUMN BASE

A

B

c

ANCHOR (CUSTOMER SUPPLIED)

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4.2.5 Connecting the Cables

Do not connect the encoder, power, and ground cables until after the drive

assembly is securely in place.

4.2.5.1 Connection to Motoman Controller

When the MH-Series SIGMA-5 Positioner assembly is delivered with a Motoman robot, connections between the two usually have been made at the factory, or if not, instructions for making connections can be found in the system manual. See separate documentation specific to your system.

4.2.5.2 Ground Cables – Type I

Two locations are provided for attaching weld ground cables see Figure 4-16. Use one for each welding power supply. Remove paint as required from the lug contact surface on the housing.

Fig. 4-16: Ground Cable Connections

4.2.6 Home Position

The MH-Series SIGMA-5 Positioner are set in HOME position at the factory. See Maintenance Section 6, Maintenance, if adjustment is necessary.

NOTEWhen installing stand-along drive assemblies, user will need to mount the junction boxes close to the drive assembly for motor cables.

LUG BOLT

WELD GROUND

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4 Installation4.3 Installing the MH-Series SIGMA-5 Positioner – Type II

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4.3 Installing the MH-Series SIGMA-5 Positioner – Type II

4.3.1 Site Preparation

Each MH-Series SIGMA-5 Positioner assembly should be firmly mounted on a machine base or foundation rigid enough to withstand static and dynamic forces.

4.3.2 Unpacking

The headstock and optional tailstock are shipped on a shipping skid. To

unpack the equipment, proceed as follows:

1. Carefully remove protective plastic wrapping from equipment.

2. Inspect the equipment for shipping damage.

3. Unbolt headstock from the shipping skid using a 3/4-inch socket.

4. Remove the top cover and attach eye bolts to the top of the housing and lift.

5. Place the equipment in a position using the layout prints.

WARNING

See the specification tables for drive assembly weight. Make sure that the lifing device is capable of handling the weight or injury to personnel can result.

NOTE Notify shipping contractor if there is any shipping damage.

NOTE Make sure there is room on all sides of the positioner for parts fixtures.

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4.3.3 Unbolting the Drive Assembly

Floor Mounting – Type II

Figure 4-17 provides dimensions for accurately floor mounting the MH3105 headstocks.

Fig. 4-17: MH3105 Floor Mounting

SHIPPING BOLT

SHIPPING SKID

1110.0 MM45 MM

415.0 MM

695.0 MM

45 MM

710.0 MM

6 X CLEARANCE FORM12 ANCHOR

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4.3.3.1 Installing the Type II Headstock

Before proceeding, refer to the system layout drawings to ensure precise set up location.

Refer to Figure 4-18 and proceed as follows:1. Set the column assembly in desired position.

2. Use leveling bolt holes as a guide and transfer the hole locations to the concrete.

3. Remove column assembly.

4. Install the anchors per the manufacture’s instructions.

5. Install a leveling shim at each anchor location and reset the column assembly.

6. Screw each leveling bolt down until it just contacts the leveling shim and hand tighten the anchor bolts or nuts.

Fig. 4-18: Leveling Hardware

4.3.3.2 Leveling the Type II Headstock

The headstock must be leveled in two directions;• Parallel to the faceplate

• Perpendicular to the faceplate.

Since it only takes three points to define a plane, use only three of the six leveling bolts to level the positioner. It is important to consistently use the same three leveling bolts throughout each process. The other three leveling bolts will be used as anchors only.

Before proceeding, make sure that the headstock is in the proper place. Make sure a leveling bolt, lock-nut, and leveling shim is installed in each column base hole.

To level the headstock assembly axially, proceed as follows:1. Place a level on top of the housing, perpendicular to the faceplate.

2. Use the two leveling bolts beneath the faceplate (A and B), and a third beneath the motor (C) to level axially. If the faceplate side needs adjustment, A and B must be turned equally.

LEVELING SHIM

ANCHOR (CUSTOMERSUPPLIED)

B

C

A

LEVELING BOLT

LOCK-NUT

HEADSTOCKRISER

FACEPLATE

COLUMN BASE

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To level the headstock assembly cross-axially, proceed as follows:1. Place a level on top of the housing, parallel to the faceplate.

2. Use the same three leveling bolts used above and adjust them until the level is balanced, adjusting B + C equally.

3. Repeat the axial and cross-axial leveling steps until level readings are achieved in both directions.

4. Drive the remaining leveling bolts down to their leveling shims.

5. Check level axially and cross-axially again. When level, tighten the anchor system (customer-supplied) to the specified torque.

6. Tighten the six lock-nuts to the column base.

4.3.4 Connecting the Cables

Do not connect the encoder, power, and ground cables until after the drive assembly is securely in place.

4.3.4.1 Connection to Motoman Controller

When the MH-Series SIGMA-5 Positioner assembly is delivered with a Yaskawa Motoman robot, connections between the two usually have been made at the factory, or if not, instructions for making connections can be found in the system manual. See separate schematics and/or documentation specific to the system.

4.3.4.2 Ground Cables – Type II

A ground cable bar is provided for attaching weld ground cables. Route the ground cables from the power source, up through the bottom of the Type II base, and attach to the ground cable bar.

Fig. 4-19: Ground Cable Connection MH3105

4.3.5 Home Position

The MH-Series SIGMA-5 Positioner are set in the HOME position at the factory. See Section 6, if HOME position must be adjusted.

HEADSTOCK

DRIVE ASSEMBLY

LUG BOLT

WELD GROUND

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4 Installation4.4 Tailstock Column Installation

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4.4 Tailstock Column Installation

4.4.1 Type I Installation

Before proceeding to install the tailstock, make sure the Type I headstock is anchored to the floor. If it is not, refer to Section 4.2.

To install the tailstock onto a cell base or floor, proceed as follows:1. Ensure the proper position of the headstock assembly per system

layout. The headstock must be permanently anchored to the floor/base.

2. Using a carpenter’s chalk string, strike a chalk line on the floor from the edge of the headstock base toward the location of the tailstock.

Fig. 4-20: Strike a Chalk Line

3. Set the tailstock in its approximate position on the floor using the chalk line.The headstock and tailstock are now facing each other.

4. Measure the distance (D) between the headstock and tailstock base. To find the distance (D) between the headstock base and tailstock base, use the following tailstock mounting formula:

D = PD + X (PD = Tooling pin-to-pin distance; X = MotoMount Offset)

Fig. 4-21: Tailstock Placement without Tooling - Type I

NOTE The placement position derived form this formula will position the tailstock in the nominal center position.

CHALKLINEHEADSTOCKCOLUMN BASE

HEADSTOCKCOLUMN BASE

TAILSTOCKCOLUMN BASED

CHALKLINE

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5. To find the X value in the tailstock mounting formula for the drive assembly, locate the drive assembly model name in Table 4-6

4.4.2 Type II Installation

To install the tailstock of a Type II assembly onto a cell base or floor, proceed as follows:1. Ensure the proper position for the headstock assembly per system

layout. The headstock must permanently anchored to the floor/base.

2. Using a carpenter’s chalk string, strike a chalk line on the floor from the edge of the headstock base towards location of the tailstock.

Fig. 4-22: Strike Chalk Line

3. Position the tailstock on the floor across from the headstock.

4. Use the chalk line and the center line of each component as guides for placement of the tailstock column on the floor.

5. To position the tailstock accurately on the bearing center line, make two measurements from the tailstock base to the chalk line and adjust the base as necessary.

Fig. 4-23: Tailstock Placement - Type II

Table 4-6: MotoMount Offset (X Value)

Type I System X - value

MHT95 - mm 8

MHT180 - mm 8

MHT505 - mm 57

MHT1605 - mm 168

MHT3105 - mm 145

NOTE

Keeping the center line of each component aligned is not critical. However, the closer the bearings of both components are aligned with one another, the greater the degree of misalignment allowed with other system components.

CHALKLINE

HEADSTOCKCOLUMN BASE

CHALK LINE 225 MM(8.85 IN.)

TAILSTOCKRISER BASE

D

HEADSTOCK/TAILSTOCKBEARING CENTERLINE

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4.4.3 Leveling the Tailstock

4.4.3.1 Type I Leveling Procedures

The tailstock must be leveled in two directions, axially and cross-axially. Since it only takes three points to define a plane, use only three of the four leveling bolts to level the system. It is important to consistently use the same three leveling bolts throughout each process. The fourth leveling bolt will be used as an anchor only.Before proceeding, make sure that the tailstock is in the proper place. Make sure a leveling bolt, lock-nut, and leveling shim is installed in each column base hole.

Fig. 4-24: Leveling the Tailstock - Type I

To level the tailstock assembly axially, proceed as follows:1. Place a level on top of the tailstock column in the axial direction.

2. Use the leveling bolts A, B, and C to adjust the axial level. Adjust bolts A and B equally.

To level the tailstock assembly cross-axially, proceed as follows:1. Place a level on top of the tailstock in the cross-axial direction.


3. Repeat the axial and cross-axial leveling steps until level readings are achieved both ways


5. Check level axially and cross-axially again. When level, tighten the anchoring system (customer-supplied) to the specified torque.


AXIAL

CROSS-AXIAL

DRIVE ASSEMBLY

AB

C

LEVELING SHIM

ANCHOR (CUSTOMER SUPPLIED)

LEVELING BOLT

LOCK-NUT

HEADSTOCKRISER

COLUMN BASE

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4.4.3.2 Type II Leveling Procedures

The Type II tailstock must be leveled in two directions, axially and cross-axially.Since it only takes three points to define a plane, use only three of the four leveling bolts to level the system. It is important to consistently use the same three leveling bolts through out each process. The fourth leveling bolt will be used as an anchor only.Before proceeding, make sure that the tailstock is in the proper place. Make sure a leveling bolt, lock-nut, and leveling shim is installed in each column base hole.

Fig. 4-25: Leveling the Tailstock - Type II

To level the tailstock assembly axially, proceed as follows:1. Place a level on top of the tailstock column in the axial direction.

2. Use the leveling bolts A, B, and C to adjust the axial level. Adjust bolts A and B equally.

To level the tailstock assembly cross-axially, proceed as follows:1. Place a level on top of the tailstock in the cross-axial direction.


3. Repeat the axial and cross-axial leveling steps until level readings are achieved both directions.


5. Check level axially and cross-axially again. When level, tighten the anchoring system (customer supplied) to the specified torque.


B

C

AXIAL

CROSS-AXIAL

A

LEVELING SHIM

ANCHOR (CUSTOMERSUPPLIED)

LEVELING BOLT

LOCK-NUT

HEADSTOCKRISER

COLUMN BASE

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4.4.3.3 Allowable Misalignment

The flexibility of MotoMount HD allows for a misalignment between the tailstock and the tooling fixture without affecting performance. A misalignment of 0.5 degrees is allowed. If the tailstock is out of alignment more than 0.5 degrees, adjust the tailstock using the tailstock leveling bolts.

Fig. 4-26: Allowable Axial Leveling - Side ViewLEVELINGDEVICE

0 – 0.5 DEGREE MAX.

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4.4.4 Tooling Fixture Installation (initial)

The initial tooling installation is required prior to the headstock/tailstock alignment procedure.1. Jog the headstock to the Home position. The tooling mounting holes

and locating pin must be pointing up. If not, remove the MotoMount drive components and re-install in the proper orientation.

2. Use a suitable lifting device to position the tooling above the headstock/tailstock assemblies.

3. Slowly lower tooling fixture while aligning with the headstock and tailstock locating pins.

Fig. 4-27: Tooling Fixture Installation - Headstock/Tailstock

4. Continue lowering the tooling until the hoisting straps are loose.

5. Secure the tooling to the drive assembly with customer supplied M12, grade 8.8 (or better) bolts and hardened washers. Eight hardened washers are included with the MotoMount kit for this purpose.

6. Remove the hoisting straps.

WARNING

Make certain servo power is OFF for the remainder of the installation, or serious operator injury and/or equipment damage may result.

CUSTOMER SUPPLIEDTOOLING FIXTURE

HARDENED WASHERS(MOTOMAN SUPPLIED)

CUSTOMER SUPPLIED BOLTSM12 GRADE 8.8

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4.4.5 Tooling Fixture Installation (regular)

1. Jog the headstock until MotoMount is horizontal. The tooling mounting holes and locating pin must be pointing up.

2. Use a suitable lifting device to position the tooling above the headstock assembly.

3. Slowly lower one side of the tooling fixture onto the headstock using the locating pin.

4. Install the M12 tool mounting bolts and washers onto the headstock (customer-supplied grade 8.8 bolts), and torque the bolts to 76 N•m (56 lbf-ft).

4.4.6 Final Alignment Check

The MotoMount system helps reduce the load on bearings due to tooling fixture misalignment with the headstock and tailstock. However, optimum performance is achieved when the alignment is as close as possible. Horizontal and vertical misalignment is possible. Both the horizontal and vertical alignment procedures require the measurement of the same gap on the MotoMount drive components. A tooling fixture must be installed to align the system.

4.4.6.1 Horizontal Alignment

Check the horizontal alignment by measuring the gap (see Figure 4-23) between the mounting fixture and mounting block. The measurement of this gap must not change more than 1 mm after the headstock is rotated 180 degrees. To check MotoMount’s horizontal alignment, proceed as follows:1. Jog the positioner until MotoMount is horizontal.

2. Using calipers, measure the alignment gap.

3. Rotate the positioner 180 degrees.

4. Measure the alignment gap at the second position. If the gaps differ by more than 1 mm, the horizontal alignment must be adjusted. Use the following procedure to adjust horizontal alignment:

• Calculate the average gap between the two positions, by adding both measurements together and dividing by two.

WARNING


NOTE The alignment procedure may be easier if the weld ground cable is removed.

NOTE It is important to measure the alignment gap at the same location. This will ensure proper alignment.

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• Loosen the bearing mounting bolts and move the tailstock bearing housing towards the direction of the larger gap until the gap is at the average value.

• Ensure the bearing housing is perpendicular to the tailstock adapter within 1/2 degree (a visual check with a square is acceptable).

• Repeat this process until the gap at both positions is within 1 mm. If moving the bearing housing cannot provide the desired results, the columns are out of basic alignment and must be repositioned.

• Tighten the bearing mounting bolts to 76 N • m (56 lbf-ft).

Fig. 4-28: Measurement Point for Horizontal Alignment, Bottom View HEADSTOCK FACEPLATE

ALIGNMENT GAP

MOUNTING BLOCK

DRIVE BUSHING

FIXTURE BLOCK

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4.4.6.2 Vertical Alignment

MotoMount must be at a vertical position to check the vertical alignment.

Fig. 4-29: Vertical Position - Drive Bushing on Bottom

The vertical alignment is checked by measuring the gap between the mounting fixture and mounting block. The measurement of this gap must not change more than 1 mm after the headstock is rotated 180 degrees.

To align MotoMount vertically, proceed as follows:1. Jog the positioner to vertical position until the drive bushing is at the

bottom.

2. Using calipers, measure the alignment gap.

3. Rotate the positioner 180 degrees until the drive bushing is at the top.

4. Measure the alignment gap at the second position. If the gaps are different by more than 1 mm, the vertical alignment must be adjusted. Use the following procedure:

• Calculate the average gap between the two positions by adding both measurements together and dividing by two.

• If the first measurement (with drive bushing at the bottom) is greater than the second measurement, the headstock must be raised until the gap is at the average gap value. Raise the headstock by making equal clockwise turns on the headstock leveling bolts.

DRIVE BUSHING

NOTE It is important to measure the alignment gap at the same location. This will ensure a proper alignment.

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• If the first measurement (with drive bushing at the bottom) is less than the second measurement, the tailstock must be raised until the gap is at the average gap value. Raise the tailstock by making equal clockwise turns on the tailstock leveling bolts.

Fig. 4-30: Vertical Position - Drive Busing on Top

• Recheck the alignment gap and verify that both gaps are within one mm. If multiple attempts fail to reduce the gap difference below one mm, contact Yaskawa Motoman Customer Service.

• Recheck the horizontal alignment.

• Insure ground cable is installed and properly secured.

• When horizontal and vertical alignment is complete, ensure all bolts are tightened to the appropriate torque, including tailstock bearing mounting bolts.

4.4.7 Tooling Fixture Removal

1. Jog the headstock until the MotoMount is horizontal, with the tool mounting bolts and locating pin pointed up.

2. Position a suitable lifting device and hoisting straps above the tooling. Attach the hoisting straps to the tooling fixture.

3. Remove the tool fixture mounting bolts and tailstock bearing cap.

4. Slowly lift the tooling fixture off the headstock/tailstock assemblies.

DRIVE BUSHING

WARNING

Make certain servo power is OFF for the remainder of the removal, or serious operator injury and/or equipment damage may result.

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4 Installation4.5 MotoMount Installation

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4.5 MotoMount Installation

The MotoMount drive components are usually delivered assembled to the drive assembly (MH95, MH185, or MH505). However, if retrofitting MotoMount on a system already installed in the plant, follow these instructions:

4.5.1 Preparation

Successful installation requires the MotoMount drive components be firmly mounted to the headstock faceplate. Before installation, ensure the faceplate is clean and is not warped or deformed.

4.5.2 Unpack and Assemble

The MotoMount system will be shipped in a box with the following components (unless it is part of a larger system):

• MotoMount drive components

• Dowel pins (2)

• Mounting hardware

• Weld ground cable

Carefully remove plastic wrapping from components and inspect them for

shipping damage.

4.5.2.1 Installing Fixture Dowel Pins

The dowel pins must be installed into the back of the mounting block before the assembly is mounted onto the faceplate. There are four holes in the back of the mounting block. See Figure 4-31 to determine which holes to use for your application. If your headstock faceplate does not have the matching dowel holes, it must be modified per the following template.

Fig. 4-31: MotoMount Mounting Hole Pattern

NOTENotify shipping contractor if there is any shipping damage.

M12 X 1.75MH95/185 DOWEL

POSITION

250.00 MM +/- 0.015

125 MM

CENTER OFROTATION DIA. 12.00 THRU

FOR DOWEL

200 MM

80 MM

100.0 MM

160.00 MM +/- 0.015

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To install the dowel pins, proceed as follows:

1. Use a small, 3-mm thick metal spacer (a 1/8-in. thick washer will work) to transfer the press force from the mounting block to the fixture block.

2. Place the spacer between the mounting block and the fixture block so that it is located behind the appropriate dowel hole.

3. Use an arbor press to force the dowel pins into the appropriate dowel pin hole in the mounting block. It is important that the dowel pin is pressed in as far as possible.

4. Relocate the spacer behind the other dowel hole and install the second dowel pin.

5. After the dowel pins are inserted properly, remove the spacer.

The MotoMount drive components are now ready to install onto the faceplate.

Fig. 4-32: Dowel Pin Installation

WARNING

Be sure to handle the MotoMount components carefully to avoid damage to the equipment or injury to personnel.

MH500MOUNTINGHOLES

ARBOR PRESS

DOWEL PIN

MH95/185MOUNTING HOLES

INSERT SPACER

FIXTURE BLOCK

MOUNTING BLOCK

ARBOR PRESSBASE

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4.5.3 Securing MotoMount Drive Components onto Faceplate

Use the previously inserted dowel pins to locate the exact position for the MotoMount drive components to the faceplate. To mount the fixture block onto the faceplate, proceed as follows:1. Jog the face plate to the Home position.

2. Align the previously installed dowel pins with the proper holes in the faceplate and push fixture block in as far as possible.

3. Insert both mounting bolts through the fixture block and tighten into the faceplate holes. Torque bolts to 76-N•m (56 lbf-ft.).

4. Install the ground cable with one lug secured to the fixture block. Use the fixture block hole nearest to the drive bushing. The other lug is secured to the appropriate hole in the headstock face plate.

Fig. 4-33: MotoMount Fixture Installation

4.5.4 Retrofitting Tailstock Assembly

Remove old tailstock and replace with new.

MOUNTING BLOCK

MOUNTING BOLT

GROUNDCABLE

HEADSTOCKFACEPLATE

FIXTURE BLOCK

M16 LOCATING PIN

DRIVEBUSHING

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4 Installation4.6 MotoMount HD Adjustments

4.6 MotoMount HD Adjustments

MotoMount HD is used on the MH1605 (Type I), and MH3105 (Type II) drive assemblies.The MotoMount components are delivered assembled to the headstock and tailstock assemblies. See Section 4.4 for installation of the headstock and tailstock assemblies.

Fig. 4-34: Nominal Center Position - Side View

4.6.1 Allowable Misalignment

The flexibility of MotoMount allows for misalignment between the tailstock and the tooling fixture without affecting performance. A total misalignment (combined tooling and headstock/tailstock) up to two degrees, from top view is permissible. If misalignment exceeds two degrees, check tooling and/or position of tailstock.

Fig. 4-35: Allowable Misalignment - Top View

22 MM

29 MM

TAILSTOCKCOLUMNTOP

ADAPTERCLAMP

ADAPTERSHAFT

TAILSTOCKADAPTER

TAILSTOCKCOLUMN

TOOLINGFIXTURE

TAILSTOCKADAPTER

TOOLINGFIXTURE

2 DEGREES

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4 Installation4.6 MotoMount HD Adjustments

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4.6.2 Tooling Fixture Installation – MotoMount HD

Both the headstock and tailstock must be permanently anchored to the floor and leveled prior to installation of the tooling fixture.1. Jog the headstock until MotoMount HD is horizontal. The tooling

mounting holes and locating pin must be pointing up.

2. Use a suitable lifting device to position the tooling above the headstock assembly.

3. Slowly lower one side of the tooling fixture onto the headstock using the locating pin.

4. Install the M16 tool mounting bolts and washers onto the headstock (customer-supplied grade 8.8 bolts), and torque the bolts to 190 N•m (140 lbf-ft). Hardened washers are recommended.

5. Slowly lower tooling fixture onto the tailstock using the locating pin.

6. Install the M16 tool mounting bolts and washers onto the tailstock (customer-supplied grade 8.8 bolts), and torque the bolts to 190 N•m (140 lbf-ft). Hardened washers are recommended.

7. Remove the hoisting straps.

4.6.3 Tooling Fixture Removal

1. Jog the headstock until the MotoMount is horizontal, with the tool mounting bolts and locating pin pointed up.

2. Position a suitable lifting device and hoisting straps above the tooling. Attach the hoisting straps to the tooling fixture.

3. Remove the tool fixture mounting bolts and tailstock bearing cap.

4. Slowly lift the tooling fixture off the headstock/tailstock assemblies.

WARNING


WARNING

The servo motor must be off for the remainder of the removal, or serious operator injury and/or equipment damage may result.

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4 Installation4.7 Conducting a Safety/Operation Check

4.6.4 Variable Tooling Size Accommodations

The MotoMount system can adapt to small variations in tooling fixture lengths without changing the tailstock’s performance or permanent location. Two steps can be taken to adjust the tooling fixture distance.

4.6.4.1 Changing Adapter Shaft Position

The preferred way change the adapter shaft position is to simply slide the tailstock adapter either way along the adapter shaft. If more adjustment is needed, loosen the four tailstock bolts and slide the adapter shaft and the tailstock adapter until a suitable position is acquired. These two processes do not effect MotoMount’s performance. It is important that a minimum distance is maintained between the tailstock adapter and the top of the tailstock column.

Fig. 4-36: Adapter Shaft Position

4.6.4.2 Reinstalling the Adapter Shaft

Once the new position for the adapter shaft is found, torque the tailstock bolts to 350 N•m (259 lbf-ft.).

4.7 Conducting a Safety/Operation Check

Before operating either MH-Series SIGMA-5 Positioner take a few minutes to perform a safety/operation check. To perform a safety/operation check, proceed as follows:1. Check that all cable connections are tight.

2. Verify the headstock and tailstock are level and parallel.

12.7 MM MINIMUM DISTANCE

ADAPTERSHAFT

TAILSTOCKADAPTOR

TAILSTOCKBOLT

TAILSTOCKCOLUMNTOP

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5 Tooling Recommendations5.1 Headstock Only – Tooling Recommendations

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5 Tooling Recommendations

Installation of tooling and fixtures should be performed by personnel who are familiar with the operation of this system. Tooling and fixtures are supplied by the customer.There are two system configurations possible with the MH-SERIES POSITIONER headstock only and headstock/tailstock with MotoMount. To ensure optimal performance from the MH-SERIES POSITIONER tooling system, Yaskawa Motoman makes the following recommendations for each configuration.

5.1 Headstock Only – Tooling Recommendations

The stand-alone headstock assembly provides the only support for tooling and production parts. Proper tooling design directly effects the headstock performance and longevity. All tooling practices apply to the headstock assembly whether it is accompanied by a column or not.

Fig. 5-37: Headstock Assembly - Type I

Fig. 5-38: Headstock Assembly - Type II

HOUSING

COLUMN

FACEPLATEAC SERVOMOTOR

FACEPLATE

HOUSING

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5.1.1 Customer-supplied Tooling Fixture

The customer-supplied tooling hangs from the faceplate as it supports production parts for welding. Customers control/change the design of tooling fixtures to match the design of the production parts.

5.1.1.1 Recommendations

To ensure optimum performance from the customer-supplied tooling fixture, please read the following recommendations:

• Use all bolt holes on the faceplate to mount the tooling fixture.

• Use the dowel pins.

5.1.1.2 Mounting Holes – Faceplate

The customer-supplied tooling must be designed to fit the MH-SERIES POSITIONER faceplate mounting holes. See the following figure for the faceplate mounting hole pattern;

• Figure 5-39 for MH95/185 faceplate

• Figure 5-40 for MH505 faceplate

• Figure 5-41 for MH1605 faceplate

• Figure 5-42 for the 3105 faceplate

Fig. 5-39: Mounting Holes on Faceplate MH95/185

100.0 MM

80.0 MM 80.0 MM

100.0 MM

100.0 MM 100.0 MM

4 X 12 X 1.7518 MM DEEP

2 X SLIP FIT FORM12 DOWEL

320.0 MM

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Fig. 5-40: Mounting Holes on Faceplate MH505


100 MM 100 MM

250 MM

125 MM

2 X SLIP FITFOR M12

DOWEL

4 X M12 x 1.75

100 MM

100 MM

CAUTION

To proper secure fixture, rated loads required the use of all M16 mounting holes.

0.0

30 MM OD X 6 ID THRUPILOT – 1/8-28 BSPT

M16 X 2 THRU

225.0 MM

274.5 MM

30 MMTYP.

TYP.12.5 MM

4 X M10 1.5 THRU

2 X M12 THRU

225.0 MM

194.9 MM 194.9 MM

112.5 MM 112.5 MM0.0

225.0 MM

194.9 MM

112.5 MM

225.0 MM

194.9 MM

112.5 MM

5 MM DEEP200 MM

284.5 MM

264.5 MM

TYP.

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0.0

0.0

DIA. 120 THRU

M16 X 2 THRU

225.0 MM

274.5 MM

30 MMTYP.

TYP.12.5 MM

4 X M10 1.5 THRU

2 X M12 THRU

225.0 MM

194.9 MM 194.9 MM

112.5 MM 112.5 MM

225.0 MM

194.9 MM

112.5 MM

225.0 MM

194.9 MM

112.5 MM

5 MM DEEP200 MM

284.5 MM

264.5 MM

TYP.

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5 Tooling Recommendations5.2 Headstock/Tailstock with MotoMount

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5.2 Headstock/Tailstock with MotoMount

5.2.1 Customer-supplied Tooling Fixtures

With MotoMount, the customer-supplied tooling fixture bridges the headstock and tailstock together as it supports production parts for welding. Customer design their tooling fixtures to fit their specific needs. Modifications to existing tooling fixtures will be minimal as long it fits the current headstock/tailstock configuration (retrofit application)

5.2.2 Multiple Tooling Fixtures

Some applications require multiple tooling fixtures that are switched in and out of the positioner as production needs change. To prepare these extra fixtures to work with MotoMount, the following spare parts are needed:

• Bearing adapter

• Bearing

Contact Yaskawa Motoman Customer Service at (937) 847-3200, to purchase these parts.

5.2.3 Specifications

To ensure that the customer-supplied tooling fixture fits properly to MotoMount, the following specifications must be met.

5.2.3.1 Parallelism

Inspect both mounting flanges for parallelism to one another. The combined angle of misalignment for both flanges should not exceed 1/2 degree (Figure 5-43).

Fig. 5-43: Tooling Fixture Inspection

FLANGE

TOOLING FIXTURE1/4-DEGREE ANGLE OF MISALIGNMENT

1/4-DEGREE ANGLE OF MISALIGNMENT

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5.2.3.2 Hole Pattern on MotoMount

The tooling fixture flange that attaches to MotoMount must have the following hole pattern (Figure 5-44).

Fig. 5-44: Tooling Template - MotoMount

5.2.3.3 Hole Pattern on MotoMount HD

The tooling fixture flange that attaches to MotoMount HD must have the following hole pattern (Figure 5-45).

Fig. 5-45: Tooling Template - MotoMount HD

SLIP FIT FOR M16 LOCATING PIN

2 X DIAM. 13 MM177.8 MM

88.9 MM

400 MM

200 MM

200 MM

4 X 17.5 MM

43.5 MM

20 MM31.8 MM 100 MM

SLIP FIT FOR M16 LOCATING PIN

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5.2.3.4 Headstock Flange Specifications

Figure 5-46 shows the specifications for the tooling fixture flange that is secured to MotoMount. 5.2.3.5 shows the specifications for the tooling fixture flange that is secured to MotoMount and MotoMount HD.

Fig. 5-46: Drive Component Clearance - MotoMount

Fig. 5-47: Drive Component Clearance - MotoMount HD

5.2.3.5 Tailstock Flange Specifications

Figure 5-48 shows the specifications for the tooling fixture flange that is secured to the MotoMount tailstock adapter. Figure 5-49 shows the specifications for the tooling fixture flange that is secured to the

CENTERLINE

12.5

48.2

88.9

Ø30

15.1

TOOLING FIXTURE

2X M12 X 1.75 ` 25.0

88.9

Ø 16.0 LOCATING PIN

32 MM MAXIMUM

MOTOMOUNT

TOOLINGFIXTUREFLANGE 50 MM MINIMUM

LOCATING PIN

CENTERLINE

90 MM DIAM X 20 MM DEEPSHAFT CLEARANCE REQUIREDFOR AUXILIARY MOUNTING

63.5 MM

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MotoMount HD tailstock adapter.

Fig. 5-48: Tailstock Adapter - MotoMount

Fig. 5-49: Tailstock Adapter - MotoMount HD

36.5 +/- 7 MM MINIMUM

TOOLINGFIXTUREFLANGE

70 MMMINIMUM

TAILSTOCKADAPTER

TOOLINGFIXTUREFLANGE

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5.2.3.6 Auxiliary Mounting Holes – MotoMount HD

To further secure the tooling fixture, there are two auxiliary mounting holes Figure 5-50 on the face of the MotoMount HD tooling adapter. These auxiliary mounting holes are for added security only. Do not use the auxiliary mounting holes for the primary tooling support.Center shaft clearance required on the tooling fixture when using auxiliary mounting holes on the headstock are shown in Figure 5-47. Center shaft clearance required when using auxiliary mounting holes on the tailstock are shown in Figure 5-50.

Fig. 5-50: Auxiliary Mounting Holes

63.5 MM

175.0 MM 175.0 MM

2 X M16 X 2.0 THRU

DIAM. 90 MM THRU

TAILSTOCKADAPTER

31.8 MM

TAILSTOCKADAPTER

TOOLING PIN

90 MM DIAM X 40 MM DEEPSHAFT CLEARANCE REQUIREDFOR AUXILIARY MOUNTING

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6 Maintenance6.1 Spare Parts

6 Maintenance

Maintenance of the MH-SERIES POSITIONER components should be performed only by authorized personnel who are familiar with the design and construction of this positioner. The following procedures should be performed only as needed. Read through the instructions completely before performing any maintenance procedure. Be sure to understand the procedure, have the proper tools, and observe all applicable safety precautions.

6.1 Spare Parts

When a part malfunctions, it is helpful to have replacement parts in stock for quick replacement. Table 6-1: lists the recommended spare parts with Yaskawa Motoman part numbers. Motoman recommends the following parts be kept on hand:

6.2 Servomotor

The AC servomotor has no wear parts (i.e. brushes), so a simple daily inspection is sufficient. Do not disassemble the motor. Contact the Yaskawa Motoman Customer Service at (937) 847-3200 when an overhaul becomes necessary.

WARNING

Ensure that servo power is off before performing the following procedures. Observe standard lockout/tageout practices.

Table 6-1: Recommended Spare Parts

Component MH95/185/505/1605/3105 RecommendedQuantity

Weld Ground Brush Post 144370-1 1

Weld Ground Brush Holder 144372-1 1

Switch 149473-1 3

Brush 144371-1 1

Grease Moly white RE00132412-1

1

NOTEThe motor and reducer are not recommended for field service. The unit should be returned to Yaskawa Motoman for repairs to these components.

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6 Maintenance6.3 Weld Ground Brush Replacement – Type I

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6.3 Weld Ground Brush Replacement – Type I

6.3.1 MH95/185/505/1605

To replace the grounding brush(s) proceed as follows:1. Shut down cell using main disconnect.

2. Use a flathead screwdriver to disconnect the brush cable(s) from the ground post (Figure 6-1).

Fig. 6-1: Brush Cable Removal

3. Release the spring tensioner on the back of the brush by squeezing both black spring levers and pulling away from the faceplate.

4. Reach in and steady the brush case with one hand.

GROUND POST

GROUND BRUSHCABLE

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5. Use a 7/16-in. wrench to loosen and remove the two screws on top of the housing (Figure 6-2) that retains the case.

Fig. 6-2: Brush Assembly

6. Lower the case below the retaining edge, and slowly pull the brush holder out of the housing (Figure 6-3).

Fig. 6-3: Brush removal MH95/185/505/1605

NOTE When pulling the brush holder out, identify and secure the nut plate that slides in the top side of the case.

FACE PLATE

BRUSH NUT

RETAININGEDGE

BRUSH

VERIFY FULLCONTACT WITHFACEPLATE

SERVOMOTOR

RETAININGSCREW

FACE PLATE

HOUSING

BRUSHHOLDER

1/4 IN. SCREW

BRUSH HOLDERWITH BRUSH

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7. Slide the old brush out of the housing and replace it with the new one.

8. Put the brush holder back into housing compartment until the both holes on the nut plate are aligned with holes in the housing.

9. Insert both screws through housing and into nut plate. Thread the screws into nut plate loosely.

10. Push the brush holder up in front of the retaining edge and hold steady.

11. Squeeze the brush retaining spring and push the brush against the faceplate then release. The spring must hold the brush firmly against the face plate (Figure 6-2).

12. Tighten the screws to 6.0 N•m (4.4 lbf-ft.).

13. Insert the ground cables onto the ground posts.

CAUTION

The weld ground brush must be affixed hold and evenly against the faceplate. Uneven contact can subject the gear reducer bearing to weld current.

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6 Maintenance6.4 Weld Ground Brush Replacement – Type II

6.4 Weld Ground Brush Replacement – Type II

6.4.1 MH3105

To replace the grounding brush(s) proceed as follows:1. Shut down cell using main disconnect.

2. Remove the back panel of the drive assembly.

3. Use a flathead screwdriver to disconnect the brush cable(s) from the ground post (Figure 6-4).

Fig. 6-4: Brush Cable Post

4. Release the spring tensioner on the back of the brush by squeezing both black spring levers and pulling away from the faceplate.

5. Reach in and steady the brush case with one hand.

HEADSTOCK

DRIVE ASSEMBLY

GROUND BRUSHCABLE

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6 Maintenance6.4 Weld Ground Brush Replacement – Type II

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6. Use a 7/16-in wrench to loosen and remove the two screws on top of the housing (Figure 6-5) that retains the case.

Fig. 6-5: Brush Assembly

7. Lower the case below the retaining edge, and slowly pull the brush holder out of the housing (Figure 6-6).

Fig. 6-6: Brush Removal 3105

NOTE When pulling the brush holder out, identify and secure the nut plate that slides in the top side of the case.

BRUSH NUT

BRUSH

VERIFY FULLCONTACT WITHPLATE

RETAININGSCREW

BRUSHHOLDER

HOUSING

MOTOR

BRUSH

HOUSING

HEADSTOCK

DRIVE ASSEMBLY

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6 Maintenance6.5 Reset Headstock To Home Position

8. Slide the old brush out of the housing and replace it with the new one.

9. Put the brush holder back into housing compartment until the both holes on the nut plate are aligned with holes in the housing.

10. Insert both screws through housing and into nut plate. Thread the screws into nut plate loosely.

11. Push the brush holder up in front of the retaining edge and hold steady.

12. Squeeze the brush retaining spring and push the brush against the faceplate then release. The spring must hold the brush firmly against the face plate (Figure 6-2).

13. Tighten the screws to 6.0 N•m (4.4 lbf-ft.).

14. Insert the ground cables onto the ground posts.

6.5 Reset Headstock To Home Position

The home position on the drive assembly is set in the controller by the operator. Any position of the headstock can be programmed as home. The factory setting of home position is found using the alignment hole, an alignment tool, and the programming pendant.Resetting of the home position is typically done before new tooling and fixturing is installed, or when the motor has been serviced.

6.5.1 Homing

6.5.1.1 MH95/185/505/1605 – Type I

The factory home position for Type I positioners is located by aligning the homing pin against the housing, after installing the pin in the faceplate hole. Once Home position is found, some minor programming with the programming pendant is required. To reset a MH95/MH185/MH505/MH1605 headstock, proceed as follows:1. Make sure robot(s) is in home position.

CAUTION

The weld ground brush must be hold firmly and evenly against the faceplate. Uneven contact can subject the gear reducer bearing to weld current.

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2. Using the programming pendant in TEACH MODE, jog the faceplate slowly until the homing hole is near the home feature on the side of the housing (Figure 6-7).

Fig. 6-7: Home Position - Type I

3. Once the faceplate has been jogged close to the Home position, install the homing pin through the hole in the faceplate. The pin may need to be tapped in with a hammer.

4. Slowly jog the drive assembly until the plastic pin just touches the home feature (Figure 6-7) on the housing. If you go too far the pin will bend, causing a gap at the other end of the pin. Slowly jog the faceplate in reverse rotation until the gap closes.

• Now that the faceplate has been set to home position, proceed with Step 5 of resetting instructions:

HOMINGHOLE

HOMINGPIN

HOME FEATURE

ROTATE

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5. Switch the programming pendant to MAINTENANCE MODE and proceed:

• Press TOP MENU key on programming pendant.

• Cursor to ROBOT and press SELECT.

• Cursor to HOME POSITION and press SELECT.

• Press the PAGE OVER key to the desired station (indicated in the top right corner).

• Make sure the headstock is in the position that you want to teach as home and press SELECT.

• Cursor to YES and press SELECT. The headstock is now reset to zero

6.5.1.2 MH3105 – Type II

The factory home position is located by aligning two homing pins after installing them into holes in the faceplate and housing. Once both pins are aligned, some minor programming with the programming pendant is required. To reset each a MH3105 headstock, proceed as follows:1. Make sure robot(s) is in home position.

2. Locate the headstock homing hole. Using the programming pendant in TEACH MODE, jog the faceplate slowly until the faceplate homing hole is just below to the headstock homing hole.

3. Install the faceplate homing pin through the faceplate homing hole in the faceplate. The pin may need to be tapped in with a hammer.

4. Install the headstock homing pin through the headstock homing hole in the headstock. The pin may need to be tapped in with a hammer.

5. Slowly jog the faceplate until faceplate homing pin just touches the headstock homing pin (Figure 6-8) on the housing. If you go too far both pins will bend, causing an inaccuracy. Slowly jog the faceplate in reverse rotation until the both pins are straight and still touching each other.

Fig. 6-8: Home Position - Type II

HEADSTOCKHOMING PIN

HEADSTOCKHOMING HOLE

FACEPLATE

FACEPLATEHOMING PIN

HEADSTOCKHOMING HOLE

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6. Switch the programming pendant to MAINTENANCE MODE and proceed:

• Press TOP MENU key on programming pendant.

• Cursor to ROBOT and press SELECT.

• Cursor to HOME POSITION and press SELECT.

• Press the PAGE OVER key to the desired station (indicated in the top right corner).

• Make sure the headstock is in the position that you want to teach as home and press SELECT.

• Cursor to YES and press SELECT. The headstock is now reset to zero.

7. Remove both alignment pins from the faceplate headstock.

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6 Maintenance6.6 Maintenance Schedule

6.6 Maintenance Schedule

6.6.1 MH-Series SIGMA-5 Positioner

See Table 6-2: for the periodic maintenance schedule.

6.6.2 MotoMount

See Table 6-3: for periodic maintenance procedures.

Table 6-2: Maintenance Schedule

Inspection Item

Frequency Inspection Operation

Physical damage

Daily Check for physical damage; this indicates a load collision and is evidence of misuse.

Excessive or unusual noise

Daily Listen for grinding, excessive or irregular noise. Contact Yaskawa Motoman Service Department at (937) 847-3200.

Weld Brushes

First Week Check for dirt and ensure full contact with faceplate.

Weekly Check for dirt and ensure full contact with faceplate.

Cleaning As required Clean with dry cloth or compressed air.

Lubrication Every 20,000 hours or 5 years

Flush and relubricate using Moly white grease.

Table 6-3: Periodic Maintenance

Frequency Procedure

Daily Using compressed air or a suitable brush, remove any weld spatter and dirt from the drive components with particular attention to the drive bushing area.

Verify tooling bolts are tight.

Monthly Provide 2-3 pumps of grease (Motoman, Inc. 133174-2, Kluber #039067, Lubriplate 3000, or equivalent) to the main bearing zerk fitting.

Verify the leveling and lag bolts are tight on the headstock/tailstock columns

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6 Maintenance6.7 Troubleshooting

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6.7 Troubleshooting

6.7.1 MH-Series SIGMA-5 Positioner

6.7.2 MotoMount

6.7.2.1 High Duty Cycles

High duty cycles under heavy loads and/or dirty operating conditions may cause the drive bushing to wear. This may be indicated by an increase in the tooling position repeatability. Call Yaskawa Motoman Customer Service for details.

Table 6-4: Troubleshooting

Symptom Probable Cause Corrective Action

Motor does not start Loose connection Check all wire connections.

Incorrect wiring Check that system has been wired correctly.

Overload Reduce load or reduce unbalanced load.

Unstable operation Incorrect wiring Inspect and correct wiring across motor terminals L1, L2, L3, and PE.

Motor overheats Excessive ambient temperature

Reduce ambient temperature below 40° C (104° F). Positioner has an operating range of 0 to 45° C (32 to 113°F).

Motor surface is dirty Clean motor surface.

Motor overloaded Reduce load or unbalanced load.

Unusual noise Motor loosely mounted Tighten mounting bolts.

Positioners misaligned Realign headstock/tailstock (see Section 4.4.3, "Leveling the Tailstock")

Noisy bearing Check alignment, noise of bearing, lubrication. Call Yaskawa Motoman Customer Service.

Weld quality bad Brushes misaligned Remove brush(s) and reinstall them properly. Recheck as needed.

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A Performance ChartsA.1 MH-Series Positioner Assemblies

A Performance Charts

A.1 MH-Series Positioner Assemblies

A.1.1 MH95

Fig. A-1: MH95 Performance ChartsRated Peak

Holding Torque (N*m)= 195 225

Load CG Offcenterr (mm) Rated W (kgf) Max W (kgf)

40 497 57460 332 38380 249 287100 199 230120 166 191140 142 164160 124 143180 111 128200 99 115220 90 104240 83 96260 77 88280 71 82300 66 77

Maximum Bearing Moment (N*m) = 882

Load CG Overhang (from Tooling Plate)D (mm) Rated W (kgf) Max W (kgf)

50 275 41360 260 38980 233 349100 211 316120 193 289140 178 266160 165 247180 153 230200 144 215220 135 202240 127 191260 120 181280 114 171300 109 163

HTS Applications assume 1/2 load onNote: headstock @ 50 mm, using MotoMount.

2) Rated load based upon 50% maximum bearingmoment.3) Maximum load based upon 75% maximum bearing moment.

Reflected RatioLoad Inertia Jl/Jm

20 2.522 2.7524 326 3.2528 3.530 3.7532 434 4.2536 4.538 4.7540 5

Note: Maximum recommend inertia ratio is 5.

Rated Bearing Moment; Load CG Overhang

0

50

100

150

200

250

300

350

400

450

0 50 100 150 200 250 300

CG Distance from Tooling Plate, D (mm)

App

licat

ion

Load

, W (k

gf)

Rated W (kgf)

Max W (kgf)

Allowable Load Inertia

2

2.5

3

3.5

4

4.5

5

5.5

15 16 17 18 19 20 21 22 23 24 25 26 27 28 29

Application Inertia, kg*m2

Iner

tia R

atio

, Jl/J

m

Jl/Jm

Holding Torque; Load CG Offcenter

0

100

200

300

400

500

600

700

0 50 100 150 200 250 300

Rated W (kgf)

Max W (kgf)

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A.1.2 MH185




40 763 88060 508 58780 381 440100 305 352120 254 293140 218 251160 191 220180 169 196200 153 176220 139 160240 127 147260 117 135280 109 126300 102 117



50 275 41375 239 358100 211 316125 189 283150 171 256175 156 234200 144 215225 133 199250 124 186275 116 174300 109 163325 103 154350 97 146375 92 138400 88 131425 84 125450 80 120475 76 115500 73 110

HTS Applications assume 1/2 load onNote: headstock @ 50 mm, using MotoMount.

2) Rated load based upon 50% maximum bearingmoment.3) Maximum load based upon 75% maximum bearing moment.


47 2.551 2.7556 361 3.2566 3.570 3.7575 480 4.2584 4.589 4.7594 5



0

100

200

300

400

500

600

700

800

900

1000

0 50 100 150 200 250 300

Rated W (kgf)

Max W (kgf)


0

50

100

150

200

250

300

350

400

450

0 100 200 300 400 500


App

licat

ion

Load

, W (k

gf)

Rated W (kgf)

Max W (kgf)


2

2.5

3

3.5

4

4.5

5

5.5

58 68 78 88 98 108


Iner

tia R

atio

, Jl/J

m

Jl/Jm

A-2

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A.1.3 MH505



Load CG Offcenter from Tooling Plater (mm) Rated W (kgf) Max W (kgf)

80 1057 1219100 845 976120 705 813140 604 697160 528 610180 470 542200 423 488220 384 443240 352 406260 325 375280 302 348300 282 325



50 537 80575 478 717100 431 647125 393 589150 361 541175 333 500200 310 465225 289 434250 271 407275 256 384300 242 362325 229 344350 218 327375 207 311400 198 297425 190 284450 182 273475 174 262500 168 252

Note: HTS Applications assume 1/2 load onheadstock @ 50 mm, using MotoMount.2) Rated load based upon 50% maximum bearingmoment.3) Maximum load based upon 75% maximum bearing moment.


105 2.5115 2.75126 3136 3.25147 3.5157 3.75168 4178 4.25189 4.5200 4.75210 5


Holding Torque; Load CG Offcenter (from Tooling Plate)

0

200

400

600

800

1000

1200

1400

0 50 100 150 200 250 300

Load CG Offcenter, r (mm)

App

licat

ion

Load

, W (K

gf) Rated W (kgf)

Max W (kgf)


0

100

200

300

400

500

600

700

800

900

0 100 200 300 400 500CG Distance from Tooling Plate, D (mm)

App

licat

ion

Load

, W (k

gf)

Rated W (kgf)

Max W (kgf)


2

2.5

3

3.5

4

4.5

5

5.5

110 130 150 170 190 210 230 250


Iner

tia R

atio

, Jl/J

m

Jl/Jm

A-3

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162068-1CD


A.1.4 MH1605


Holding Torque (N*m) 2826 3261


40 7202 830960 4801 554080 3601 4155100 2881 3324120 2401 2770140 2058 2374160 1800 2077180 1600 1847200 1440 1662220 1309 1511240 1200 1385260 1108 1278280 1029 1187300 960 1108



50 1284 192760 1240 186080 1160 1740100 1090 1635120 1028 1541140 972 1458160 922 1383180 877 1316200 836 1255220 799 1199240 765 1148260 734 1101280 705 1058300 679 1018

Note: HTS Applications assume 1/2 load onheadstock @ 50 mm, using MotoMount.2) Rated load based upon 50% maximum bearingmoment.3) Maximum load based upon 75% maximum bearing moment.


672 2.5742 2.75811 3880 3.25950 3.5

1019 3.751088 41158 4.251227 4.51296 4.751365 5



0

500

1000

1500

2000

2500

0 50 100 150 200 250 300CG Distance from Tooling Plate, D (mm)

App

licat

ion

Load

, W (k

gf)

Rated W (kgf)

Max W (kgf)


2.5

3

3.5

4

4.5

5

5.5

678 778 878 978 1078 1178 1278 1378 1478


Iner

tia R

atio

, Jl/J

m


0

1000

2000

3000

4000

5000

6000

7000

8000

9000

0 50 100 150 200 250 300

CG Offcenter, r (mm)

App

licat

ion

Load

, W (k

gf) Rated W (kgf)

Max W (kgf)

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A.1.5 MH3105

Fig. A-5: MH3105 Performance Charts

Rated PeakHolding Torque (N*m)= 5479 6322


50 11170 1288860 9308 1074080 6981 8055100 5585 6444120 4654 5370140 3989 4603160 3491 4028180 3103 3580200 2792 3222220 2539 2929240 2327 2685260 2148 2479280 1995 2301300 1862 2148



50 3174 4761100 2757 4135150 2437 3655200 2183 3274250 1977 2966300 1807 2710350 1664 2495400 1541 2312450 1436 2154500 1344 2016550 1263 1895600 1191 1787650 1127 1691700 1070 1605750 1018 1527800 971 1456850 928 1392900 889 1333950 852 1279

Note: 1) HTS Applications assume 1/2 load onheadstock @ 50 mm, using MotoMount.2) Rated load based upon 50% maximum bearingmoment.3) Maximum load based upon 75% maximum bearing moment.


3058 2.53394 2.753730 34066 3.254402 3.54738 3.755073 45409 4.255745 4.56081 4.756417 5



2

2.5

3

3.5

4

4.5

5

5.5

3000 3500 4000 4500 5000 5500 6000 6500


Iner

tia R

atio

, Jl/J

m

Jl/Jm


0

500

1000

1500

2000

2500

3000

3500

4000

4500

5000

0 200 400 600 800 1000


App

licat

ion

Load

, W (k

gf)

Rated W (kgf)

Max W (kgf)


0

2000

4000

6000

8000

10000

12000

14000

0 50 100 150 200 250 300

Rated W (kgf)

Max W (kgf)

Load CG Offcenter r(mm)

App

licat

ion

Load

, W (k

gf)

A-5

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B Illustrated Parts listB.1 Introduction

162068-1CD


B Illustrated Parts list

B.1 Introduction

This Illustrated Parts List identifies, describes, and illustrates detail parts of the main assemblies for the MH-SERIES POSITIONER manufactured by Yaskawa Motoman.This list provides parts identification and descriptive information for use in provisioning, requesting, purchasing, storing, and issuing spare parts.

B.1.1 Contents

The parts list contains a breakdown of the equipment into detail parts. All parts of the equipment are listed except the following:1. Standard hardware items (attaching parts) such as nuts, screws,

washers, etc., which are available commercially.

2. Bulk items such as wire, cable, sleeving, tubing, etc., which are also commercially available.

3. Permanently attached parts which lose their identity by being welded, soldered, riveted, etc., to other parts, or assemblies.

B.1.2 Parts List

This form is divided into four columns as follows:1. “Figure - Item Number” Column

• This column lists the figure number of the illustration applicable to a particular parts list and also identifies each part in the list by an item number. These item numbers also appear on the illustration. Each item number on the illustration is connected to the part to which it pertains by a leader line and arrow. Thus, the figure and item num-bering system ties the parts list to the illustrations and vice versa

2. “Motoman Part Number” Column

• All part numbers appearing in this column are Yaskawa Motoman part numbers.

3. “Description” Column

• The item nomenclature appears in this column.

4. “QTY” Column

• This column indicates the quantity of parts required for an assembly or subassembly in which the part appears. This column does not necessarily reflect the total used in the complete end item.

B-1

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B.1.3 Symbols and Abbreviations

The following is a list of symbols and abbreviations used in the parts list.• amp – ampere

• AC – alternating current

• cyl – cylinder

• DC – direct current

• fig – figure

• hex – hexagon

• ID – inside diameter

• in – inch

• m – meter

• mm – millimeter

• No– number

• psi – pounds per square inch

• v – voltage

B-2

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B.1

Introduction

B-3

16

206

8-1C

D

162068-1CD

Fig. B-1: MH95/M185 Head Stock

302

11

12

15 16

10

918

17

32 6

31

33

34 26

TORQUE TO 40.0 Nm

TORQUE TO 3.6 Nm

81/99

24

27

19

1

22

23

6

2920

19

19

3

5

6

4

7

25

26

1413

38

TORQUE TO 6.0 Nm

TORQUE TO 73.5 Nm

TORQUE TO 15.6 Nm

162068-1CD



Table B-1: MH95/M185 Head Stock Parts ListItem P/N Title Qty

B-1 158238-1 DRIVE ASSY, MH95, HEADSTOCK SERVO REF

1 158241-2 PLATE, FACE, MH95/185 HEADSTOCK 1

2 156009-1 MOTOR, AC SERVO, 450W, SIGMA V 1

3 158242-1 HOUSING, MH95/185 HEADSTOCK 1

4 144371-1 BRUSH, GROUND, METAL, GRAPHITE 1

5 130235-3 SCREW,HHC,1/4-20X5/8,ZP,GR5 2

6 470602-1 WASHER, CONICAL, SPRING, M6 22

7 144372-1 BRUSH HOLDER, 1" X 1.5" X 2" 1

8 144370-1 TERMINAL, QUICK DISC, WELD GROUND LUG 2

9 479154-1 CLAMP, CABLE SUPPORT 1

10 407249-3 SCREW,SHC,M6x12 1

11 407248-6 SCREW, SHC, M8 X 25, CLASS 12.9 4


13 133984-1 NAMEPLATE, GROUND 1

14 132616-3 SCREW,HHC,M8 X 16 1

15 479148-5 WASHER_LOCK_M8 1

16 479147-5 WASHER_FLAT_M8 1

17 158342-1 SCREW, PPH, M4x0.7 X 8, MACHINE 4

18 479154-4 TIE MOUNT 4

19 479281-105 FITTING, PLUG, 1/8BSPT, BLACK 3

20 158941-9 LABEL, PRODUCT ID 1

21 133963-3 BOLT,EYE,M10,DIN 580 2

22 146122-1 SEAL KIT, RV-20E, O-RING S120, S100, & S12.5 1

23 407249-7 SCREW,SHC,M6X30,CLASS 12.9 16

24 479297-4 SCREW, SHC, M10x1.5 X 25, CLASS 12.9 6



27 133937-1 FITTING, ZERK 1/8 PT 1

29 145913-3 REDUCER, RV, MH95 HEADSTOCK 1

30 158686-1 GEAR, PINION, INPUT, RV REDUCER, 105:1 1

31 158244-1 BRACKET, MTG, LIMIT SWITCH 2

32 407249-4 SCREW_SHC_M6X16 4

33 149473-1 LIMIT SWITCH 2

34 479296-6 SCREW,SHC,M5X16 4

38 145896-1 PIN, HOMING 1

Below Items Replace Above Items For A MH185

B-1 158238-2 DRIVE ASSY, MH185, HEADSTOCK SERVO Ref

20 158941-10 LABEL, PRODUCT ID 1

29 145913-2 REDUCER, RV, RV-20E-161 1

30 158686-2 GEAR, PINION, INPUT, RV REDUCER, 161:1 1

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B.1

Introduction

B-5

16

206

8-1C

D

162068-1CD

Fig. B-2: MH505 Head Stock

4

38

15

35 2

27 28

TORQUE TO 40.0 Nm

29

7

6

30 31 32

20

19 15

18

16 17

TORQUE TO 3.6 Nm

83/99

4

37

9

10

TORQUE TO 73.5 Nm

TORQUE TO 37 Nm

1

34

33

28TORQUE TO 37 Nm

5

3

24

1523

TORQUE TO 6 Nm

22 25

21

36

162068-1CD



Table B-2: MH505 Head Stock Parts List

Item P/N Title Qty

B-2 158482-1 MH505 Positioner Assembly Ref

1 158484-2 PLATE, FACE, MH550/MSR205, HEADSTOCK 1

2 156009-3 MOTOR, AC SERVO, SIGMA V, 1.3 kW 1

3 158483-1 HOUSING, MH505/MSR205, HEADSTOCK 1


5 158941-11 LABEL, PRODUCT ID MH505 1

6 479154-4 TIE MOUNT 4

7 158342-1 SCREW, PPH, M4x0.7 X 8, MACHINE 4

8 133963-3 BOLT,EYE,M10,DIN 580 2

9 479297-4 SCREW, SHC, M10x1.5 X 25, CLASS 12.9 6



16 479296-6 SCREW,SHC,M5X16 4



19 407249-4 SCREW_SHC_M6X16 4


21 145896-1 PIN, HOMING 1


23 130235-6 SCREW, HHC, 1/4-20 X 1", ZP, GR5 4

24 130443-15 WASHER, FLAT, 1/4", SAE 4

25 144372-1 BRUSH HOLDER, 1" X 1.5" X 2", WELD GROUNDING

2





30 132616-3 SCREW,HHC,M8 X 16 1

31 479148-5 WASHER_LOCK_M8 1

32 479147-5 WASHER_FLAT_M8 1


34 146123-1 SEAL KIT, RV80E 1

35 141575-2 GEAR, PINION, INPUT, GEAR REDUCER, 153:1 1

36 151594-5 REDUCER, RV, RV-80E 1

37 133937-1 FITTING, ZERK 1/8 PT 1

38 407249-20 SCREW,SHC,M6X65 1

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B.1

Introduction

B-7

16

206

8-1C

D

162068-1CD

Fig. B-3: MH1605 Head Stock

34 35

37

36

22

23

7

TORQUE TO 73.5 Nm

TORQUE TO 318 Nm

2

85/99

TORQUE TO 29.5 Nm

TORQUE TO 6 Nm5

6

3

15

24

16

23

17

18

19

25

26

27

11

29

30

39

31

32

20

6

13

38

28

14

4

12

1110

TORQUE TO 3.6 Nm

TORQUE TO 3.6 Nm

TORQUE TO 3.6 Nm

TORQUE TO 128 Nm

TORQUE TO 128 Nm

33

1

162068-1CD



Table B-3: MH1605 Head Stock ComponentsItem P/N Title Qty

B-3 161825-1 MH1605 Positioner Assembly Ref

1 161829-1 HOUSING, MACHINED 1

2 161767-1 PLATE, FACE, MH-1605 DRIVE ASSY 1

3 156009-6 MOTOR, AC SERVO, SIGMA V, 3.7 kW 1

4 133963-4 BOLT, EYE, M16, DIN580 2


6 471075-1 WASHER, CONICAL SPRING, M12 20

7 145896-1 PIN, HOMING 1

8 144372-1 BRUSH HOLDER, 1" X 1.5" X 2" 2




12 130235-8 SCREW, HHC, 1/4 X 1 1/2 4


14 151592-7 REDUCER, RV, RV-320E, 185 1

15 152538-1 ADAPTER, FLYWHEEL, MRM2-250/750-M3X 1

16 151593-7 GEAR, INPUT, PINION, 185 1

17 145428-2 WASHER, FLAT, M8 X 16 OD X 3 THK 1


19 407248-21 SCREW, SHC, M8 X 100 1

20 146924-1 SEAL, O-RING, INPUT 1

21 133419-1 ADHESIVE, LOCTITE, #242, 0.5CC 1

22 133937-1 FITTING, ZERK 1/8 PT 1


24 147078-1 LABEL,WARNING 1

25 479154-4 CLAMP, CABLE SUPPORT 4

26 158342-1 SCREW,PPH,M4 X 07 X 8 4


28 158941-21 LABEL, PRODUCT ID,MH1605 TR 1

29 407249-4 SCREW_SHC_M6X16 4



32 479296-6 SCREW,SHC,M5X16 4

33 162068-1CD MANUAL, MH1605 DRIVE ASSEMBLY SIGMA 5 1


35 479297-7 screw_shc_m10x40 18

36 130532-2 SCREW, SHC, M16 X 35 6

37 132049-1 WASHER, CONICAL SPRING, GTS16 6


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B.1

Introduction

B-9

16

206

8-1C

D

162068-1CD

Fig. B-4: Type II Drive Assembly Components

6

7

8

9

87/99

1 23

4 52120

18

13

11

1010

22

19

15

16

17

162068-1CD



Table B-4: Type II Drive Assembly ComponentsItem P/N Title Qty

B-4 162579-3 DRIVE ASSY,TYPE II,SIGMA 5 Ref

1 146198-1 PLATE, DRIVE ASSY 1

2 146199-1 PLATE, FACE, 2000kg HEADSTOCK 1

3 130532-3 SCREW, SHC, M16 X 40 15

4 132049-1 WASHER, CONICAL SPRING, GTS16 32

5 146010-1 HOUSING, CAST, POSITIONER 1

6 162584-1 PLATE, MTG, DRIVE ASSY, TYPE II 1

7 131272-7 SCREW,HHC,M12X40,GRADE 8.8 10


9 162580-1 MOTOR ASSY,AC SERVO,4.4KW,SIGMA 5,TYPE II

1


11 479296-9 SCREW, SHC, M5 X 30 4



14 146015-2 BRACKET, MTG, BRUSH HOLDER 3

15 407249-8 SCREW, SHC, M6 X 35 6


17 130060-12 SCREW, SHC, 1/4”20 X 2 1/2”, GR8 6

18 130444-5 WASHER, LOCK, 1/4 6

19 130443-15 WASHER, FLAT, 1/4”, SAE 6


21 144372-1 BRUSH HOLDER, 1" X 1.5" X 2" 3

22 140837-6 PIN,DOWEL,M10X35 2


24 131272-3 SCREW,HHC,M12X35,GRADE 8.8 2

25 133937-1 FITTING, ZERK 1/8 PT 1

26 145785-1 FITTING, PLUG 2

27 130532-21 SCREW,SHC,M16X25 17

28 146742-2 GEAR ASSY, COMPOUND 1

29 146970-1 GEAR ASSY, IDLER 1

30 407249-5 SCREW, SHC, M6 X 20 4

31 146743-1 GEAR ASSY, DRIVE 1

32 140568-4 SEAL OIL, 130 X 160 X 14, VITON 1

33 162589-1 PLATE, GROUNDING BRUSH, DUAL CHANNEL 1

34 407249-6 SCREW_SHC_M6X25 8

35 146009-1 REDUCER, RV, POSITIONER 1

36 146071-2 SEAL, O”RING, 129.6 X 5.7 1

37 146022-1 POST, MTG, DRIVE GEAR, RV 1


39 146071-3 SEAL, O”RING, 380.59 X 3.53 1


41 132613-4 SCREW, SET, M12 X 16 2

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Introdu

ction

B-11

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13

14

15

89/99

Fig. B-5: MotoMountTM Tailstock Components – 95/185/505

7

3

2

162068-1CD



Table B-5: MotoMountTM Tailstock Components – 95/185/505Item P/N Title Qty

B-5 155871-1 ADAPTER ASSY, TAILSTOCK, GEN2, MOTOMOUNT

Ref

1 148757-1 SHAFT, FLANGED, MTG, MOTOMOUNT, TS 1

2 148136-2 BEARING, SPHERICAL ROLLER 1

3 148135-1 SCREW, SET, CONE PT M8X6 1

4 148124-1 PIN, LOCATOR, 16MM 1

5 155870-1 ADAPTER, BLOCK, TAILSTOCK, GEN2 1

6 156164-1 RETAINER, TAILSTOCK BEARING 2

7 146953-3 RING, RETAINING, EXTERNAL, 55 1

8 407249-3 SCREW, SHC,M6X12 6

9 470602-1 WASHER,CONICAL SPRING, M6 8

10 156211-1 SEAL, FACE, SPHERICAL BEARING 2

11 407249-1 SCREW, SHC, M6x1 X 8 2

12 155941-1 COLUMN,TAILSTOCK,MHT-500,GEN 2 1

13 145260-1 BOLT,LEVELING,M20X50 4

14 130429-11 NUT,HEX JAM,M20,ZP 4

15 146456-1 WASHER,SQUARE,3/8IDX1/4X2X2 4

B-12

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Fig. B-6: MotoMountTM Tailstock Components – 1605/3105

2

3

4

5

6

7

9

10

11

12

13

14

15

8

B-13

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Table B-6: MotoMountTM Tailstock Components – 1605/3105Item P/N Title Qty

B-6 146964-3 ADAPTER, ASSY, TAILSTOCK, MOTOMOUNT HD

Ref

2 131275-1 SCREW, HHC, M20 X 120 4

3 146951-1 CLAMP, SHAFT 1

4 148124-1 PIN, LOCATING, DIA16 1

5 146950-4 SHAFT, SQUARE 1

6 148136-1 BEARING, SPHERICAL, ROLLER 1

7 146940-4 RING, RETAINING, INTERNAL 1

8 146965-3 ADAPTER, TAILSTOCK 1

9 146953-3 RING, RETAINING, EXTERNAL 1

10 146949-1 COLUMN, TAILSTOCK 1

11 140784-1 BOLT, LEVELING 1

12 130440-12 NUT, HEX JAM, M20 4

13 146456-2 WASHER, SQUARE, 1/2 ID 4

14 148135-1 SCREW, SET, M8 X 6, POINTED 4

15 147632-2 BUMPER,ROTATION LIMITER 1

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B.1

Introduction

B-15

16

206

8-1C

D

162068-1CD

Fig. B-7: MotoMount Components

21

19

17

16

3

4

26

5

93/99

6

28

31

1178

9 10

7

8

1824202322 21

12131415

30

29

2527

162068-1CD



Table B-7: MotoMount ComponentsItem P/N Title Qty

B-7 155873 FIXTURE ASSY, HEADSTOCK, GEN2, MOTOMOUNT

REF

1 145708-1 BLOCK,MTG,MOTO-MOUNT 1

2 151233-1 PIN,DOWEL,M12X40,MODIFIED 2


4 471075-1 WASHER,CONICAL SPRING,GTS12 2

5 155872-1 BLOCK,MOUNTING,FIXTURE,GEN2 1

6 146497-1 COVER,DUST,CAM BLOCK 1

7 139965-1 SCREW,HHC,M6X10,CLASS 8.8 4


9 132614-1 SCREW,HHC,M10X40,CLASS 8.8 2


11 146503-1 PLATE,SIDE,BLOCK 1

12 130887-11 CABLE,WELD,4/0,1FT 2

13 131272-1 SCREW,HHC,M12X25,ZP,CLASS 8.8 3

14 479148-7 WASHER,LOCK,M12 3

15 147462-1 WASHER,M12,HIGH STRENGH 5

16 145848-1 SEAL,O-RING,34.29MM ID X 5.33 1

17 145848-2 SEAL,O-RING,43.82MM ID X 5.33 1

18 133937-1 FITTING,ZERK,GREASE,1/8(R)PT 1

19 145849-1 SPACER,CUSTOM,25.0ID X 8.0LG 1

20 130398-4 RING,RETAINING,INTERNAL,42MM 1


22 131274-5 SCREW,HHC,M16X65,ZP,CL 8.8 1

23 145724-1 BUSHING,BEARING,MAIN 1

24 145753-1 BEARING,SPHERICAL,25ID 1

25 148135-1 SCREW,SET,M8X6,POINTED 1

26 148124-1 PIN,LOCATOR,16mm 1

27 132613-3 SCREW,SET,M8X10 2

28 145710-1 BLOCK,GUIDE 1

29 146496-1 PLATE,CAM BLOCK 1

30 146993-1 PIN,DOWEL,WHISTLE STOP 1

31 145725-1 BUSHING,BLOCK,MOTOMOUNT 1

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B.1

Introduction

B-17

16

206

8-1C

D

162068-1CD

Fig. B-8: MotoMount HD Drive Components

7

9

10

8

95/99

5

3

2

4

6

11

162068-1CD



Table B-8: MotoMount HD Drive ComponentsItem P/N Title Qty

B-8 146200-2 ADAPTER, ASSY, MOTOMOUNT HD Ref

2 149227-1 HUB, MOUNTING 1

3 146195-3 BLOCK, GUIDE 1

4 149768-1 BEARING, CAM FOLLOWER 1

5 148124-1 PIN, LOCATING, DIA. 16 MM HEAD 1

6 146196-3 BLOCK, MOUNTING, FIXTURE 1

7 146927-1 BEARING, SPHERICAL, PRECISION, 50 MM ID 1

8 146940-1 RING, RETAINING, INTERNAL, 80 MM 1

9 130330-7 NUT, BEARING 1

10 130887-11 CABLE, WELD, 4/0, 1 FT 1

B-18

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162068-1CD


Fig. B-9: Slip Ring Components

2

3

4

5

6

7

8

B-19

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162068-1CD



Table B-9: Slip Ring Kit ComponentsItem P/N Title Qty

B-9 148634-1 ACCESSORY, SLIP RING, MOTOMOUNT HD Ref

2 148636-1 SUPPORT, GUARD, SLIP RING 1

3 148635-1 GUARD, SLIP RING 1

4 148848-1 SLIP RING ASSY, MOTOMOUNT HD 1

5 146913-2 FITTING, NIPPLE, PIPE, BRASS, 3/8-INCH 1

6 148847-1 RING, RETAINING, EXT, 42 MM SHAFT 1

7 148637-1 GUIDE, OUTLET, PIPE 1

8 148849-1 PLATE, CLAMP, DRIVE, DOG 1

B-20

162068-1CD 98/99

MH-SERIES SIGMA-5 POSITIONER MANUAL

0162068-1CDMANUAL NO.

Specifications are subject to change without noticefor ongoing product modifications and improvements.

99/99

162068-1cd

Documents

potentially hazardous situation

maximum load based

maximum bearing moment

additional mounting support

allowable load inertia5

notify shipping contractor

suitable lifting device

understand potential dangers