Download - 162068-1CD
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.
MANUAL NO.
0162068-1CD 1/99
162068-1CD
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.
ii
162068-1CD 2/99
162068-1CD
MH-SERIES POSITIONER
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.”
iii
162068-1CD 3/99
162068-1CD
MH-SERIES POSITIONER
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.
iv
162068-1CD 4/99
162068-1CD
MH-SERIES POSITIONER
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
v
162068-1CD 5/99
162068-1CD
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
vii
162068-1CD 6/99
Table of Contents
162068-1CD
MH-SERIES POSITIONER
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
viii
162068-1CD 7/99
162068-1CD
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
ix
162068-1CD 8/99
1 Introduction1.1 About this Document
162068-1CD
MH-SERIES POSITIONER
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).
1-1
162068-1CD 9/99
162068-1CD
MH-SERIES POSITIONER
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.
1-2
162068-1CD 10/99
1 Introduction1.3 System Layout
162068-1CD
MH-SERIES POSITIONER
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
1-3
162068-1CD 11/99
162068-1CD
MH-SERIES POSITIONER
1 Introduction1.3 System Layout
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
1-4
162068-1CD 12/99
1 Introduction1.3 System Layout
162068-1CD
MH-SERIES POSITIONER
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
1-5
162068-1CD 13/99
162068-1CD
MH-SERIES POSITIONER
1 Introduction1.3 System Layout
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
1-6
162068-1CD 14/99
1 Introduction1.4 Customer Support Information
162068-1CD
MH-SERIES POSITIONER
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:
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
1-7
162068-1CD 15/99
162068-1CD
MH-SERIES POSITIONER
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.
2-1
162068-1CD 16/99
2 Safety2.3 Mechanical Safety Devices
162068-1CD
MH-SERIES POSITIONER
• 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.
2-2
162068-1CD 17/99
162068-1CD
MH-SERIES POSITIONER
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.
2-3
162068-1CD 18/99
2 Safety2.5 Programming, Operation, and Maintenance Safety
162068-1CD
MH-SERIES POSITIONER
• 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).
2-4
162068-1CD 19/99
162068-1CD
MH-SERIES POSITIONER
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
3-1
162068-1CD 20/99
3 Equipment Description3.2 MH-Series SIGMA-5 Positioner Assembly – Type I
162068-1CD
MH-SERIES POSITIONER
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
3-2
162068-1CD 21/99
162068-1CD
MH-SERIES POSITIONER
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
3-3
162068-1CD 22/99
3 Equipment Description3.3 MH-Series SIGMA-5 Positioner Assembly – Type II
162068-1CD
MH-SERIES POSITIONER
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
3-4
162068-1CD 23/99
162068-1CD
MH-SERIES POSITIONER
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.
3-5
162068-1CD 24/99
3 Equipment Description3.4 * MotoMount™
162068-1CD
MH-SERIES POSITIONER
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
3-6
162068-1CD 25/99
162068-1CD
MH-SERIES POSITIONER
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
4-1
162068-1CD 26/99
4 Installation4.2 Installing the MH-Series SIGMA-5 Positioner – Type I
162068-1CD
MH-SERIES POSITIONER
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
4-2
162068-1CD 27/99
162068-1CD
MH-SERIES POSITIONER
4 Installation4.2 Installing the MH-Series SIGMA-5 Positioner – Type I
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
4-3
162068-1CD 28/99
4 Installation4.2 Installing the MH-Series SIGMA-5 Positioner – Type I
162068-1CD
MH-SERIES POSITIONER
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
4-4
162068-1CD 29/99
162068-1CD
MH-SERIES POSITIONER
4 Installation4.2 Installing the MH-Series SIGMA-5 Positioner – Type I
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
4-5
162068-1CD 30/99
4 Installation4.2 Installing the MH-Series SIGMA-5 Positioner – Type I
162068-1CD
MH-SERIES POSITIONER
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)
4-6
162068-1CD 31/99
162068-1CD
MH-SERIES POSITIONER
4 Installation4.2 Installing the MH-Series SIGMA-5 Positioner – Type I
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
4-7
162068-1CD 32/99
4 Installation4.3 Installing the MH-Series SIGMA-5 Positioner – Type II
162068-1CD
MH-SERIES POSITIONER
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.
4-8
162068-1CD 33/99
162068-1CD
MH-SERIES POSITIONER
4 Installation4.3 Installing the MH-Series SIGMA-5 Positioner – Type II
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
4-9
162068-1CD 34/99
4 Installation4.3 Installing the MH-Series SIGMA-5 Positioner – Type II
162068-1CD
MH-SERIES POSITIONER
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
4-10
162068-1CD 35/99
162068-1CD
MH-SERIES POSITIONER
4 Installation4.3 Installing the MH-Series SIGMA-5 Positioner – Type II
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
4-11
162068-1CD 36/99
4 Installation4.4 Tailstock Column Installation
162068-1CD
MH-SERIES POSITIONER
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
4-12
162068-1CD 37/99
162068-1CD
MH-SERIES POSITIONER
4 Installation4.4 Tailstock Column Installation
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
4-13
162068-1CD 38/99
4 Installation4.4 Tailstock Column Installation
162068-1CD
MH-SERIES POSITIONER
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.
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 axially and cross-axially again. When level, tighten the anchoring system (customer-supplied) to the specified torque.
6. Tighten the four lock-nuts to the column base.
AXIAL
CROSS-AXIAL
DRIVE ASSEMBLY
AB
C
LEVELING SHIM
ANCHOR (CUSTOMER SUPPLIED)
LEVELING BOLT
LOCK-NUT
HEADSTOCKRISER
COLUMN BASE
4-14
162068-1CD 39/99
162068-1CD
MH-SERIES POSITIONER
4 Installation4.4 Tailstock Column Installation
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.
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 directions.
4. Drive the fourth leveling bolt down to the leveling shim.
5. Check level axially and cross-axially again. When level, tighten the anchoring system (customer supplied) to the specified torque.
6. Tighten the four lock-nuts to the column base.
B
C
AXIAL
CROSS-AXIAL
A
LEVELING SHIM
ANCHOR (CUSTOMERSUPPLIED)
LEVELING BOLT
LOCK-NUT
HEADSTOCKRISER
COLUMN BASE
4-15
162068-1CD 40/99
4 Installation4.4 Tailstock Column Installation
162068-1CD
MH-SERIES POSITIONER
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.
4-16
162068-1CD 41/99
162068-1CD
MH-SERIES POSITIONER
4 Installation4.4 Tailstock Column Installation
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
4-17
162068-1CD 42/99
4 Installation4.4 Tailstock Column Installation
162068-1CD
MH-SERIES POSITIONER
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
Make certain servo power is OFF for the remainder of the installation, or serious operator injury and/or equipment damage may result.
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.
4-18
162068-1CD 43/99
162068-1CD
MH-SERIES POSITIONER
4 Installation4.4 Tailstock Column Installation
• 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
4-19
162068-1CD 44/99
4 Installation4.4 Tailstock Column Installation
162068-1CD
MH-SERIES POSITIONER
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.
4-20
162068-1CD 45/99
162068-1CD
MH-SERIES POSITIONER
4 Installation4.4 Tailstock Column Installation
• 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.
4-21
162068-1CD 46/99
4 Installation4.5 MotoMount Installation
162068-1CD
MH-SERIES POSITIONER
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
4-22
162068-1CD 47/99
162068-1CD
MH-SERIES POSITIONER
4 Installation4.5 MotoMount Installation
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
4-23
162068-1CD 48/99
4 Installation4.5 MotoMount Installation
162068-1CD
MH-SERIES POSITIONER
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
4-24
162068-1CD 49/99
162068-1CD
MH-SERIES POSITIONER
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
4-25
162068-1CD 50/99
4 Installation4.6 MotoMount HD Adjustments
162068-1CD
MH-SERIES POSITIONER
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
Make certain servo power is OFF for the remainder of the installation, or serious operator injury and/or equipment damage may result.
WARNING
The servo motor must be off for the remainder of the removal, or serious operator injury and/or equipment damage may result.
4-26
162068-1CD 51/99
162068-1CD
MH-SERIES POSITIONER
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
4-27
162068-1CD 52/99
5 Tooling Recommendations5.1 Headstock Only – Tooling Recommendations
162068-1CD
MH-SERIES POSITIONER
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
5-1
162068-1CD 53/99
162068-1CD
MH-SERIES POSITIONER
5 Tooling Recommendations5.1 Headstock Only – Tooling Recommendations
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
5-2
162068-1CD 54/99
5 Tooling Recommendations5.1 Headstock Only – Tooling Recommendations
162068-1CD
MH-SERIES POSITIONER
Fig. 5-40: Mounting Holes on Faceplate MH505
Fig. 5-41: Mounting Holes on Faceplate MH1605
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.
5-3
162068-1CD 55/99
162068-1CD
MH-SERIES POSITIONER
5 Tooling Recommendations5.1 Headstock Only – Tooling Recommendations
Fig. 5-42: Mounting Holes on Faceplate MH3105
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.
5-4
162068-1CD 56/99
5 Tooling Recommendations5.2 Headstock/Tailstock with MotoMount
162068-1CD
MH-SERIES POSITIONER
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
5-5
162068-1CD 57/99
162068-1CD
MH-SERIES POSITIONER
5 Tooling Recommendations5.2 Headstock/Tailstock with MotoMount
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
5-6
162068-1CD 58/99
5 Tooling Recommendations5.2 Headstock/Tailstock with MotoMount
162068-1CD
MH-SERIES POSITIONER
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
5-7
162068-1CD 59/99
162068-1CD
MH-SERIES POSITIONER
5 Tooling Recommendations5.2 Headstock/Tailstock with MotoMount
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
5-8
162068-1CD 60/99
5 Tooling Recommendations5.2 Headstock/Tailstock with MotoMount
162068-1CD
MH-SERIES POSITIONER
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
5-9
162068-1CD 61/99
162068-1CD
MH-SERIES POSITIONER
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.
6-1
162068-1CD 62/99
6 Maintenance6.3 Weld Ground Brush Replacement – Type I
162068-1CD
MH-SERIES POSITIONER
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
6-2
162068-1CD 63/99
162068-1CD
MH-SERIES POSITIONER
6 Maintenance6.3 Weld Ground Brush Replacement – Type I
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
6-3
162068-1CD 64/99
6 Maintenance6.3 Weld Ground Brush Replacement – Type I
162068-1CD
MH-SERIES POSITIONER
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.
6-4
162068-1CD 65/99
162068-1CD
MH-SERIES POSITIONER
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
6-5
162068-1CD 66/99
6 Maintenance6.4 Weld Ground Brush Replacement – Type II
162068-1CD
MH-SERIES POSITIONER
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
6-6
162068-1CD 67/99
162068-1CD
MH-SERIES POSITIONER
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.
6-7
162068-1CD 68/99
6 Maintenance6.5 Reset Headstock To Home Position
162068-1CD
MH-SERIES POSITIONER
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
6-8
162068-1CD 69/99
162068-1CD
MH-SERIES POSITIONER
6 Maintenance6.5 Reset Headstock To Home Position
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
6-9
162068-1CD 70/99
6 Maintenance6.5 Reset Headstock To Home Position
162068-1CD
MH-SERIES POSITIONER
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.
6-10
162068-1CD 71/99
162068-1CD
MH-SERIES POSITIONER
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
6-11
162068-1CD 72/99
6 Maintenance6.7 Troubleshooting
162068-1CD
MH-SERIES POSITIONER
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.
6-12
162068-1CD 73/99
162068-1CD
MH-SERIES POSITIONER
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)
A-1
162068-1CD 74/99
A Performance ChartsA.1 MH-Series Positioner Assemblies
162068-1CD
MH-SERIES POSITIONER
A.1.2 MH185
Fig. A-2: MH185 Performance ChartsRated Peak
Holding Torque (N*m)= 299 345
Load CG Offcenterr (mm) Rated W (kgf) Max W (kgf)
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
Maximum Bearing Moment (N*m) = 882
Load CG Overhang (from Tooling Plate)D (mm) Rated W (kgf) Max W (kgf)
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.
Reflected RatioLoad Inertia Jl/Jm
47 2.551 2.7556 361 3.2566 3.570 3.7575 480 4.2584 4.589 4.7594 5
Note: Maximum recommend inertia ratio is 5.
Holding Torque; Load CG Offcenter
0
100
200
300
400
500
600
700
800
900
1000
0 50 100 150 200 250 300
Rated W (kgf)
Max W (kgf)
Rated Bearing Moment; Load CG Overhang
0
50
100
150
200
250
300
350
400
450
0 100 200 300 400 500
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
58 68 78 88 98 108
Application Inertia, kg*m2
Iner
tia R
atio
, Jl/J
m
Jl/Jm
A-2
162068-1CD 75/99
162068-1CD
MH-SERIES POSITIONER
A Performance ChartsA.1 MH-Series Positioner Assemblies
A.1.3 MH505
Fig. A-3: MH505 Performance ChartsRated Peak
Holding Torque (N*m)= 829 957
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
Maximum Bearing Moment (N*m) = 2156
Load CG Overhang (from Tooling Plate)D (mm) Rated W (kgf) Max W (kgf)
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.
Reflected RatioLoad Inertia Jl/Jm
105 2.5115 2.75126 3136 3.25147 3.5157 3.75168 4178 4.25189 4.5200 4.75210 5
Note: Maximum recommend inertia ratio is 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)
Rated Bearing Moment; Load CG Overhang
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)
Allowable Load Inertia
2
2.5
3
3.5
4
4.5
5
5.5
110 130 150 170 190 210 230 250
Application Inertia, kg*m2
Iner
tia R
atio
, Jl/J
m
Jl/Jm
A-3
162068-1CD 76/99
A Performance ChartsA.1 MH-Series Positioner Assemblies
162068-1CD
MH-SERIES POSITIONER
A.1.4 MH1605
Fig. A-4: MH1605 Performance ChartsRated Peak
Holding Torque (N*m) 2826 3261
Load CG Offcenterr (mm) Rated W (kgf) Max W (kgf)
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
Maximum Bearing Moment (N*m) = 7056
Load CG Overhang (from Tooling Plate)D (mm) Rated W (kgf) Max W (kgf)
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.
Reflected RatioLoad Inertia Jl/Jm
672 2.5742 2.75811 3880 3.25950 3.5
1019 3.751088 41158 4.251227 4.51296 4.751365 5
Note: Maximum recommend inertia ratio is 5.
Rated Bearing Moment; Load CG Overhang
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)
Allowable Load Inertia
2.5
3
3.5
4
4.5
5
5.5
678 778 878 978 1078 1178 1278 1378 1478
Application Inertia, kg*m2
Iner
tia R
atio
, Jl/J
m
Holding Torque; Load CG Offcenter
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)
A-4
162068-1CD 77/99
162068-1CD
MH-SERIES POSITIONER
A Performance ChartsA.1 MH-Series Positioner Assemblies
A.1.5 MH3105
Fig. A-5: MH3105 Performance Charts
Rated PeakHolding Torque (N*m)= 5479 6322
Load CG Offcenterr (mm) Rated W (kgf) Max W (kgf)
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
Maximum Bearing Moment (N*m) = 20580
Load CG Overhang (from Tooling Plate)D (mm) Rated W (kgf) Max W (kgf)
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.
Reflected RatioLoad Inertia Jl/Jm
3058 2.53394 2.753730 34066 3.254402 3.54738 3.755073 45409 4.255745 4.56081 4.756417 5
Note: Maximum recommend inertia ratio is 5.
Allowable Load Inertia
2
2.5
3
3.5
4
4.5
5
5.5
3000 3500 4000 4500 5000 5500 6000 6500
Application Inertia, kg*m2
Iner
tia R
atio
, Jl/J
m
Jl/Jm
Rated Bearing Moment; Load CG Overhang
0
500
1000
1500
2000
2500
3000
3500
4000
4500
5000
0 200 400 600 800 1000
CG Distance from Tooling Plate, D (mm)
App
licat
ion
Load
, W (k
gf)
Rated W (kgf)
Max W (kgf)
Holding Torque; Load CG Offcenter
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
162068-1CD 78/99
B Illustrated Parts listB.1 Introduction
162068-1CD
MH-SERIES POSITIONER
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
162068-1CD 79/99
162068-1CD
MH-SERIES POSITIONER
B Illustrated Parts listB.1 Introduction
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
162068-1CD 80/99
B Illustrated P
arts listM
H-S
ER
IES
PO
SIT
ION
ER
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
MH-SERIES POSITIONER
B Illustrated Parts listB.1 Introduction
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
12 470617-1 WASHER, CONICAL, SPRING, M8 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
25 479296-14 SCREW, SHC, M5 X 60, CLASS 12.9 1
26 471009-1 WASHER, CONICAL, SPRING, M5 5
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
B-4
162068-1CD 82/99
B Illustrated P
arts listM
H-S
ER
IES
PO
SIT
ION
ER
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
MH-SERIES POSITIONER
B Illustrated Parts listB.1 Introduction
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
4 479281-105 FITTING, PLUG, 1/8BSPT, BLACK 2
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
10 407248-5 SCREW, SHC, M8 X 20, CLASS 12.9 12
15 470602-1 WASHER, CONICAL, SPRING, M6 9
16 479296-6 SCREW,SHC,M5X16 4
17 471009-1 WASHER, CONICAL, SPRING, M5 4
18 149473-1 LIMIT SWITCH 2
19 407249-4 SCREW_SHC_M6X16 4
20 158244-1 BRACKET, MTG, LIMIT SWITCH 2
21 145896-1 PIN, HOMING 1
22 144371-1 BRUSH, GROUND, METAL, GRAPHITE 2
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
26 144370-1 TERMINAL, QUICK DISC, WELD GROUND LUG 4
27 407248-6 SCREW, SHC, M8 X 25, CLASS 12.9 4
28 470617-1 WASHER, CONICAL, SPRING, M8 20
29 133984-1 NAMEPLATE, GROUND 1
30 132616-3 SCREW,HHC,M8 X 16 1
31 479148-5 WASHER_LOCK_M8 1
32 479147-5 WASHER_FLAT_M8 1
33 407248-7 SCREW, SHC, M8 X 30, CLASS 12.9 16
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
B-6
162068-1CD 84/99
B Illustrated P
arts listM
H-S
ER
IES
PO
SIT
ION
ER
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
MH-SERIES POSITIONER
B Illustrated Parts listB.1 Introduction
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
5 472303-7 SCREW,SHC,M12X40,CLASS 12.9 4
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
9 144371-1 BRUSH, GROUND, METAL, GRAPHITE 2
10 144370-1 TERMINAL, QUICK DISC, WELD GROUND LUG 4
11 470602-1 WASHER, CONICAL, SPRING, M6 8
12 130235-8 SCREW, HHC, 1/4 X 1 1/2 4
13 472303-9 SCREW, SHC, M12 X 50, CLASS 12.9 16
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
18 470617-1 WASHER, CONICAL, SPRING, M8 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
23 479281-105 FITTING, PLUG, 1/8BSPT, BLACK 2
24 147078-1 LABEL,WARNING 1
25 479154-4 CLAMP, CABLE SUPPORT 4
26 158342-1 SCREW,PPH,M4 X 07 X 8 4
27 158244-1 BRACKET, MTG, LIMIT SWITCH 2
28 158941-21 LABEL, PRODUCT ID,MH1605 TR 1
29 407249-4 SCREW_SHC_M6X16 4
30 149473-1 LIMIT SWITCH 2
31 471009-1 WASHER, CONICAL, SPRING, M5 4
32 479296-6 SCREW,SHC,M5X16 4
33 162068-1CD MANUAL, MH1605 DRIVE ASSEMBLY SIGMA 5 1
34 470541-1 WASHER, CONICAL SPRING, M10 18
35 479297-7 screw_shc_m10x40 18
36 130532-2 SCREW, SHC, M16 X 35 6
37 132049-1 WASHER, CONICAL SPRING, GTS16 6
38 133984-1 NAMEPLATE, GROUND 1
B-8
162068-1CD 86/99
B Illustrated P
arts listM
H-S
ER
IES
PO
SIT
ION
ER
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
MH-SERIES POSITIONER
B Illustrated Parts listB.1 Introduction
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
8 471075-1 WASHER, CONICAL SPRING, M12 32
9 162580-1 MOTOR ASSY,AC SERVO,4.4KW,SIGMA 5,TYPE II
1
10 149473-1 LIMIT SWITCH 2
11 479296-9 SCREW, SHC, M5 X 30 4
12 471009-1 WASHER, CONICAL, SPRING, M5 4
13 144370-1 TERMINAL, QUICK DISC, WELD GROUND LUG 6
14 146015-2 BRACKET, MTG, BRUSH HOLDER 3
15 407249-8 SCREW, SHC, M6 X 35 6
16 470602-1 WASHER, CONICAL, SPRING, M6 18
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
20 144371-1 BRUSH, GROUND, METAL, GRAPHITE 3
21 144372-1 BRUSH HOLDER, 1" X 1.5" X 2" 3
22 140837-6 PIN,DOWEL,M10X35 2
23 472303-6 SCREW,SHC,M12X35,CLASS 12.9 4
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
38 472303-15 SCREW,SHC,M12X80,CLASS 12.9 16
39 146071-3 SEAL, O”RING, 380.59 X 3.53 1
40 479281-105 FITTING, PLUG, 1/8BSPT, BLACK 1
41 132613-4 SCREW, SET, M12 X 16 2
B-10
162068-1CD 88/99
B Illustrated P
arts listM
H-S
ER
IES
PO
SIT
ION
ER
B.1
Introdu
ction
B-11
162
068
-1C
D
162068-1CD
12
13
14
15
89/99
Fig. B-5: MotoMountTM Tailstock Components – 95/185/505
7
3
2
162068-1CD
MH-SERIES POSITIONER
B Illustrated Parts listB.1 Introduction
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
162068-1CD 90/99
B Illustrated Parts listB.1 Introduction
162068-1CD
MH-SERIES POSITIONER
Fig. B-6: MotoMountTM Tailstock Components – 1605/3105
2
3
4
5
6
7
9
10
11
12
13
14
15
8
B-13
162068-1CD 91/99
162068-1CD
MH-SERIES POSITIONER
B Illustrated Parts listB.1 Introduction
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
B-14
162068-1CD 92/99
B Illustrated P
arts listM
H-S
ER
IES
PO
SIT
ION
ER
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
MH-SERIES POSITIONER
B Illustrated Parts listB.1 Introduction
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
3 472303-9 SCREW,SHC,M12X50,CLASS 12.9 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
8 470602-1 WASHER,CONICAL SPRING,GTS6 4
9 132614-1 SCREW,HHC,M10X40,CLASS 8.8 2
10 470541-1 WASHER,CONICAL SPRING,GTS10 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
21 132049-1 WASHER,CONICAL SPRING,GTS16 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
B-16
162068-1CD 94/99
B Illustrated P
arts listM
H-S
ER
IES
PO
SIT
ION
ER
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
MH-SERIES POSITIONER
B Illustrated Parts listB.1 Introduction
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
162068-1CD 96/99
B Illustrated Parts listB.1 Introduction
162068-1CD
MH-SERIES POSITIONER
Fig. B-9: Slip Ring Components
2
3
4
5
6
7
8
B-19
162068-1CD 97/99
162068-1CD
MH-SERIES POSITIONER
B Illustrated Parts listB.1 Introduction
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