Miller 5 TURNTABLE User manual

FORM: OM-890
Miller®
MODEL: 5 TURNTABLE
IMPORTANT: Illustrations and text in this
manual are forthe latest Model 5 Turntable. Ear-
lier models may vary slightly. When ordering
parts, be sure to identify parts by name, part
number and serial number of the machine for
which the parts are being ordered.
OWNER’S MANUAL
IMPORTANT: Read and understand the entire contents of this manual,
with special emphasis on the safety material throughout the manual,
Mlflm Electric Mfg. Co.
AMd~, G,o,,~ Lid Co~’,p,nv
before installing, operating, or maintaining this equipment. This unit and P0. Box 1079
these instructions are for use only by persons trained and experienced in Appleton, WI 54912 USA
the safe operation of welding equipment. Do not allow untrained persons Tel. [phone]
to install, operate, or maintain this unit. Contact your distributor if you
do not fully understand these instructions.
July 1988
PRgNTED IN U.S.A. ADDITIONAL COPY PRICE $1.40

LIMITED WARRANTY
EFFECTIVE FEBRUARY 16, 1988
This warranty supersedes all prevIous MILLER warranties and is exclusive with no other guarantees or warranties expressed or implied.
LIMITED WARRANTY - Subject to the terms and condi- In the case of Miter’s breach of warranty or any other duty
tions hereof, Miller Electric Mfg. Co., Appleton, Wisconsin with respect to the quality of any goods, the exclusive remedies
warrants to its Distributor/Dealer that all new and unused therefore shall be, at Millers optIon (11 repair or (2) replacement
Equipment furnished by Miller is free from defect in workman- or, where authorited in writing by Miller in appropriate c, (3)
ship and material as of the time and place of delivery by Miller. the reasonable cost of repair or replacement at an authorized
No warranty is made by Miller with respect to engines, trade Miller seivtce station or (4) payment of or credit for the purchase
accessories or other items manufactured by others. Such price (less reasonable depreciation based upon actual use) upon
engines, trade accessories and other items are sold subject to retum of the goods at Customer’s risk and experue. MILLER~s
the warranties of their respective manufacturers, if any . All option of repair or replacement will be FOB., Factory, at
engines are warranted by their manufacturer for one year from Appleton, Wmconsin, or F.O.B., at a MILLER authorized senice
date of original purchase, except Tecumseh engines which facility, therefore, no compensation for transportation costs of
have a two year warranty. any kind will be allowed. Upon receipt of notice of apparent
defect or failure, Miller shall instiuct the claimant on the warranty
Except as specified below, Miller’s warranty does not apply claim procedures to be followed.
to components having normal useful life of less than one (1)
year, such as spot welder tips, relay and contactor points,
MILLERMATIC parts that come in contact with the welding ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND
• wire including nozzles and nozzle insulators where failure does ANY IMPUED WARRANTY, GUARANTY OR REPRESENTA -
BREACH OF CONTRACT WHICH, BUT FOR THIS PROViSION,
• not result from defect in workmanship or material. TION AS TO PERFORMANCE, AND ANY REMEDY FOR
7~ Miller shall be required to honor warranty claims on war- MIGHT ARISE BY IMPLICATiON, OPERATION OF LAW,
ranted Equipment in the event of failure resulting from a defect CUSTOM OF TRADE OR COURSE OF DEAUNG, INCLUDING
within the following periods from the date of delivery of Equip- ANY IMPUED WARRANTY OF MERCHANTABIUTY OR OF
ment to the original user: FIThESS FOR PARTiCULAR PURPOSE, WiTH RESPECT TO
ANY AND ALL EQUIPMENT FURNISHED BY MILLER IS EX -
1. Aac welders, p~r sources, robots, and components . 1 ~er CLUDED AND DISCLAIMED BY MILLER.
2. Load banks . 1 year
3. Original main power rectifiers 3 years
(labor - 1 year onlyl EXCEPT AS EXPRESSLY PROViDED BY MILLER IN
• 4. All welding guns, feeder/guns and torches 90 days WRITING, MILLER PRODUCTS ARE INTENDED FOR
5. All other Millermatic Feeders 1 year ULTIMATE PURCHASE BY COMMERCIAL/INDUSTRIAL
6. Replacement or repair parts, exclusive of labor .. 60 days USERS AND FOR OPERATION BY PERSONS TRAINED AND
7. Batteries 6 months EXPERIENCED IN THE USE AND MAINTENANCE OF
WELDING EQUIPMENT AND NOT FOR CONSUMERS OR
• provided that Miller is notified in writing within thirty 130) days CONSUMER USE. MILLER’S WARRANTIES DO NOT EXTEND
of the date of such failure. TO, AND NO RESELLER IS AUTHORIZED TO EXTEND
As a matter of general policy only, Miller may honor clalew MILLER’S WARRANTIES TO, ANY CONSUMER.
submitted by the original user within the foregoing periods.

TABLE OF CONTENTS
Section No. Page No.
SECTION 1 - INTRODUCTION
1 - 1. General Information And Safety 2
1 - 2. Receiving-Handling 2
1 - 3. Description 2
SECTION 2 - INSTALLATION
2 - 1. Work Cable Connections 3
2 - 2. Operation Control Cord Connections 5
SECTION 3 - OPERATION
3 - 1. Program Example For Turntable Mounting Plate Rotation 6
3 - 2. Program Example For Side 001 Welding Operation 7
3 - 3. Prgoram Example For Side 000 Welding Operation 8
3 - 4. Job Example For Linking Programs 8
3 - 5. Setting Relay Time For High-Speed Valve 11
SECTION 4 - MAINTENANCE ft TROUBLESHOOTING
4 - 1. Cleaning And Inspection 12
4 - 2. Lubrication 13
4-3. QilFilter 13
4 - 4. Checking Reservoir Fluid Level 14
4 - 5. Adjustment Of Low-Speed Rotation Control 15
4 - 6. Adjustment Of Locking Pin Speed Control 16
4 -7. AdjustmentQf ShockAbsorbers 17
4-8. SettingHardStops 18
4 - 9. Adjustment Of Pressure Switch For Accumulator 19
4-10. Adjustment Of Drive Belt Tension 21
4-11. Drive Belt Replacement 22
4-12. Hydrqaulic Fittings 24
4-13. Releasing Pressurized Fluid From Accumulator 24
4-14. Replacement Of Pressure Switch 25
4-15. Replacement Of Directional Control Valve 26
4-16. Replacement Of Rotary Actuator 27
4-17. Replacement Of High-Speed Valve 30
4-18. Replacement Of Locking Pin Cylinder 31
4-19. Replacement Of Proximity Switch 32
4-20. Recharging The Accumulator 33
4-21. Replacement Of Motor/Pump And Reservoir Assembly 34
4-22. Fuses 36
4-23. Troubleshooting Charts 37

SECTION 1 - INTRODUCTION
Mounting
Plate
Diameter
Optional
Fixture
Plate
Diameter
Load
Capacity
Index
Speed*
Indexing
Repeatability
Weight
Net Ship
48 in.
(1219 mm)
60 in.
(1524 mm)
1000 lbs.
(454 kg)
5 Seconds
For 1800
Rotation
Either
Clockwise Or
Counterclockwise
At Load
Capacity
0.005 in.
(0.13 mm)
2000 lbs.
(907 kg)
2000 lbs.
(907 kg)
*Speed increases when operating with less weight.
Figure 1 - 1. Turntable Specifications
Input Power
Single-Phase
AC
Reservoir
Capacity
Hydraulic
Fluid
Pump
Flow
Rate
System
Relief
Pressure
Range Of
System
Operating
Pressure
115 Volts1
60Hz
Maximum:
8 qt.
(7.6 I)
Fill Quantity:
6 qt.
(5.7 I)
ISO 32
Antiwear
Hydraulic
Oil
0.5 gpm
(1.9 1/mm)
1500 psi
(10342 kPa)
950 psi
to
1250 psi
(6550 kPa
to 8618 kPa)
Figure 1 - 2. Hydraulic System Specifications
Dimensions
Inches Millimeters
A 32-1/4 819.2
B 48 1219.2
C 46 1158.4
D 35 989
E 24 609.6
F 13 330.2
G 2 50.9
H 1 25.4
I 47 1193.8
J 48 1219.2
Figure 1 - 3. Overall Dimensions And Base Mounting Hole Layout
OM-aSO Page 1
A
13/32 in.
(10.3 mm)
10 Holes
TC-120 288

00
1 - 1. GENERAL INFORMATION AND SAFETY
A. General
Information presented in this manual and on various
labels, tags, and plates on the unit pertains to equip-
ment design, installation, operation, maintenance, and
troubleshooting which should be read, understood, and
followed for the safe and effective use of this equip-
ment.
B. Safety
The installation, operation, maintenance, and
troubleshooting of arc welding equipment requires
practices and procedures which ensure personal safety
and the safety of others. Therefore, this equipment is to
be installed, operated, and maintained only by qualified
persons in accordance with this manual and all ap -
plicable codes and safety rules such as, but not limited
to, those listed in Section 1 - Safety of the robot
Owner’s Manual and in Section 1 - Safety Rules For
Operation of Arc Welding Power Source in the welding
power source Owner’s Manual.
Safety instructions specifically pertaining to this unit ap -
pear throughout this manual highlighted by the signal
words ~ and ~ which identify
different levels of hazard.
statements include installation, operation,
and maintenance procedures or practices which if not
carefully followed could result in serious personal injury
or loss of life.
CAUTION statements include installation, operation,
and maintenance procedures or practices which if not
carefully followed could result in minor personal injury
or damage to this equipment.
A third signal word, ~s•., highlights instruc -
tions which need special emphasis to obtain the most
efficient operation of this equipment.
1 - 2. RECEIVING-HANDLING - Before installing
this equipment, clean all packing material from around
the unit and carefully inspect for any damage that may
have occurred during shipment. Any claim for loss or
damage that may have occurred in transit must be filed
by the purchaser with the carrier. A copy of the bill
of lading will be furnished by the manufacturer on re -
quest if occasion to file claim arises.
When requesting information concerning this equip-
ment, it is essential that Model Description and Serial
Number of the equipment be supplied.
1 - 3. DESCRIPTION - The Model 5 Turntable is a
circular mounting plate and hydraulic drive system that
provides smooth, accurate rotation for deliverying parts
into a work envelope of an automated welding system.
The mounting plate operates in alternating clockwise
and counterclockwise rotations of 180 degrees. Index -
ing speed for a complete rotation at the 1000 pounds
(454 kg) load capacity is 5 seconds which includes lock -
ing the mounting plate in position. Control of the moun-
ting plate rotation and locking pin movement is provid-
ed by input/output signals through lead connections
from the Model 5 Turntable to the I/O ports on a pro -
grammable control unit.
A 60 in. (1524 mm) diameter optional fixture plate is
available for mounting weld fixtures and increasing the
working surface area. Additional fixture plates can be
used as fixturing requirements increase to provide fast
changeover of weld fixtures by only exchanging fixture
plates on the turntable.
All turntable control components are adjusted as part of
the original installation. If changes are made by the user
that affects load weight on the mounting plate, ad -
justments may then be required.
270~
•Weight of plate approximately
140 lbs. (63.5 kg)
Figure 1 - 4. DImensions And Hole Layout Of Optional Fixture Plate
1800
OM-590 Page 2

SECTION 2 - INSTALLATION
IMPORTANT: The Model 88 Gantry and Model 134
Gantry come with the Model 5 Turntable installed and
connected for operation. If the turntable is to be used
without a robot control, contact factory Technical Sales
department.
Figure 2 - 1. Connection Diagram For Turntable And MR-5 Robot Control
2 - 1. WORK CABLE CONNECTIONS (Figure 2-2)
ELECTRIC SHOCK can kill.
• Do not touch ilve electrical pafls.
• Shut down turntable, welding power source, and
robot control, and disconnect input power
employing “lockout! tagging procedures” before
making or checking work cable connection or
contact pad assembly.
Lockout/tagging procedures consist of removing plug
from receptacle, padlocking line disconnect switch in
open position, removing fuses from fuse box, or shut -
ting off and red-tagging circuit breaker or other discon-
necting device.
MOVING PARTS can cause serious injury.
• Keep clear of moving parts.
PRESSURIZED HYDRAULIC FLUID can cause
serious Injury.
• Release hydraulic fluid pressure according to Sec-
tion 4-13 before touching any hydraulic com -
ponents.
Hydraulic fluid pressure is present even though elec-
trical power is disconnected.
The welding power source work cable connects to a
contact pad assembly mounting rod located above the
spindle pulley inside the turntable chassis. Spring ten -
sion holds the contact pad against the spindle retainer
bushing to provide continuity between the work cable
connection and the mounting plate.
Be sure that work cable is routed away from moving
parts and lug connection is tight. Check for adequate
spring tension at mounting rods to properly align con -
tact pad against spindle retainer bushing, but do not
overtighten springs as this will cause premature wear of
the contact pad.
TA-120 278
OM-890 Page 3

Mounting
Plate
Mounting
Rod (2)
Figure 2 - 2. Contact Pad Assembly For Work Cable Connection
Robot Control’
with Cabinet
Door Open
Retainer.
Bushing
Nut
Cable
Connects To
This End
Of Mounting
Rod
Insulating
Bushing ~ A
Inside
,,~ Portion Of
urntable Chassis
Tension Spring
Pad
Fits Against
Retainer Bushing
Rof; TB-120 281
Figure 2 - 3. Location Of Terminal Strips TB3 And TB4 Inside MR-5 Robot Control
OM-890 Page 4

2 -2. OPERATION CONTROL CORD CONNEC -
TIONS
~ ELECTRIC SHOCK can kill.
• Do not touch live electrical parts.
• Shut down turntable, welding power source, and
robot control, and disconnect input power
employing “lockout! tagging procedures” before
making or checking operation control cord con -
nections.
Lockout/tagging procedures consist of removing plug
from receptacle, padlocking line disconnect switch in
open position, removing fuses from fuse box, or shut -
ting off and red-tagging circuit breaker or other discon-
necting device.
Output Leads 31, 32, 33,
And 34 Connect To Terminals 175,
176, 177, And 178 Respectively
F~L~1
ELECTROSTATIC DISCHARGE (ESD) can damage
circuit board components.
• Put on propedy grounded wrist strap BEFORE
handling circuit boards.
• Transport all static-sensitive components in pro -
per static-shielding carriers or packages.
• Perform work only at a static-safe work area.
Control of turntable operation for mounting plate rota -
tion, locking pin movement, and the Emergency Stop
function is provided by lead connections from the turn -
table control panel to Input/Output and Emergency
Stop terminals inside the MR-S Robot Control. The
location of the Robot Control terminal strips and ter -
minal designations are shown in Figures 2-3 and 2-4.
Be sure that all lead connections are correct and secure
to terminals on appropriate Robot Control terminal
strips (refer to circuit diagram Figure 4-25 for identifica -
tion of leads and connection points).
Input Leads 50, 51, And
52 Connect To Terminals
101, 140, And 141 Respectively
F-i--i
~
.±. ..L ~. .1. .J.. .L .1.. .L. ~ ‘ I j6j6j6j6j~j~j6j~
~F ~T ~r ~T ~T ~T ~r~r ~f!T ~i ~
Input/Output Terminal Strip TB3
Jumper Lead
Connection From
Terminal 195
For Emergency Stop
Lead 30 For
24VAC Power
Supply Connects
To Terminal 194
K
Jumper Lead
Connection From
Terminal 174
For Emergency Stop
External Control Emergency
Stop Terminals
• ~L ‘I I~L LL uLN (ii •1 !1IjdI~al~aI\~A
o
• -I--l--r--1----!--1-I ~
~ ~ 2 ~ -~
~ —— ~ Mli~
~4~ - EUERGENC STOP
Emergency Stop And Function
Control Terminal Strip TB4
Terminals For
Additional
Start Modules
Figure 2 - 4. Operation Control Cord Lead Connections To Terminal Strips TB3 And TB4 Inside MR-S
Robot Control
SECTION 3- OPERATION
For the robot system to perform operations in the pro -
per sequence, it will be necessary to write and enter
programs and jobs that coordinate turntable functions
with weld programs.
This Section provides program and job examples that
control turntable operation, combine the turntable
operation with weld programs, and links the individual
programs together into a job for total robotic system
operation.
IMPORTANT: The program and job data sequences
or steps shown in the examples can be used for actual
programs or jobs; however, some modification may be
necessary to provide different functions for specific
system applications (see Section 5 - Teaching in the
robot Owner’s Manual for additional data information).
OM-890 Page 5

3 - 1. PROGRAM EXAMPLE FOR TURNTABLE
MOUNTING PLATE ROTATION - To provide proper
turntable operation, it is necessary to write and enter a
program that controls the mounting plate rotation.
Since a full rotation of the mounting plate is 180
degrees either clockwise or counterclockwise, only half
of the mounting plate surface will be located in the work
envelope. By dividing the mounting plate surface into
halves, and assigning a numerical side designation to
each half, signals from the turntable allow checking for
appropriate side location within the work envelope. In -
put ports 000 and 001, located on the I/O terminal strip
inside the Robot Control, match the numerical side
designations. The edge of the mounting plate is
stamped with the numerical designations to identify the
two sides.
IMPORTANT: If the sequence data in example pro -
gram 999 is used for an actual program, check turntable
operation for the program sequences in BLOCK FOR -
WARD CONTINUOUS mode before beginning welding
operations. Mounting plate load weight may require ad -
justing the time-delay relay setting (see Section 3-5).
PROGRAM NUMBER 999
Sequence No. Sequence Data Sequence Operation
001 P Position (home) move by manipulator to a location which does not interfere
with jigs, fixtures, or weldments on mounting plate of turntable.
002 JNO 000 Jump to destination PM0 if side 000 is in work envelope. Jump is performed
if signal is present at Robot Control input port 000.
003 P Position (home) move by manipulator (see Sequence Number 001).
004 ROOO Turn off signal at Robot Control output port 000 that activates locking pin
movement in the up direction.
005 TOO.5 Robot Control timer set for 0.5 seconds to deenergize directional control
valve solenoid.
006 SOOl Turn on signal at Robot Control output port 001 that activates locking pin
movement in the down direction.
007 TOl .0 Robot Control timer set for 1 .0 second to allow time for locking pin move
ment.
008 S002 Turn on signal at Robot Control output port 002 that activates mounting plate
rotation in the clockwise direction and energize time-delay relay (see Section
3-5).
009 ROOl Turn off signal at Robot Control output port 001 that activates locking pin
movement in the down direction.
010 NOQO
WDT 00
(infinite)
Check for signal at Robot Control input port 000 which indicates side 000 is in
the work envelope.
011 TOl .0 Robot Control timer set for 1 .0 second to allow mounting plate position to
stabilize at end of rotation.
012 SOQO Turn on signal at Robot Control output port 000 that activates locking pin
movement in the up direction.
013 R002 Turn off signal at Robot Control output port 002 that activates mounting
plate rotation in the clockwise direction and reset time-delay relay.
014 P Position (home) move by manipulator (see Sequence Number 001).
015 JP2 Unconditional jump to destination PM2 after mounting plate rotation to side
000.
016 P Position (home) move by manipulator (see Sequence Number 001).
017 PMO Destination point 0 for jump sequence JNO 000 (see Sequence Number 002).
018 P Position (home) move by manipulator (see Sequence Number 001).
019 ROOO Turn off signal at Robot Control output port 000 that activates locking pin
movement in the up direction.
OM-890 Page 6

PROGRAM NUMBER 999
Sequence No. Sequence Data Sequence Operation
020 TOO.5 Robot Control timer set for 0.5 seconds to deenergize directional control
valve solenoid.
021 5001 Turn on signal at Robot Control output port 001 that activates locking pin
movement in the down direction.
022 TOl .0 Robot Control timer set for 1 .0 second to allow time for locking pin move
ment.
023 S003 Turn on signal at Robot Control output port 003 that activates mounting plate
rotation in the counterclockwise direction and energize time-delay relay (see
Section_3-5).
024 ROOl Turn off signal at Robot Control output port 001 that activates locking pin
movement in the down direction.
025 NOOl Check for signal at Robot Control input port 001 which indicates side 001 is in
WDT 00 work envelope.
(infinite)
026 TOl .0 Robot control timer set for 1 .0 second to allow mounting plate position to
stabilize at end of rotation.
027 SOQO Turn on signal at Robot Control output port 000 that activates locking pin
movement in the up direction.
028 R003 Turn off signal at Robot Control output port 003 that activates mounting
plate rotation in the counterclockwise direction and reset time-delay relay.
029 PM2 Destination point 2 for jump sequence JP2 (see Sequence Number 015).
030 P Position (home) move by manipulator (see Sequence Number 001).
031 END End of Program Number 999.
OUTPUTS INPUTS
000: Pin Up 000: CW Arrival
001: Pin Down 001: CCW Arrival
002: CW Rotation
003: CCW Rotation
3 -2. PROGRAM EXAMPLE FOR SIDE 001 Data in example Program 111 provides the necessary
WELDING OPERATION - Sequence data that mat- check for the location of side 001 before beginning any
ches side 001 in the work envelope with the appropriate weld sequence.
welding operations is necessary in the weld program.
PROGRAM NUMBER 111 (SIDE 001)
Sequence No. Sequence Data Sequence Operation
001 P Position (home) move by manipulator to a location which does not interfere
with jigs, fixtures, or weldments on mounting plate of turntable.
002 JN4 000 Jump to destination 4 if side 000 is in the work envelope. Jump is performed
if signal is present at Robot Control input port 000.
003
050
I Enter sequence data for welding operation. Total number of sequences and
specific data will depend on the desired operation.
051 PM4 Destination point 4 for jump sequence (see Sequence Number 002).
052 P Position (home) move by manipulator (see Sequence Number 001).
OM-890 Page 7

PROGRAM NUMBER 111 (SIDE 001)
Sequence No. Sequence Data Sequence Operation
053 END End of Program Number 111.
3 - 3. PROGRAM EXAMPLE FOR SIDE 000 Data in example Program 222 provides the necessary
WELDING OPERATION - Sequence data that mat- check for location of side 000 before beginning any
ches side 000 in the work envelope with the appropriate weld sequence.
welding operations is necessary in the weld program.
PROGRAM NUMBER 222 (SIDE 000)
Sequence No. Sequence Data Sequence Operation
001 P Position (home) move by manipulator to a location which does not interfere
with jigs, fixtures, or weldments on mounting plate of turntable.
002 JN4 001 Jump to destination 4 if side 001 is in the work envelope. Jump is performed
if signal is present at Robot Control input port 001.
003 I Enter sequence data for welding operation. Total number of sequences and
f specific data will depend on the desired operation.
050
051 PM4 Destination point 4 for jump sequence (see Sequence Number 002).
052 P Position (home) move by manipulator (see Sequence Number 001).
053 END End of Program Number 222.
3 - 4. JOB EXAMPLE FOR LINKING PROGRAMS the program number to rotate mounting plate ONLY
once in the job on line number 7.
When linking weld programs together
in a job for the turntable application, AL WAYS enter
JOB NO. LINE NO. LINE DATA LINE OPERATION
J777 1: P999 Run Program 999 to rotate mounting plate on turntable.
2: Pill Run Program 111 if side 001 of mounting plate is in the work envelope.
3: P222 Run Program 222 if side 000 of mounting plate is in the work envelope.
4: END EndofJob777.
IMPORTANT:
Example Job 100 is a linking method using job level
logic for individual parts in the turntable application that
combines the weld programs for each part with example
Program 999 for mounting plate rotation. The job logic
in this example only runs the weld programs for mat -
ching parts located at the weld side of the turntable.
OM-890 Page 8

Parts Loading/unloading Side
Weld Side
TA-120 271
Figure 3 - 1. Example Job 100 Starting Position Of Turntable Parts Layout And Matching
Program Numbers
JOB NO. LINE NO. LINE DATA LINE OPERATION
J100 1: P999 Run Program 999 to rotate mounting plate on turntable.
2: CNOOO P300 Call and run Program 300 if side 000 is at weld side of turntable.
3: CNOOO P400 Call and run Program 400 if side 000 is at weld side of turntable.
4: CNOOO P500 Call and run Program 500 if side 000 is at weld side of turntable.
5: CNOO1 P100 Call and run Program 100 if side 001 is at weld side of turntable.
6: CNOO1 P200 Call and run Program 200 if side 001 is at weld side of turntable.
7: END EndofJobl00.
Prior to selecting Automatic mode for running Job 100,
parts for weld Programs 300, 400, and 500 are loaded
in side 000 fixtures.
Running Job 100 the first time in Automatic mode will
perform the line data as follows:
Line 1: Program 999 runs and rotates mounting plate
on turntable. Parts on side 000 for weld Pro-
grams 300, 400, and 500 are now located at
weld side of turntable (see Figure 3-2).
Line 2: Control unit of manipulator checks for an in -
put signal at port 000. Turntable proximity
switch for side 000 is on and supplies input
signal to port 000 indicating side 000 is at
weld side of turntable. Control unit calls and
runs Program 300.
Line 4: Proximity switch for side 000 supplies input
signal to control unit port 000. Control unit
calls and runs Program 500.
Line 5: Control unit of manipulator checks for an in -
put signal at port 001. Turntable proximity
switch for side 001 is off and no input signal is
present at control unit input port 001 in -
dicating side 001 is not at weld side of turn -
table. Control unit does not run Program 100.
Line 6: No input signal is present at control unit input
port 001. Control unit does not run Program
200.
Line 7: End first run of Job 100.
Line 3: Proximity switch for side 000 supplies input
signal to control unit port 000. Control unit
calls and runs Program 400.
OM-890 Page 9

Parts Loading/Unloading Side
While Job 100 runs the first time in Automatic mode
and manipulator performs welding operations for Pro -
grams 300, 400, and 500, parts for weld Programs 100
and 200 are loaded in side 001 fixtures at parts
loading/unloading side of turntable. Running Job 100
the second time in Automatic mode will perform the line
data as follows:
Line 1: Program 999 runs and rotates mounting plate
on turntable. Parts on side 001 for weld Pro -
grams 100 and 200 are now locate at weld
side of turntable (see Figure 3-3).
Line 2: Control unit of manipulator checks for an in -
put signal at port 000. Turntable proximity
switch for side 000 is off and no input signal is
present at control unit input port 000 in -
dicating side 000 is not at weld side of turn -
table. Control unit does not run Program 300.
TA-120 271
Line 3: No input signal is present at control unit input
port 000. Control unit does not run Program
400.
Line 4: No input signal is present at control unit input
port 000. Control unit does not run Program
500.
Line 5: Control unit of manipulator checks for an in -
put signal at port 001. Turntable proximity
switch for side 001 is on and supplies input
signal to port 001 indicating side 001 is at
weld side of turntable. Control unit calls and
runs Program 100.
Line 6: Proximity switch for side 001 supplies input
signal to control unit and input port 001. Con -
trol unit calls and runs Program 200.
Line 7: End second run of Job 100.
Parts LoadIng/UnloadIng Side
Weld Side
TA 120 271
Weld Side
Figure 3 - 2. Position Of Turntable Parts Layout During First Run Of Job 100
Figure 3 - 3. Position Of Turntable Parts Layout During Second Run Of Job 100
OM-890 Page 10

While Job 100 runs the second time in Automatic mode
and manipulator performs welding operations for Pro -
grams 100 and 200, finished parts for Programs 300,
400, and 500 from first run of Job 100 are unloaded
and new parts are loaded in side 000 fixtures.
Each additional run of Job 100 rotates mounting plate
and runs weld programs that match parts located at
weld side of turntable while finished parts are unloaded
and new parts loaded in fixtures at parts
loading/unloading side.
3 - 5. SETTING RELAY TIME FOR
VALVE (Figure 3-4)
HIGH-SPEED
Figure 3 - 4. Adjustable Time-Delay Relay
An adjustable time-delay relay, located inside the turn -
table control panel, provides a time range of 0.1 to 1 .0
second in 0.05 second increments for energizing the
high-speed valve. The relay contacts are closed at the
beginning of each mounting plate rotation which opens
the high-speed valve to increase mounting plate
rotating speed. The contacts open when the relay times
RELAY
TIME
1.0 sec.
out which closes the high speed valve and the low-
speed rotation control decreases mounting plate final
rotating speed.
To adjust relay time, proceed as follows:
WARNING:
ELECTRIC SHOCK can kill.
• Do not touch live electrical parts.
• Shut down turntable, welding power source, and
robot control, and disconnect input power
employing “lockout/tagging procedures” before
setting relay time.
Lockout/tagging procedures consist of removing plug
from receptacle, padlocking line disconnect switch in
open position, removing fuses from fuse box, or shut -
ting off and red-tagging circuit breaker or other discon -
necting device.
1. Open hinged front cover on control panel.
IMPORTANT: Setting relay time depends on the
Ret TD-120 289 amount of mounting plate load weight. The chart in
Figure 3-5 is a guide for setting an appropriate relay
time for a given load weight. A specific setting for relay
time to provide the most efficient operation may vary
from the chart due to location and distribution of weight
on the mounting plate.
2. Locate time-delay relay in upper left corner inside
control panel, and rotate adjustment knob to
desired time selection.
3. Close and secure front cover.
——
0 lbs. 100 lbs. 200 lbs. 300 lbs. 400 lbs. 500 Ibm. 600 lbs. 700 lbs. 800 ibm.
(0 kg) (45 kg) (91 kg) 1136 kg) (¶81 kg) (227 kg) (272 kg) (318 kg) (363 kg)
900 lbs. 1000 lbs.
(408 kg) (454 kg)
Figure 3 - 5.
LOAD WEIGHT
Load Weight And Relay Time Chart
Turntable control
Panel
0.9 sec.
0.8 sec.
0.7 sec.
0.6 sec.
0.5 sec.
0.4 sec.
0.3 sec.
0.2 sec.
0.1 sec.
0.0 sec.
OM-83O Page 11

SECTION 4 - MAINTENANCE & TROUBLESHOOTING
IMPORTANT: All directions, such as leftor right, are
with respect to the operator facing the turntable (front)
on the weld side of work envelope and with locking pin
assembly located at opposite side (rear).
4 - 1. CLEANING AND INSPECTION
WARNING: ELECTRIC SHOCK can kill.
• Do not touch live electrical parts.
• Shut down turntable, welding power source, and
robot control, and disconnect input power
employing “lockout/tagging procedures” before
inspecting or servicing.
Lockout/tagging procedures consist of removing plug
from receptacle, padlocking line disconnect switch in
open position, removing fuses from fuse box, or shut -
ting off and red-tagging circuit breaker or other discon -
necting device.
MOVING PARTS can cause serious injury.
• Keep clear of moving parts.
PRESSURIZED HYDRAULIC FLUID can cause
serious Injury.
• Release hydraulic fluid pressure according to Sec-
tion 4-73 before touching any hydraulic com-
ponents.
Hydraulic fluid pressure is present even though elec -
trical power is disconnected.
Maintenance to be performed only by qualified persons.
A schedule for cleaning and inspection should be set
up, based on the type and conditions of service, to in -
clude the following:
Keep the inside of the unit clean by blowing out the unit
with clean, dry compressed air.
Wipe oil spills from base and support surface im -
mediately to avoid accumulation of dust.
Check for oil leaks indicating loose hydraulic connec -
tions inside the turntable. Tighten loose connections
and wipe oil from surfaces.
Check all hoses, cords, and cables for cracks or frayed
areas. Replace any damaged hydraulic hoses and repair
or replace faulty cords or cables.
REAR
Ref. TO-i20 290
Figure 4 - 1. Location Of Cylinder Pin Guide Bracket And Ball Bearings
FRONT
Lower
Ball
BearIng Ref: TB-120 281
OM-890 Page 12

4 - 2. LUBRICATION (Figure 4-1)
A. Lubricating Ball Bearings
WARNING: ELECTRIC SHOCK can kill; MOVING
PARTS can cause injury.
• Do not touch live electrical parts.
• Keep clear of pinch points.
Turntable operation is required to properly lubricate ball
bearings.
Every month lubricate the upper and lower ball bearings
that support the spindle on the turntable. If dusty,
moist, or corrosive environmental conditions are pre -
sent, more frequent lubrication may be necessary.
Remove rear cover from turntable chassis to gain ac -
cess to lower bearing lube fitting.
IMPORTANT:
Use a lithium-base grease for lubrica -
tion. While adding grease to the bearings, rotate spindle
to evenly distribute grease. Sufficient lubrication is add-
ed to bearings when a slight leakage of grease is present
at the seals. Wipe off any excess grease from around
lube fittings and bearings.
B. Lubricating Locking Pin
Every month lubricate the locking pin that secures the
mounting plate after each rotation. If dusty, moist, or
corrosive environmental conditions are present, more
frequent lubrication may be necessary.
Lube fitting is located below mounting plate in the
cylinder pin guide bracket.
~ Use a lithium-base grease for lubrica -
tion. Sufficient lubrication is added when a slight
leakage of grease is present at the seals. Wipe off any
excess grease from around lube fitting and cylinder pin
guide bracket.
4 - 3. OIL FILTER (Figure 4-2)
WARNING: ELECTRIC SHOCK can kill.
• Do not touch live electrical parts.
• Shut down turntable, welding power source, and
robot control, and disconnect input power
employing “lockout/tagging procedures” before
sen’icing or inspecting.
Lockout/tagging procedures consist of removing plug
from receptacle, padlocking line disconnect switch in
open position, removing fuses from fuse box, or shut -
ting off and red-tagging circuit breaker or other discon -
necting device.
MOVING PARTS can cause serious injury.
• Keep clear of pinch points.
PRESSURIZED HYDRAULIC FLUID can cause
serious Injury:
• Release hydraulic fluid pressure according to Sec -
tion 4-13 before touching any hydraulic com-
ponents.
Hydraulic fluid pressure is present even though elec -
trical power is disconnected.
Ret TD-120 290
Figure 4 - 2. Location Of Oil Filter
FRONT
And Base
OM-890 Page 13

The turntable is equipped with a spin-on type oil filter in
the return line of the hydraulic system. Replace the filter
after every 350 hours of turntable operation as follows:
~ A guide for replacement filters is pro -
videdin Table 4-1.
1. Remove front and rear covers from turntable
chassis.
2. Press the push button on top of the motor/pump
adapter to release pressurized fluid from ac -
cumulator, and check for a zero (0) reading at
pressure switch gauge.
3. Remove filter from base assembly.
4. Lubricate gasket on replacement filter with
hydraulic oil, and install filter securely Onto base
assembly. After seal contacts base, tighten filter
one more turn.
Table 4 - 1. Interchangable Replacement Oil Filters
Filter Manufacturer
Or Brand Name Series Or Type
CANFLO CFRS-30
CROSS F 1
FRAM 1653 F
GRESSEN F 100
LENZ CP 750
MICHIGAN S-28
RAND* F515
RIPLEY DP-752
UCC US 1500
*Original equipment oil filter.
Before beginning regular turntable
operation after replacing the filter, manually run the pro -
gram for rotating the mounting plate using the BLOCK
FOR WARD CONTINUOUS mode, and inspect filter and
base assembly for fluid leaks. Check the reservoir fluid
level, and add oil if necessary (see Section 4-4).
5. Reinstall covers onto turntable chassis.
4 - 4. CHECKING RESERVOIR FLUID LEVEL
(Figure 4-3)
IMPORTANT: The initial break-in time for the
hydraulic system is 2 days of turntable operation which
allows the fluid level in the reservoir to stabilize. After
operating the turntable for 2 days, check reservoir fluid
level according to this procedure.
The turntable is shipped with the proper amount of fluid
in the hydraulic reservoir. A sight gauge, located on the
end of the reservoir, is provided for ease of visually
checking the fluid level. After the initial 2 days of opera -
tion, and again after every 350 hours of operation,
check reservoir fluid level as follows:
~ ELECTRIC SHOCK can kill.
• Do not touch live electrical parts.
• Shut down turntable, welding power source, and
robot control, and disconnect input power
employing “lockout! tagging procedures” before
inspecting or servicing.
Lockout/tagging procedures consist of removing plug
from receptacle, padlocking line disconnect switch in
open position, removing fuses from fuse box, or shut -
ting off and red-tagging circuit breaker orother discon -
necting device.
MOVING PARTS can cause serious injury.
• Keep clear of pinch points.
PRESSURIZED HYDRAULIC FLUID can cause
serious injury.
• Release hydraulic fluid pressure according to Sec-
tion 4-13 before touching any hydraulic com-
ponents.
Hydraulic fluid pressure is present even though elec -
trical power is disconnected.
Prmure
Figure 4 - 3. Location Of Sight Gauge
TA-120 280
OM-890 Page 14

1. Remove front, rear, and left side covers from
turntable chassis.
UJ~~~iU Check reservoir fluid level only when
hydraulic system is at zero (0) pressure. Any pressurized
fluid stored in the accumulator must first be released
before fluid level in reservoir can be checked accurately.
2. Press the push button on top of the motor/pump
adapter to release pressurized fluid from ac -
cumulator, and check for a zero (0) reading at
pressure switch gauge.
3. Visually check sight gauge to verify that fluid
level is 1/2 to 3/4 above the LOW mark. If fluid
level is less than halfway between HIGH and
LOW marks, add hydraulic oil to reservoir as
follows:
a. Remove vent cap from reservoir.
IMPORTANT: Add only ISO 32 antiwear hydraulic
oil to reservoir, always use clean equipment to prevent
fluid contamination, and do not overfill reservoir when
adding hydraulic oil.
b. Add the necessary quantity of hydraulic oil
to reservoir to raise fluid level in sight gauge
to halfway between HIGH and LOW marks.
4 - 5. ADJUSTMENT OF LOW-SPEED ROTATION
CONTROL (Figure 4-4) - The adjustable low-speed
rotation control reduces mounting plate speed during
rotation after the high-speed valve deenergizes. The
low-speed rotation control, located in the return line
between the filter and directional control valves, is
equipped with an adjustment knob to allow increasing
or decreasing the exhaust flow of hydraulic oil to the
reservoir (meter-out flow control).
Adjustment of the low-speed rotation control and time
set on the time-delay relay to keep the high-speed valve
open must be coordinated together to accommodate
the amount of weight placed on the turntable mounting
plate.
IMPORTANT: When weight on the mounting plate
decreases, adjust setting of time-delay relay according
to Section 3-5, and rotate adjustment knob on low-
speed rotation control slightly clockwise from previous
setting to decrease exhaust flowof hydraulic oil. When
weight on the mounting plate increases, adjust setting
of time-delay relay according to Section 3-5, and rotate
adjustment knob on low-speed rotation control slightly
counterclockwise from previous setting to increase ex -
haust flow of hydraulic oil, Low-speed rotation control
adjustment can’ change locking pin speed. Be sure to
check and adjust locking pin speed as necessary (see
Section 4-6).
c. Reinstall vent cap on reservoir.
4. Reinstall covers onto turntable chassis.
Adjustment Knob
For Regulating
Oil Flow To
Control Rotating Speed
To Filter
TA-120 272
Speed
Rotation
Control
Control Valve Ret TC-120 284
Figure 4 - 4. Location Of Low Speed Rotation Control
Manifold
Block
OM-890 Page 15

WARNING:
To adjust mounting plate low speed rotation, proceed
as follows:
ELECTRIC SHOCK can kill; MOVING
PARTS can cause serious injury.
• Do not touch live electrical parts.
• Keep clear of pinch points.
Turntable operation is required to properly adjust moun-
ting plate rotation speed.
1. Remove front cover from turntable chassis.
2. Depending on the amount of weight on the turn -
table mounting plate, adjust time-delay relay set -
ting (see Section 3-5).
4. Manually run the program for rotating the moun -
ting plate using the BLOCK FORWARD CON -
TINUOUS mode to check the time-delay relay
setting that keeps the high-speed valve open and
low speed rotation after the relay times out
which closes the high-speed valve. Be sure to
check locking pin speed during turntable opera -
tion, and adjust the pin speed control according
to Section 4-6.
5. Make fine adjustments to the time-delay relay for
energizing the high-speed valve, and slightly
rotate adjustment knob on low-speed rotation
control to increase or decrease speed as
necessary.
IMPORTANT: Rotating low-speed flow control ad -
justment knob counterclockwise increases final rotating
speed of mounting plate and can cause knocker block
to slam into hard stops. An initial setting of the low-
speed rotation control can be obtained by rotating the
adjustment knob fully clockwise to the closed position;
then rotate adjustment knob one fully turn
counterclockwise, and make fine adjustment from this
coarse setting as necessary. Slight clockwise or
counterclockwise mtation of the adjustment knob from
its initial position will decrease or increase rotational
speed respectively after the high-speed valve closes.
3. Loosen locknut below knob, rotate adjustment
knob clockwise to decrease rotational speed, or
counterclockwise to increase rotational speed,
and retighten locknut.
6. Steps 4 and 5 may require repeating several
times to obtain the appropriate mounting plate
rotational speed without knocker block slamm -
ing into the hard stops.
7. Reinstall front cover on turntable chassis.
4 - 6. ADJUSTMENT OF LOCKING PIN SPEED
CONTROL (Figure 4-5) - The adjustable locking pin
speed control provides a smooth, even cylinder stroke ;
by metering the flow of fluid during locking and unlock -
ing pin movement. The locking pin speed control,
located in the hydraulic line between the directional
control valves and the rod end of the cylinder, is equip -
ped with an adjustment knob to allow increasing or
decreasing pressure and exhaust flow of hydraulic oil at
pin cylinder (meter-in and meter-out flow control).
Locking Pin
Speed Control
TA-120 272
Adjustment Knob
For Regulating Oil
Flow To Control
Locking Pin Speed
Figure 4 - 5. Location Of Locking Pin Speed Control
OM-890 Page 16

If pin speed is too slow, the locking cylinder stroke may
not secure the mounting plate position after rotation. If
pin speed is too fast, the locking and unlocking cylinder
strokes will be excessively rapid and cause a hard, noisy
stop. Locking pin speed can change as a result of ad -
justing the low speed rotation control which may re -
quire pin speed adjustment.
To adjust locking pin speed, proceed as follows:
WARNING:
ELECTRIC SHOCK can kill; MOVING
PARTS can cause serious injury.
• Do not touch live electrical parts.
• Keep clear of pinch points.
Turntable operation is required to properly adjust lock-
ing pin speed.
1. Remove front cover from turntable chassis.
IMPORTANT: An initial setting of the locking pin
speed control can be obtained by rotating the adjust -
ment knob fully clockwise to the closed position; then
rotate adjustment knob one full turn counterclockwise,
and make fine adjustment from this coarse setting as
necessary. Slight clockwise or counterclockwise rota -
tion of the adjustment knob from its initial position will
decrease or increase pin speed respectively.
2. Loosen locknut below knob, rotate adjustment
knob clockwise to decrease speed or
counterclockwise to increase pin speed, and
retighten locknut.
3. Manually run the program for rotation the moun -
ting plate using the BLOCK FORWARD CON -
TINUOUS mode to check pin speed during both
locking and unlocking movement.
4. Make fine adjustment to the locking pin speed
control by slightly rotating the adjustment knob
to increase or decrease speed as necessary.
5. Steps 3 and 4 may require repeating several
times to obtain appropriate locking pin speed
without pin slamming into receiver holes.
6. Reinstall front cover on turntable chassis.
4 - 7. ADJUSTMENT OF SHOCK ABSORBERS
(Figure 4-6 and 4-7) - The two hard stops on the turn -
table chassis are equipped with an adjustable shock ab -
sorber. The adjusting ring, located at the rod end of the
sock absorber body, rotates to allow changing the
amount of shock absorber cushioning. A scale from 0 to
9 on the shock absorber body indicates maximum to
minimum cushioning adjustment respectively.
If cushioning is set too hard, the shock absorber will
prevent knocker block contact with the hard stop as
mounting plate rotation ends, and the locking pin will
not secure the mounting plate. If cushioning is set too
soft, the shock absorber will allow the knocker block to
continue excessively rapid movement as mounting plate
rotation ends causing a sudden, forceful contact with
the hard stops. Both shock absorber adjustment set -
tings should provide firm cushioning for smooth,
decelerating contact between the knocker block and
hard stop at the end of a clockwise or counterclockwise
mounting plate rotation.
To adjust shock absorber cushioning, proceed as
follows:
WARNING: MOVING PARTS can cause serious
injury.
• Keep clear of moving parts and pinch points.
Turntable operation is required to properly adjust shock
absorber cushioning.
1. Loosen setscrew securing shock absorber ad -
justing ring.
IMPORTANT: The low speed rotation and amount of
weight on the turntable mounting plate will determine
the amount of cushioning required by the shock ab -
sorber. An initial setting of the cushioning can be ob -
tained by rotating the adjusting ring to a setting from
3-7/2 to 6-1/2 as indicated by the adjustment scale.
2. Rotate adjusting ring toward the 0 scale position
for firmer cushioning or toward the 9 scale posi -
tion for softer cushioning.
3. Manually run the program for rotating the moun -
ting plate using the BLOCK FORWARD CON -
TINUOUS mode to check cushioning at the end
of both clockwise and counterclockwise moun-
ting plate rotation.
4. Make fine adjustment to cushioning of both
shock absorbers by slightly rotating the adjusting
rings to change cushioning for either a firmer or
softer setting.
5. Steps 3 and 4 may require repeating several
times to obtain appropriate shock absorber
cushioning.
6. Retighten adjusting ring setscrew.
Setscrew
Adjusting
Ring
TC-120 287
Figure 4 - 6. Shock Absorber Components
OM-890 Page 17