YASKAWA MOTOMAN-MH5S II, Maintenance Manual

Page 1: ...YASKAWA Upon receipt of the product and prior to initial operation read these instructions thoroughly and retain for future reference MOTOMAN INSTRUCTIONS MOTOMAN MH5S MH5F INSTRUCTIONS MOTOMAN MH5S...

Page 2: ...yrighted property of Yaskawa and may not be sold or redistributed in any way You are welcome to copy this document to your computer or mobile device for easy access but you may not copy the PDF files...

Page 3: ...Battery Pack Connection 2 1 3 Home Position Return 3 1 3 1 Home Position Return after Motor Replacement 3 2 3 1 1 Home Position Return by Robot Calibration MOTOCALV EG 3 2 3 1 2 Home Position Return...

Page 4: ...ed Reducer 6 8 6 4 Disassembly and Reassembly of R Axis Speed Reducer 6 12 6 5 Disassembly and Reassembly of B Axis Speed Reducer 6 15 6 6 Disassembly and Reassembly of T Axis Speed Reducer 6 19 7 Dis...

Page 5: ...v 176183 1CD HW1483638 Table of Contents MH5S II MH5F 11 Parts List 11 1 11 1 S Axis Unit 11 1 11 2 L U Axes Unit 11 4 11 3 R Axis Unit 11 7 11 4 Wrist Unit 11 9 5 of 99...

Page 6: ...operating and maintenance this product The drawings and photos in this manual are representative examples and differences may exist between them and the delivered product YASKAWA may modify this mode...

Page 7: ...that can result from improper operation of the equipment The customer is responsible for providing adequately trained personnel to operate program and maintain the equipment NEVER ALLOW UNTRAINED PERS...

Page 8: ...us injury to personnel CAUTION Indicates 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 ale...

Page 9: ...within the P point maximum envelope of the manipulator Be sure to use a lockout device to the safeguarding when going inside Also display the sign that the operation is being performed inside the safe...

Page 10: ...is released clear the cell of all items which could interfere with the operation of the manipulator Then turn the servo power ON Injury may result from unintentional or unexpected manipulator motion...

Page 11: ...r Failure to observe this caution may result in disappearance of the home position data Perform the following inspection procedures prior to conducting manipulator teaching If problems are found repai...

Page 12: ...dant dummy connector optional In this manual the equipment is designated as follows 1 5 Registered Trademark In this manual names of companies corporations or products are trademarks registered tradem...

Page 13: ...y of the manipulator Prior to operating the manipulator confirm the contents The warning labels of MH0005F A00 are shown below as an example Warning label B Warning label B Nameplate WARNING Do not en...

Page 14: ...e whenever it is not in use In accordance with ANSI RIA R15 06 2012 section 4 2 5 Sources of Energy use lockout tagout procedures during equipment maintenance Refer also to Section 1910 147 29CFR Part...

Page 15: ...rams 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 the controller unit can cause...

Page 16: ...trained qualified personnel 1 11 Summary of Warning Information This manual is provided to help users establish safe conditions for operating the equipment Specific considerations and precautions are...

Page 17: ...tely 24 to 36 hours for a response to your inquiry Please have the following information ready before you call Customer Support techsupport motoman com NOTE Please use e mail for routine inquiries onl...

Page 18: ...the battery backup connector before removing the encoder connector Removing the encoder connector without connecting the battery pack leads to disappearance of the encoder absolute data Do not remove...

Page 19: ...unit Replacement of the motor or encoder Clearing stored memory Home position deviation caused by hitting the MOTOMAN against a workpiece etc Replacement disassembly and reassembly of the main parts s...

Page 20: ...eparation before Replacement Refer to the Fig 3 1 Preparation before Replacement Example Before replacement create the standard position hereinafter called the check point for home position adjustment...

Page 21: ...e It is therefore recommended to create the check point for each axis under normal operating conditions Check the home position of the replacing axis Use the position screen and move the replacing axi...

Page 22: ...lacement as an example Remove the motor then conduct the replacement of the U axis Fig 3 2 Replacement Example CAUTION Since the motor is removed the manipulator cannot keep its posture during motor r...

Page 23: ...xis Using the above values calculate the amount of deviation Subtract the command value from the present value Present value Command value the amount of deviation U 3067 2989 78 Perform stepping back...

Page 24: ...TIONS DX200 INSTRUCTIONS or FS100 INSTRUCTIONS Move the axis again to the check point by the check JOB Check if the axis is in the check point created before the operation to complete the adjustment I...

Page 25: ...ulse between the key position and the home position which is set when MOTOMAN is delivered on the home position label affixed inside of the DX100 DX200 FS100 When the home position data disappears mov...

Page 26: ...programming pendant so that the pin fits into the slot of the S head Fig 3 4 L Axis Positioning 3 U axis Positioning As shown in Fig 3 5 U Axis Positioning insert the positioning pin equivalent to int...

Page 27: ...cc 4 Move the S axis for a few minutes to discharge excess grease 5 Wipe the discharged grease with a cloth Remove the grease zerk from the grease inlet Reinstall the screw M6 to the grease inlet and...

Page 28: ...utes to discharge excess grease 5 Wipe the discharged grease with a cloth Remove the grease zerk from the grease inlet Reinstall the plugs PT1 8 to the grease inlet and to the exhaust port Apply Three...

Page 29: ...axis for a few minutes to discharge excess grease 5 Wipe the discharged grease with a cloth Remove the grease zerk from the grease inlet Reinstall the screw M6 to the grease inlet and the plug M5 to...

Page 30: ...for a few minutes to discharge excess grease 5 Wipe the discharged grease with a cloth Remove the grease zerk from the grease inlet Reinstall the screw M6 to the grease inlet and the plug M5 to the e...

Page 31: ...inutes to discharge excess grease 5 Wipe the discharged grease with a cloth Remove the grease zerk from the grease inlet Reinstall the plug M5 to the grease inlet and the screw M6 to the exhaust port...

Page 32: ...grease zerk from the grease inlet Reinstall the screw M6 to the grease inlet and the plug M5 to the exhaust port Apply Three Bond 1206C on the thread parts of the plug screw Exhaust port T axis gear...

Page 33: ...grease 5 cc 4 Move the T axis for a few minutes to discharge excess grease 5 Wipe the discharged grease with a cloth Remove the grease zerk from the grease inlet Reinstall the screw M6 to the grease i...

Page 34: ...oval tap 7 Unscrew the hexagon socket head cap screws and remove the gear 8 Unscrew the hexagon socket head cap screws and remove the M base from the S axis motor Reassembly 1 Install the M base on th...

Page 35: ...or Table 5 1 S Axis Motor Parts Checklist No Item Qty Remark S axis motor HW0388651 A 1 Hexagon socket head cap screw M4 length 25 mm Conical Spring Washer 2L 4 Washer M4 2 Tightening Torque 2 80 N m...

Page 36: ...Reassembly 1 Mount the pulley on the L axis motor 2 Attach the conical spring washer to the hexagon socket head cap screw then apply LOCTITE 242 to the thread part and tighten it with the tightening...

Page 37: ...SA bolt M4 length 16 mm Washer M4 3 Tightening Torque 2 80 N m Pulley HW0414070 B 1 Hexagon socket head cap screw M5 length 16 mm Conical spring washer 2L 5 1 Tightening Torque 10 0 N m M base HW04140...

Page 38: ...assembly and Reassembly of the Motor 5 2 Disassembly and Reassembly of the L Axis Motor 5 5 176183 1CD HW1483638 MH5S II MH5F Fig 5 2 Disassembly Assembly of L Axis Motor 8 1 2 3 4 5 5 6 6 6 7 9 9 38...

Page 39: ...ly 1 Mount the pulley on the U axis motor 2 Attach the conical spring washer and the washer to the hexagon socket head cap screw then apply LOCTITE 242 to the thread part and tighten it with the tight...

Page 40: ...ength 16 mm Washer M4 3 Tightening Torque 2 80 N m Pulley HW0414072 A 1 Hexagon socket head cap screw M4 length 18 mm Conical spring washer 2L 4 1 Tightening Torque 4 80 N m M base HW0414027 1 1 GT SA...

Page 41: ...183 1CD HW1483638 5 Disassembly and Reassembly of the Motor 5 3 Disassembly and Reassembly of the U Axis Motor MH5S II MH5F Fig 5 3 Disassembly Assembly of U Axis Motor 7 8 10 1 2 3 4 5 5 6 6 6 9 9 41...

Page 42: ...n the R axis motor 2 Attach the conical spring washer to the hexagon socket head cap screw then apply LOCTITE 242 to the thread part and tighten it with the tightening torque shown in Table 5 4 R Axis...

Page 43: ...m Qty Remark R axis motor HW0388647 A 1 GT SA bolt M3 length 12 mm Washer M3 2 Tightening Torque 1 40 N m Pulley HW0414074 A 1 Hexagon socket head cap screw M3 length 12 mm Conical spring washer CDW L...

Page 44: ...ey on the B axis motor 2 Attach the conical spring washer to the hexagon socket head cap screw then apply LOCTITE 242 to the thread part and tighten it with the tightening torque shown in Table 5 5 B...

Page 45: ...tor HW0388794 A 1 GT SA bolt M3 length 10 mm Washer M3 2 Tightening torque 1 40 N m Pulley HW1401268 1 1 Hexagon socket head cap screw M3 length 30 mm Conical spring washer CDW L3 1 Tightening torque...

Page 46: ...the conical spring washer to the hexagon socket head cap screw then apply LOCTITE 242 to the thread part and tighten it with the tightening torque shown in Table 5 6 T Axis Motor Parts Checklist 3 Mou...

Page 47: ...tor HW0388794 A 1 GT SA bolt M3 length 10 mm Washer M3 2 Tightening torque 1 40 N m Pulley HW1401269 1 1 Hexagon socket head cap screw M3 length 30 mm Conical spring washer CDW L3 1 Tightening torque...

Page 48: ...cular spline the flex spline from the S head 10 Remove the wave generator from the bearing and the bearing and the oil seal from the S head as well 11 Remove old sealing from each parts Reassembly 1 M...

Page 49: ...T SA bolts and tighten them with the tightening torque shown in Table 6 1 17 Mount the S axis motor Refer to section 5 1 Disassembly and Reassembly of the S Axis Motor 18 Put the internal wiring harne...

Page 50: ...3 176183 1CD HW1483638 MH5S II MH5F Fig 6 1 Disassembly Reassembly of the S Axis Speed Reducer Oil seal AE 2343 E0 1 TC405208 Collar HW0414024 1 1 O ring S39 1 Table 6 1 S Axis Speed Reducer Parts Ch...

Page 51: ...the removal tap Because the L arm and the S head are detached without the housing be sure to support the L arm before removing the housing 9 Remove the bearing the oil seal and the hexagon socket head...

Page 52: ...to the outside and inside walls of a and insert it in the housing and the wave generator When replace the speed reducer replace the bearings too 11 Tighten the GT SA bolts with the tightening torque...

Page 53: ...ing Torque 2 80 N m GT SA bolt M4 length 10 mm 4 Tightening Torque 2 80 N m Hexagon socket head cap screw M5 length 20 mm Conical spring washer 2L 5 1 Tightening Torque 10 0 N m Pulley HW0414071 B 1 2...

Page 54: ...d Reducer 6 2 Disassembly and Reassembly of L Axis Speed Reducer 6 7 176183 1CD HW1483638 MH5S II MH5F Fig 6 2 Disassembly Reassembly of the L Axis Speed Reducer a 3 7 8 9 11 16 18 19 20 12 13 13 14 1...

Page 55: ...he casing and the L arm are detached without the housing be sure to support the U arm before removing the housing 9 Remove the bearing the oil seal and the hexagon socket head cap screws Then remove t...

Page 56: ...s of a and insert it in the housing and the wave generator When replace the speed reducer replace the bearings too 11 Tighten the GT SA bolts with the tightening torque shown in Table 6 3 12 Mount the...

Page 57: ...er CDW L3 32 Tightening Torque 1 40 N m GT SA bolt M4 length 10 mm 4 Tightening Torque 2 80 N m Hexagon socket head cap screw M4 length 18 mm Conical spring washer 2L 4 1 Tightening Torque 4 80 N m Pu...

Page 58: ...Reducer 6 3 Disassembly and Reassembly of U Axis Speed Reducer 6 11 176183 1CD HW1483638 MH5S II MH5F Fig 6 3 Disassembly Reassembly of the U Axis Speed Reducer a 13 1 13 2 2 4 5 6 7 9 10 11 16 16 17...

Page 59: ...screw the hexagon socket head cap screws and remove the circular spline flex spline from the U arm 10 Remove old sealing from each parts Reassembly 1 Apply ThreeBond 1206C to the matching face between...

Page 60: ...Wrist Unit 10 Attach the conical spring washers to the hexagon socket head cap screws and apply ThreeBond 1206C to their thread parts Then tighten them with the tightening torque shown in Table 6 4 11...

Page 61: ...pring washer CDW L3 12 Tightening Torque 1 40 N m Bearing 6808ZZ NS7 1 Bearing 6806ZZ 1 Hexagon socket head cap screw M3 length 20 mm Conical spring washer CDW L3 16 Tightening Torque 1 40 N m Housing...

Page 62: ...head cap screws With the removal tap remove the housing bearing retaining ring and wave generator together 10 Remove the wave generator and the retaining ring from the housing Then remove the bearing...

Page 63: ...hexagon socket head cap screw and tighten it with the tightening torque shown in Table 6 5 9 Mount the U arm 2 unit on the U arm with the GA SA bolts b Tighten them with the tightening torque shown in...

Page 64: ...ring 699ZZ 1 Hexagon socket head cap screw M3 length 8 mm Conical spring washer CDW L3 3 Tightening Torque 1 40 N m Cover HW1301269 2 2 Hexagon socket button head screw M4 length 10 mm trivalent chrom...

Page 65: ...eed Reducer 6 5 Disassembly and Reassembly of B Axis Speed Reducer MH5S II MH5F Fig 6 5 Disassembly Reassembly of the B Axis Speed Reducer 1 2 3 3 4 5 6 7 7 8 8 8 9 10 10 11 11 16 17 18 19 20 12 13 b...

Page 66: ...replace the retaining ring too 4 Apply LOCTITE 515 to the matching face between the housing and the circular spline and mount the circular spline on the housing Also apply Harmonic Grease SK 1A on the...

Page 67: ...DX100 DX200 FS100 power supply Shim Type Thickness mm SPS 010005 0 05 SP 009010 0 1 SP 009015 0 15 SP 009020 0 2 Table 6 6 T Axis Speed Reducer Parts Checklist No Item Qty Remark Speed reducer HW03887...

Page 68: ...sembly of Speed Reducer 6 6 Disassembly and Reassembly of T Axis Speed Reducer 6 21 176183 1CD HW1483638 MH5S II MH5F Fig 6 6 Disassembly Reassembly of the T Axis Speed Reducer 3 5 6 7 11 12 13 15 1 9...

Page 69: ...Reassembly of R Axis Timing Belt 10 Unscrew the hexagon socket head cap screws With the removal tap remove the wrist unit 11 Remove old sealing from each parts Reassembly 1 Apply Three Bond 1206C to...

Page 70: ...screws 12 Turn ON the DX100 DX200 FS100 power supply Table 7 1 Wrist Unit Parts Checklist No Item Qty Remark Wrist unit 1 Cover HW1200087 2 1 Hexagon socket button head screw M4 length 10 mm trivalent...

Page 71: ...7 3 176183 1CD HW1483638 7 Disassembly and Reassembly of Wrist Unit MH5S II MH5F Fig 7 1 Disassembly Reassembly of Wrist Unit 5 13 4 1 12 14 8 2 6 3 4 5 7 11 11 9 10 71 of 99...

Page 72: ...pport the L arm to avoid it from rotating 4 Unscrew the GT SA bolts and remove the U axis timing belt However without the U axis timing belt its posture cannot be kept as the L axis So when remove the...

Page 73: ...Belts Table 8 1 L and U Axis Timing Belts Parts Checklist No Item Qty Remark L axis timing belt 100S5M305 1 U axis timing belt 100S5M390 1 GT SA bolt M4 length 16 mm Washer M4 2 Tightening Torque 2 80...

Page 74: ...s motor Refer to section 5 4 Disassembly and Reassembly of the R Axis Motor 7 Remove the R axis timing belt Reassembly 1 Mount the R axis timing belt 2 Mount the R axis motor Refer to section 5 4 Then...

Page 75: ...Belt Parts Checklist No Item Qty Remark R axis timing belt 060S3M219 1 R axis motor HW0388647 A 1 GT SA bolt M3 length 12 mm Washer M3 2 Tightening torque 1 40 N m Pipe HW9406285 E 1 GT SA bolt M3 le...

Page 76: ...4 Adjustment of Timing Belts Then tighten the GT SA bolts with the tightening torque shown in Table 8 3 B and T Axis Timing Belts Parts Checklist 2 Mount the B axis timing belt and adjust the initial...

Page 77: ...638 8 Disassembly and Reassembly and Adjustment of Timing Belts 8 3 Disassembly and Reassembly of B and T Axis Timing Belts MH5S II MH5F Fig 8 3 Disassembly Reassembly of B and T Axis Timing Belts 5 6...

Page 78: ...ming Belt Loosen the GT SA bolts and adjust the initial tension to be the specific initial tension as shown in Table 8 4 with the tension meter Then tighten them with the specified tightening torque B...

Page 79: ...nd Fig 9 3 Battery Connection 9 1 Battery Pack Replacement The battery packs are installed in the position shown in Fig 9 1 If the battery alarm occurs in the DX100 DX200 FS100 replace the battery in...

Page 80: ...the old battery pack from the connector on the board 6 Mount the new battery pack to the holder 7 Reinstall the support in the connector base with the fixing screws for the battery pack A View A A Ba...

Page 81: ...e internal wiring harness 4 Remove the air hoses and the internal user I O wiring harness connectors 3BC and 4BC 5 Cut off the cable tie and pull out the internal wiring harness to the U arm side Fig...

Page 82: ...L and U axis connectors connected to the internal wiring harness 7 Cut off all the cable ties which fix the internal wiring harness and unscrew the hexagon socket head cap screws Then remove the saddl...

Page 83: ...10 3 176183 1CD HW1483638 10 Cable Wiring 10 1Disconnecting Cables MH5S II MH5F Fig 10 2 Cable Wiring in Casing and L Arm Internal wiring harness Casing L arm 1 7 8 2 3 4 5 6 9 10 11 12 83 of 99...

Page 84: ...he power cable 5 Pull out the C base and connect the backup battery with the S axis motor 6 Disconnect the S axis connector connected to the internal wiring harness 7 While pull out the base connector...

Page 85: ...10 5 176183 1CD HW1483638 10 Cable Wiring 10 1Disconnecting Cables MH5S II MH5F Fig 10 3 Cable Wiring in S Head and Base 1 2 5 7 8 3 4 6 85 of 99...

Page 86: ...ness to the L arm side 8 Mount the cover with the hexagon socket button head screws 10 2 2 U Arm and Casing Refer to Table 10 2 Checklist for Cable Wiring Parts in Casing and L Arm and Fig 10 2 Cable...

Page 87: ...hoses and the internal user I O wiring harness connectors Refer to section 10 1 2 Casing and L Arm and mount the air hoses A black and B blue Mounting them on the wrong places makes the air lines int...

Page 88: ...is Unit Fig 11 1 S Axis Unit 1001 1049 1023 1048 1020 1027 1038 1037 1014 1026 1047 1032 1031 1030 1021 1032 1036 1035 1002 1017 1016 1004 1023 1010 1018 1009 1011 1029 1028 1007 1008 1019 1045 1022 1...

Page 89: ...Oil seal 1 1018 TC25356 FKM AE1292G0 Oil seal 1 1019 S39 O ring 1 1020 PT1 8 Plug 2 1021 HW9481967 B Sheet 4 1022 POC6 01M Union 1 1023 M4X10 Hexagon socket button head screw 22 1024 M8X16 Hexagon soc...

Page 90: ...CD HW1483638 MH5S II MH5F 1041 M4X10 GT SA bolt 4 1043 M4X16 GT SA bolt 7 1045 M4X12 GT SA bolt 4 1047 SGMAV 04ANA YR11 Motor 1 1048 HW0414483 1 Cover 1 1049 HW0414484 1 Gasket 1 Table 11 1 S Axis Uni...

Page 91: ...2029 2011 2007 2046 2047 2014 2014 1002 2001 2018 2023 2015 2049 2050 2013 2018 2023 2053 2026 2025 2057 2057 2055 2055 2013 2053 2019 2022 2048 2044 2015 2015 2051 2052 2017 2036 2035 2034 2033 2037...

Page 92: ...22 SC901107 BC0604 E00X1 Oil seal 1 2023 SC751007 AC3613 E00X3 Oil seal 3 2024 LP M5 Plug 2 2025 SGMAV 04ANA YR11 Motor 1 2026 SGMAV 02A2A YR11 Motor 1 2027 HW1200089 3 Cover 1 2028 HW1200089 4 Cover...

Page 93: ...L Spring washer 29 2051 M4X16 Hexagon socket head cap screw 30 2052 2L 4 Spring washer 30 2053 M4X10 GT SA bolt 12 2055 M4X16 GT SA bolt 6 2057 M4 Washer 6 2058 M8X16 Hexagon socket head cap screw 2 2...

Page 94: ...it 11 7 176183 1CD HW1483638 MH5S II MH5F 11 3 R Axis Unit Fig 11 3 R Axis Unit 2001 3001 3002 3024 3023 3025 3026 3012 3011 3018 3014 3029 3013 3005 3016 3019 3003 3028 30273030 3010 3006 3004 3008 3...

Page 95: ...M219 Belt 1 3011 SGMAV A5ANA YR11 Motor 1 3012 OB 31 Plug 1 3013 M4X10 Hexagon socket button head screw 4 3014 M3X12 GT SA bolt 2 3016 M3X12 GT SA bolt 2 3018 M3 Washer 2 3019 M3X10 GT SA bolt 3 3021...

Page 96: ...047 4047 4043 46 4029 4009 4025 4026 4041 4012 4010 4029 4007 4034 4076 4077 4024 4015 4037 4061 4060 4001 4022 4042 4003 4031 4004 4069 4068 4001 4028 4061 4060 4050 4049 4002 4075 4027 4011 4013 403...

Page 97: ...lder 1 4018 HW1400301 1 Flange 1 4019 HW1400304 1 Housing 1 4020 HW1400413 1 Housing 1 4021 HW1400570 A Pulley 1 4022 HW1400571 A Pulley 1 4023 HW1400918 1 Cover 2 4024 HW9406260 1 Housing 1 4025 HW94...

Page 98: ...exagon socket head cap screw 2 4061 2L 4 Spring washer 2 4062 M3X8 Hexagon socket head cap screw 4 4063 CDW L3 Spring washer 4 4064 M3X12 Hexagon socket head cap screw 6 4065 CDW L3 Spring washer 6 40...

Page 99: ...n Haryana India Fax 91 124 475 8542 Phone 91 124 475 8500 YASKAWA India Private Ltd Robotics Division YASKAWA Electric China Co Ltd 22F One Corporate Avenue No 222 Hubin Road Huangpu District Shanghai...