YASKAWA MOTOMAN-HP20D Maintenance Manual Download

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MANUAL NO.

HW1480357

Part Number:

159281-1CD

Revision:

MOTOMAN-HP20D

MAINTENANCE MANUAL

TYPE:

YR-HP0020D-A00 (STANDARD SPECIFICATION FOR DX100)

YR-HP0020D-B00 (ZEROING SPECIFICATIONS FOR DX100)

YR-HP0020D-A10 (LONG U-ARM, 6kg PAYLOAD SPECIFICATION)

Procedures described in this maintenance manual should be carried out by the person who took the

maintenance-relevant trainings offered by YASKAWA.

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

for future reference.
MOTOMAN INSTRUCTIONS
MOTOMAN-HP20D INSTRUCTIONS

DX100 INSTRUCTIONS

DX100 OPERATOR’S MANUAL

DX100 MAINTENACE MANUAL

The DX100 operator’s manual above corresponds to specific usage.

Be sure to use the appropriate manual.

1 of 96

Summary of Contents for MOTOMAN-HP20D

Page 1: ...maintenance manual should be carried out by the person who took the maintenance relevant trainings offered by YASKAWA Upon receipt of the product and prior to initial operation read these instruction...

Page 2: ...hted 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 to a...

Page 3: ...ack Connection for S L and U axis Motors 2 2 2 2 2 Battery Pack Connection for R B and T axis Motors 2 2 3 Home Position Return 3 1 3 1 Home Position Return after Motor Replacement 3 1 3 1 1 Home Posi...

Page 4: ...4 10 4 8 Grease Replenishment for R Axis Cross Roller Bearing 4 11 5 Disassembly and Reassembly of Motors 5 1 5 1 Disassembly and Reassembly of S Axis Motor 5 1 5 2 Disassembly and Reassembly of L Axi...

Page 5: ...T Axis 8 3 9 Battery Pack Replacement 9 1 10 Cable Wiring 10 1 10 1 Disconnecting Cables 10 1 10 1 1 Cables in Wrist Unit 10 1 10 1 2 Cables in U Arm 10 3 10 1 3 Cables in S Head 10 6 10 2 Connecting...

Page 6: ...tenance 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 model without notice wh...

Page 7: ...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 PERSONNE...

Page 8: ...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 alert agains...

Page 9: ...ithin 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 safeg...

Page 10: ...ducting manipulator teaching If problems are found repair them immediately and be sure that all other necessary processing has been performed Check for problems in manipulator movement Check for damag...

Page 11: ...d on the body of the manipulator Prior to operating the manipulator confirm the contents Figure 3 Warning Label Locations Warning label B Warning label B Nameplate Warning label A WARNING Do not enter...

Page 12: ...enever 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 191...

Page 13: ...s 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 sev...

Page 14: ...ned qualified personnel 1 10 Summary of Warning Information This manual is provided to help users establish safe conditions for operating the equipment Specific considerations and precautions are also...

Page 15: ...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 only If you...

Page 16: ...make sure to reapply sealing bond ThreeBond 1206C Fig 2 1 Wrist Unit NOTE When performing maintenance such as replacement of a wire harness in the manipulator the encoder connector may be necessary to...

Page 17: ...he end point of the encoder cable Under this condition remove the encoder connector and carry out the maintenance checks 3 After the maintenance check confirm that all the connectors are connected the...

Page 18: ...rged View Connect battery to encoder to save the data before removing connector CAUTION Connect battery to encoder to save the data before removing connector CAUTION a Crimped contact pin pin b Crimpe...

Page 19: ...allows the home position reset by teaching the five point in five posture Refer to MOTOCALV EG for Windows Operator s Manual manual No HW0483085 for details on the operation NOTE Perform calibration a...

Page 20: ...or home position adjustment after the replacement The check point must satisfy the conditions below Furthermore create the JOB so that the manipulator safely moves to the check point from the standby...

Page 21: ...ve because of failure Therefore it is recommended to create the check point for each axis under normal operating conditions Next check the home position of the axis whose motor will be replaced Refer...

Page 22: ...00 is shown below as an example Fig 3 2 Motor Replacement Example Remove the motor and replace it CAUTION Since the motor is removed the manipulator cannot keep its posture during motor replacement Wh...

Page 23: ...CURR current value CURR CMD the amount of deviation U 3067 2989 78 Perform stepping back etc of the check JOB to move the axis whose motor was replaced to the position where the axis will not interfe...

Page 24: ...To enable the home position return by using keys write down the differential pulse between the key position and the default home position on the home position label on the inside of the DX100 If the...

Page 25: ...perform positioning with the programming pendant so that the shaft fits into the hole on the L arm Fig 3 4 L Axis Positioning U Axis Positioning As shown in Fig 3 5 U Axis Positioning insert the shaf...

Page 26: ...81 1CD HW1480357 HP20D R Axis Positioning As shown in Fig 3 6 R Axis Positioning insert the shaft SFJW4 100 in the hole on the U arm Then perform positioning with the programming pendant so that the s...

Page 27: ...plug or screw from grease exhaust port grease will leak inside a motor or an oil seal of a speed reducer will come off which may result in damage to the motor Make sure to remove the plug Do not inst...

Page 28: ...ease zerk is delivered with the manipulator 3 Inject grease through the grease inlet using a grease gun Grease type VIGO Grease RE No 0 Amount of grease 30 cc 60 cc for 1st supply Air supply pressure...

Page 29: ...delivered with the manipulator 3 Inject grease through the grease inlet using a grease gun Grease type VIGO Grease RE No 0 Amount of grease approx 1800 cc Air supply pressure of grease pump 0 3 MPa o...

Page 30: ...30 cc 60 cc for 1st supply Air supply pressure of grease pump 0 3 MPa or less Grease injection rate 8 g s or less 5 Move the L axis for a few minutes to discharge excess grease 6 Remove the grease zer...

Page 31: ...MPa or less Grease injection rate 8 g s or less 5 The grease exchange is completed when new grease appears in the exhaust port The new grease can be distinguished from the old grease by color 6 Move...

Page 32: ...re of grease pump 0 3 MPa or less Grease injection rate 8 g s or less 5 Move the U axis for a few minutes to discharge excess grease 6 Remove the grease zerk from the grease inlet and reinstall the pl...

Page 33: ...3 MPa or less Grease injection rate 8 g s or less 5 The grease exchange is completed when new grease appears in the exhaust port The new grease can be distinguished from the old grease by color 6 Mov...

Page 34: ...1 on the grease inlet by using a grease gun See Fig 4 4 R Axis Speed Reducer Grease type Harmonic Grease SK 1A Amount of grease 8 cc 16 cc for 1st supply 3 Reinstall the screw on the exhaust port App...

Page 35: ...s 10 cc 20 cc for 1st supply T axis 5 cc 10 cc for 1st supply 4 Reinstall the plug or screw on the exhaust port Apply ThreeBond 1206C to the thread part of the plug or screw 5 Remove the grease zerk f...

Page 36: ...the grease inlet using a grease gun See Fig 4 6 T Axis Gear Grease type Harmonic Grease SK 1A Amount of grease 5cc 10 cc for 1st supply 4 Reinstall the plug on the exhaust port Apply ThreeBond 1206C t...

Page 37: ...the manipulator 3 Inject grease through the grease inlet using a grease gun See Fig 4 7 R Axis Cross Roller Bearing 4 Reinstall the plug on the exhaust port Apply ThreeBond 1206C to the thread part of...

Page 38: ...6 Remove the hexagon socket head cap screw then remove the input gear and the key Reassembly 1 Mount the key and the input gear on the S axis motor The key is attached to the S axis motor 2 Put the co...

Page 39: ...ackup battery 8 Turn ON the DX100 power supply Table 5 1 S Axis Motor Parts Checklist No Name Qty Notes S axis motor HW0387862 A 1 SGMRV 09ANA YR11 GT SA bolt M8 length 30 mm 3 Tightening torque 24 5...

Page 40: ...5 Disassembly and Reassembly of Motors 5 1 Disassembly and Reassembly of S Axis Motor 5 3 159281 1CD HW1480357 HP20D Fig 5 1 Disassembly and Reassembly of S Axis Motor 1 1 5 3 6 9 4 8 7 2 2 40 of 96...

Page 41: ...put gear the key and the plate Reassembly 1 Apply ThreeBond 1206C on the matching surface between the L axis motor and the plate Then mount the plate on the L axis motor 2 Apply ThreeBond 1206C on the...

Page 42: ...ecklist No Name Qty Notes L axis motor HW0387863 A 1 SGMRV 13ANA YR21 Hexagon socket head cap screw M8 length 25 mm Conical spring washer 2H 8 4 each Tightening torque 24 5 N m M base HW0304229 1 1 In...

Page 43: ...the U axis motor horizontally from the casing 7 Remove the hexagon socket head cap screw then remove the input gear and the key Reassembly 1 Mount the key and the input gear on the U axis motor The k...

Page 44: ...otor HW0387860 A 1 SGMRV 05ANA YR11 GT SA bolt M8 length 30 mm 4 Tightening torque 24 5 N m Input Gear 1 Key 1 Hexagon socket head cap screw M5 length 65 mm Conical spring washer 2H 5 1 each Tightenin...

Page 45: ...ove the GT SA bolts Then remove the R axis motor from the M base Reassembly 1 Mount the R axis motor on the M base 2 Tighten the GT SA bolts with the tightening torque shown in Table 5 4 R Axis Motor...

Page 46: ...ty Notes R axis motor HW0389298 A 1 SGMPH 02ANA YR11 GT SA bolt M5 length 20 mm 4 Tightening torque 6 N m GT SA bolt M6 length 30 mm 3 Tightening torque 10 N m M base HW0304932 1 1 Shaft HW0404402 1 1...

Page 47: ...embly and Reassembly of R Axis Motor Fig 5 4 Disassembly and Reassembly of R Axis Motor See the step 3 of the R axis reassembly procedure Fill with Harmonic grease SK 1A See the step 4 of the R axis r...

Page 48: ...of the pulley to fix it Reassembly 1 Mount the pulley on the B axis motor 2 Apply Loctite 242 to the thread part of the hexagon socket head cap screw Then tighten it with the tightening torque shown...

Page 49: ...is Motor Parts Checklist No Name Qty Notes B axis motor HW0389298 A 1 SGMPH 02ANA YR11 GT SA bolt M5 length 20 mm 2 Tightening torque 6 N m Pulley HW9482727 A 1 Hexagon socket head cap screw M4 length...

Page 50: ...t head cap screw then remove the pulley Use the holes 2 holes diameter 4 mm on the surface of the pulley to fix it Reassembly 1 Mount the pulley on the T axis motor 2 Apply Loctite 242 to the thread p...

Page 51: ...T Axis Motor Table 5 6 T Axis Motor Parts Checklist No Name Qty Notes T axis motor HW0389298 A 1 SGMPH 02ANA YR11 GT SA bolt M5 length 20 mm 2 Tightening torque 6 N m Pulley HW9482727 A 1 Hexagon sock...

Page 52: ...Drain grease which remains inside Reassembly 1 Apply ThreeBond 1206C on the matching surface between the base and the speed reducer Then mount the speed reducer on the base 2 Tighten the GT SA bolts w...

Page 53: ...RE No 0 through the grease inlet 8 Turn ON the DX100 power supply Fig 6 1 Disassembly and Reassembly of S Axis Speed Reducer Table 6 1 S Axis Speed Reducer Parts Checklist No Name Qty Notes Speed redu...

Page 54: ...face between the speed reducer and the S head Then mount the speed reducer on the S head When mounting make sure not to apply a load on the input gear 2 Tighten the GT SA bolts with the tightening tor...

Page 55: ...Disassembly and Reassembly of Speed Reducer 6 2 Disassembly and Reassembly of L Axis Speed Reducer Fig 6 2 Disassembly and Reassembly of L Axis Speed Reducer Input gear Internal wiring harness L axis...

Page 56: ...hus when replacing the speed reducer replace the input gear too 2 Apply Loctite 242 to the thread part of the hexagon socket head cap screw Then tighten it with the tightening torque shown in Table 6...

Page 57: ...educer Parts Checklist No Name Qty Notes Speed reducer HW9280880 G 1 GT SA bolt M8 length 45 mm 12 Tightening torque 26 5 N m Hexagon socket head cap screw M14 length 35 mm Conical spring washer GT SH...

Page 58: ...circular spline Reassembly 1 Mount the circular spline on the casing 2 Tighten the hexagon socket head cap screws with the tightening torque shown in Table 6 4 R Axis Speed Reducer Parts Checklist 3 A...

Page 59: ...peed Reducer Parts Checklist No Name Qty Notes Speed reducer HW0381463 A 1 Circular spline Speed reducer HW0381463 A 1 Flex spline Speed reducer HW0381463 A 1 Wave generator Shaft HW0404403 1 1 GT SA...

Page 60: ...the tightening torque shown in Table 6 5 B Axis Speed Reducer Parts Checklist 5 Apply Harmonic Grease SK 1A on the bearing part of the wave generator Press fit the bearings and Then mount the housing...

Page 61: ...nerator GT SA bolt M4 length 16 mm 12 Tightening torque 2 8 N m Timing belt 80S4 5M653 1 Pulley HW9482725 A 1 Hexagon socket head cap screw M5 length 16 mm Conical spring washer 2H 5 1 each Tightening...

Page 62: ...peed Reducer 6 5 Disassembly and Reassembly of B Axis Speed Reducer 6 11 159281 1CD HW1480357 HP20D Fig 6 5 Disassembly and Reassembly of B Axis Speed Reducer Wrist base U arm B axis motor 1 12 13 14...

Page 63: ...tening torque shown in Table 6 6 T Axis Speed Reducer Parts Checklist 4 Mount the housing the assembly prepared in the steps 1 to 3 above on the wrist base 5 Temporarily tighten the GT SA bolts 6 Chec...

Page 64: ...Checklist 13 Replenish grease Harmonic Grease SK 1A through the grease inlet 14 Turn ON the DX100 power supply Table 6 6 T Axis Speed Reducer Parts Checklist No Name Qty Notes Speed reducer HW0382140...

Page 65: ...0357 HP20D 6 Disassembly and Reassembly of Speed Reducer 6 6 Disassembly and Reassembly of T Axis Speed Reducer Fig 6 6 Disassembly and Reassembly of T Axis Speed Reducer A Flange Wrist base 1 10 7 9...

Page 66: ...hexagon socket head cap screws with the tightening torque shown in Table 7 1 Wrist Unit Parts Checklist 3 Fix the white marked part of the B and T axis internal wiring harness to the support with a ca...

Page 67: ...me Qty Notes Wrist unit 1 Mass 14 5 kg Hexagon socket head cap screw M6 length 65 mm Conical spring washer 2H 6 8 each Tightening torque 10 N m Support HW9406556 1 1 GT SA bolt M4 length 12 mm 2 Tight...

Page 68: ...assembly of B and T Axis Timing Belts Disassembly Refer to section 5 5 Disassembly and Reassembly of B Axis Motor and section 5 6 Disassembly and Reassembly of T Axis Motor 1 Remove the B axis motor t...

Page 69: ...st No Name Qty Notes B axis timing belt 80S4 5M653 1 T axis timing belt 80S4 5M518 1 T axis motor HW0389298 A 1 SGMPH 02ANA YR11 GT SA bolt M5 length 20 mm 2 Tightening torque 6 N m B axis motor HW038...

Page 70: ...ith the following Belt mass 34 gram per meter width 10 mm Belt width 8 mm Distance between axes 276 mm 8 2 2 T Axis 1 Loosen the GT SA bolts shown in Fig 8 1 Disassembly and Reassembly of B and T Axis...

Page 71: ...packs are installed in the position shown in Fig 9 1 Battery Pack Location If the battery alarm occurs in the DX100 replace the battery in accordance with the following procedure Fig 9 1 Battery Pack...

Page 72: ...he new battery pack to an unconnected connector on the board 5 Remove the old battery pack from the board 6 Mount the new battery pack to the battery holder 7 Reinstall the plate Connector Battery pac...

Page 73: ...s 3 Disconnect the connectors of the B and T axis motors 4 Remove the GT SA bolts then remove the support 5 Cut off the cable tie which fixes the B and T axis internal wiring harness to the support NO...

Page 74: ...10 2 159281 1CD HW1480357 HP20D Fig 10 1 B and T Axis Cable Wiring B and T axis internal wiring harness B axis internal wiring harness connector T axis internal wiring harness connector Wrist unit B...

Page 75: ...onnectors 6 Remove the cross head APS bolt which fixes the ground wire 7 Remove the GT SA bolts and hexagon socket head cap screws then remove the S cover 8 Pull out the internal wiring harness to the...

Page 76: ...her 2H 5 4 2 each For part For part S cover HW0200530 1 1 Support HW0404919 1 1 Cross head APS bolt M5 length 8 mm 1 GT SA bolt M4 length 16 mm 4 Tightening torque 2 8 N m Stopper HW0404179 1 2 GT SA...

Page 77: ...s power cable R axis power cable U axis power cable U axis encoder cable R axis motor B and T axis internal wiring harness Connector of internal user I O wiring harness Main key position U axis motor...

Page 78: ...nnector of the S axis motor from the internal wiring harness 6 Remove the GT SA bolts Then pull out the holder which fixes the internal wiring harness 7 Remove the hexagon socket head cap screws then...

Page 79: ...ue 10 N m Holder HW0305812 1 1 Hexagon socket head cap screw M6 length 10 mm Conical spring washer 2H 6 2 each Tightening torque 10 N m Saddle CD 31 1 Cross head APS bolt M5 length 10 mm 6 C base HW03...

Page 80: ...159281 1CD HW1480357 HP20D Fig 10 3 S Head Cable Wiring S axis connector S head Apply sealing bond to the hatched area L axis motor S axis motor Internal wiring harness Cable ties 2 pieces T18S 1 12...

Page 81: ...the tightening torque shown in Table 10 3 S Head Cable Wiring Parts Checklist 6 Mount the holder to the internal wiring harness Fix the holder to the white marked part of the internal wiring harness b...

Page 82: ...ness through the S cover Hold the spring by using the stoppers then fix it to the S cover with the GT SA bolts 9 Tighten the GT SA bolts with the tightening torque shown in Table 10 2 U Arm Cable Wiri...

Page 83: ...bolts 3 Tighten the GT SA bolts with the tightening torque shown in Table 10 1 B and T Axis Cable Wiring Parts Checklist 4 Connect the connectors of the B and T axis motors to the internal wiring harn...

Page 84: ...11 Parts List 11 1 S Axis Unit Fig 11 1 S Axis Unit 1002 1004 1003 1007 1005 1020 1025 1014 1006 1016 1017 1018 1015 1028 1029 1030 1009 1030 1031 1032 1033 1035 1036 1034 1001 1008 1027 1024 1024 10...

Page 85: ...1 1013 HW0305809 1 Cover 1 1014 NB 0640 0 3 Tube 2 1015 HW0304221 1 Cover 1 1016 M6X15 GT SA bolt 2 1017 MSB8 15 Shoulder 1 1018 HW0400645 1 Lever 1 1019 M5X10 APS bolt 6 1020 TSH6 01M Union 2 1021 C...

Page 86: ...7 HP20D 11 2 L Axis Unit Fig 11 2 L Axis Unit 1002 2012 2011 2018 2006 2032 2002 2003 2004 2005 2001 2023 2025 2024 2007 2019 2008 2010 2017 2009 2027 2013 2013 2014 2014 2026 2028 2015 2016 2020 2031...

Page 87: ...2015 M10X35 Socket screw 6 2016 2H 10 Conical spring washer 6 2017 HW0100546 2 L arm 1 2018 HW0387753 C Speed reducer 1 2019 M10X40 Socket screw 16 2020 M12X40 Socket screw 2 2021 2H 12 Conical spring...

Page 88: ...Unit 11 5 159281 1CD HW1480357 HP20D 11 3 U Axis Unit Fig 11 3 U Axis Unit 2017 3011 3006 3019 3007 3016 3016 3005 3020 3001 3012 3002 3002 3004 3003 3004 3003 3018 3018 3017 3017 3008 3009 3010 3015...

Page 89: ...0880 G Speed reducer 1 3007 M8X45 GT SA bolt 16 3008 M5X65 Socket screw 1 3009 2H 5 Conical spring washer 1 3010 M14X35 Socket screw 6 3011 GT SH 14 GT SH washer 6 3012 M8X30 GT SA bolt 4 3013 M10X20...

Page 90: ...4034 4073 4057 4035 4036 4042 4058 4027 4040 4011 4043 4044 4039 3005 4005 4037 4045 4046 4030 4032 4012 4029 4033 4008 4071 4056 4003 4009 4074 4006 4007 4029 4010 4031 4001 5046 4002 4065 4067 4017...

Page 91: ...17 HW0403857 1 Shaft 1 4018 HW0405201 2 Block 1 4019 HW0304318 1 Housing 1 4020 HW0304085 1 Shaft 1 4021 HW0304914 1 Support 1 4022 HW0403879 1 Saddle 1 4023 M4X20 Socket screw 2 4024 M4X12 GT SA bolt...

Page 92: ...2 4066 KQE12 03 Union 1 4067 2H 4 Conical spring washer 2 4068 M4X20 Socket screw 2 4069 2H 4 Conical spring washer 2 4070 MS4 10 Pin 2 4071 2H 4 Conical spring washer 1 4072 PT 3 8 Plug 1 4073 M4X12...

Page 93: ...5039 5040 5041 5046 5064 5008 5008 5012 5016 5005 5003 5003 5006 5006 5007 5007 5048 5049 5047 5017 5036 5011 5043 5044 5045 5045 5037 5038 5033 5034 5042 5063 5062 5014 5019 5020 5021 5022 5013 5053...

Page 94: ...1 5021 SP 0120 Shim 1 5022 HW9481180 A Bearing 1 5023 M5X16 GT SA bolt 1 5024 M5X12 GT SA bolt 8 5025 HW0304232 1 Shaft 1 5026 TC60747 Oil seal 2 5027 HW9481187 A Bearing 1 5028 HW0304233 1 Shaft 1 5...

Page 95: ...t 4 5050 M6X6 Socket screw 1 5052 M5X16 GT SA bolt 5 5053 M6X6 Socket screw 1 5062 LP M5 Plug 1 5063 HW9405791 3 Housing 1 5064 6811LLU Bearing 1 5065 HW0404606 1 Cover 1 5066 HW040605 1 Plug 1 3005 H...

Page 96: ...rgaon 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 Shan...

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