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MANUAL NO.

HW1483638

Part Number:

176183-1CD

Revision:

MOTOMAN-MH5S(

)/MH5F

MAINTENANCE MANUAL

TYPE:

YR-MH0005F-A00 (STANDARD SPECIFICATION)

YR-MH0005S-A00 (STANDARD SPECIFICATION)

YR-MH0005S-J00 (STANDARD 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-MH5S/MH5F INSTRUCTIONS
MOTOMAN-MH5S II INSTRUCTIONS

DX100 INSTRUCTIONS
DX100 OPERATOR’S MANUAL
DX100 MAINTENANCE MANUAL

DX200 INSTRUCTIONS
DX200 OPERATOR’S MANUAL (for each purpose)
DX200 MAINTENANCE MANUAL

FS100 INSTRUCTIONS
FS100 OPERATOR’S MANUAL
FS100 MAINTENANCE MANUAL

The controller operator’s manual above correspond to a specific usage. Be sure to use the appropriate manual.

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Содержание MOTOMAN-MH5F

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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