Yaskawa MH80 User Manual

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MOTOMAN-MH80

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INSTRUCTIONS

TYPE: YR-MH00080-A00 (STANDARD SPECIFICATION)

TYPE: YR-MH00080

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

MOTOMAN INSTRUCTIONS

MOTOMAN-MH80 INSTRUCTIONS DX100 INSTRUCTIONS DX100 OPERATOR’S MANUAL DX100 MAINTENANCE MANUAL

The DX100 operator’s manual above corresponds to specific usage. Be sure to use the appropriate manual.

-A01 (WITH LIMIT SWITCHES FOR SLU-AXES)

Part Number: 158813-1CD Revision: 002

MANUAL NO.

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MANDATORY

CAUTION

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• This instruction manual is intended to explain operating instructions and maintenance procedures primarily for the MOTOMAN-MH80.

• General items related to safety are listed in Chapter 1: Safety of the DX100 Instructions. To ensure correct and safe operation, carefully read the DX100 instructions before reading this manual.

• Some drawings in this manual are shown with the protective covers or shields removed for clarity. Be sure all covers and shields are replaced before operating 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 when necessary due to product improvements, modifications, or changes in specifications. If such modification is made, the manual number will also be revised.

• If your copy of the manual is damaged or lost, contact a YASKAWA representative to order a new copy. The representatives are listed on the back cover. Be sure to tell the representative the manual number listed on the front cover.

• YASKAWA is not responsible for incidents arising from unauthorized modification of its products. Unauthorized modification voids your product’s warranty.

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DANGER

WARNING

CAUTION

MANDATORY

PROHIBITED

NOTE

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Notes for Safe Operation

Read this manual carefully before installation, operation, maintenance, or inspection of the MOTOMAN-MH80.

In this manual, the Notes for Safe Operation are classified as “DANGER”, “WARNING”, “CAUTION”, “MANDATORY”, or “PROHIBITED”.

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Indicates an imminent hazardous situation which, if not avoided, could result in death or serious injury to personnel.

Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury to personnel.

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 against unsafe practices.

Always be sure to follow explicitly the items listed under this heading.

Must never be performed.

Even items described as “CAUTION” may result in a serious accident in some situations. At any rate, be sure to follow these important items.

To ensure safe and efficient operation at all times, be sure to follow all instructions, even if not designated as “DANGER”, “WARNING” and “CAUTION”.

DANGER

• Maintenance and inspection must be performed by specified personnel.

Failure to observe this caution may result in electric shock or injury.

• For disassembly or repair, contact your Yaskawa representative.

• Do not remove the motor, and do not release the brake.

Failure to observe these safety precautions may result in death or serious injury from unexpected turning of the manipulator's arm.

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WARNING

TURN

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• Before operating the manipulator, check that servo power is turned off when the emergency stop buttons on the front door of the DX100 and programming pendant are pressed. When the servo power is turned OFF, the SERVO ON LED on the programming pendant is turned OFF.

Injury or damage to machinery may result if the emergency stop circuit cannot stop the manipulator during an emergency. The manipulator should not be used if the emergency stop buttons do not function.

Figure 1: Emergency Stop Button

• Once the emergency stop button is released, clear the cell of all items which could interfere with the operation of the manipulator. Then turn ON the servo power.

Injury may result from unintentional or unexpected manipulator motion.

Figure 2: Release of Emergency Stop

• Observe the following precautions when performing teaching operations 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 safeguarding and make sure no one closes the safeguarding.

– View the manipulator from the front whenever possible.

– Always follow the predetermined operating procedure.

– Ensure that you have a safe place to retreat in case of

emergency.

Improper or unintended manipulator operation may result in injury.

• Confirm that no persons are present in the P-point maximum envelope of the manipulator and that you are in a safe location before:

– Turning ON the DX100 power.

– Moving the manipulator with the programming pendant.

– Running check operations.

– Performing automatic operations.

Injury may result if anyone enters the P-point maximum envelope of the manipulator during operation. Always press an emergency stop button immediately if there is a problem. The emergency stop button is located on the right of front door of the DX100 and the programming pendant.

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CAUTION

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• Perform the following inspection procedures prior to conducting 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 damage to insulation and sheathing of external wires.

• Always return the programming pendant to the hook on the DX100 cabinet after use.

The programming pendant can be damaged if it is left in the P-point maximum envelope of the manipulator, on the floor, or near fixtures.

• Read and understand the Explanation of Warning Labels in the DX100 instructions before operating the manipulator.

Definition of Terms Used Often in This Manual

The MOTOMAN is the YASKAWA industrial robot product.

The MOTOMAN usually consists of the manipulator, the controller, the programming pendant, and manipulator cables.

In this manual, the equipment is designated as follows:

Equipment Manual Designation

DX100 controller DX100

DX100 programming pendant Programming pendant

Cable between the manipulator and the controller

Manipulator cable

Registered Trademark

In this manual, names of companies, corporations, or products are trademarks, registered trademarks, or brand names for each company or corporation. The indications of (R) and TM are omitted.

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Warning Label B

WARNING

Do not enter robot work area.

Warning Label ANameplate

WARNING

Moving parts may cause injury

WARNING Label A

WARNING Label B

Nameplate

NJ3247

MADE IN JAPAN

YASKAWA ELECTRIC CORPORATION

Kitakyushu 806-0004 Japan

2-1 Kurosakishiroishi, Yahatanishi-ku,

SERIAL NO.

PAYLOAD

TYPE

MASS

DATE

ORDER NO.

MOTOMAN

MOTOMAN-

MODEL

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Explanation of Warning Labels

The following warning labels are attached to the manipulator.

Always follow the warnings on the labels.

Also, an identification label with important information is placed on the body of the manipulator. Prior to operating the manipulator, confirm the contents.

Figure 3: Warning Labels Location

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Table of Contents

1 Product Confirmation ...................................................................................................................... 1-1

1.1 Contents Confirmation ....................................................................................................... 1-1

1.2 Order Number Confirmation............................................................................................... 1-2

2 Transport......................................................................................................................................... 2-1

2.1 Transporting Method.......................................................................................................... 2-1

2.1.1 Using a Crane....................................................................................................... 2-2

2.1.2 Using a Forklift...................................................................................................... 2-3

2.2 Shipping Bolts and Brackets .............................................................................................. 2-4

3 Installation....................................................................................................................................... 3-1

3.1 Installation of Safeguarding ............................................................................................... 3-2

3.2 Mounting Procedures for Manipulator Base....................................................................... 3-2

3.2.1 Mounting the Manipulator on the Baseplate ......................................................... 3-3

3.2.2 Mounting the Manipulator on the Floor ................................................................. 3-4

3.3 Types of Mounting ............................................................................................................. 3-5

3.3.1 S-axis Operating Range ....................................................................................... 3-5

3.3.2 Fixing the Manipulator Base ................................................................................. 3-5

3.3.3 Precautions to Prevent the Manipulator from Falling............................................ 3-5

3.4 Notes in Mounting the Manipulators on the Ceiling ........................................................... 3-6

3.6 IP (International Protection) ............................................................................................... 3-8

3.7 Location ............................................................................................................................. 3-8

4 Wiring.............................................................................................................................................. 4-1

4.1 Grounding .......................................................................................................................... 4-1

4.2 Manipulator Cable Connection........................................................................................... 4-2

4.2.1 Connection to the Manipulator.............................................................................. 4-2

4.2.2 Connection to the DX100...................................................................................... 4-2

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5 Basic Specifications ........................................................................................................................ 5-1

5.1 Basic Specifications........................................................................................................... 5-1

5.2 Part Names and Working Axes.......................................................................................... 5-2

5.3 Manipulator Base Dimensions ........................................................................................... 5-2

5.4 Dimensions and P-Point Maximum Envelope.................................................................... 5-3

5.5 Alterable Operating Range ................................................................................................ 5-4

6 Allowable Load for Wrist Axis and Wrist Flange ............................................................................. 6-1

6.1 Allowable Wrist Load ......................................................................................................... 6-1

6.2 Wrist Flange....................................................................................................................... 6-2

7 System Application ......................................................................................................................... 7-1

7.1 Peripheral Equipment Mounts ........................................................................................... 7-1

Table of Contents

7.2 Internal User I/O Wiring Harness and Air Lines................................................................. 7-2

8 Electrical Equipment Specification.................................................................................................. 8-1

8.1 Position of Limit Switch...................................................................................................... 8-1

8.1.1 Specification of Limit Switch ................................................................................. 8-1

8.1.2 Location of Limit Switches .................................................................................... 8-1

8.1.3 Setting of Operation Range .................................................................................. 8-2

8.1.3.1 S-Axis Operation Range.......................................................................... 8-2

8.1.3.2 L-Axis Operation Range .......................................................................... 8-2

8.1.3.3 Setting Range of LU-Axes Interference Angle ........................................ 8-3

8.2 Internal Connections.......................................................................................................... 8-4

9 Maintenance and Inspection ........................................................................................................... 9-1

9.1 Inspection Schedule .......................................................................................................... 9-1

9.2 Notes on Maintenance Procedures ................................................................................... 9-6

9.2.1 Battery Pack Replacement ................................................................................... 9-6

9.3 Notes on Grease Replenishment/Exchange Procedures .................................................. 9-8

9.3.1 Grease Replenishment/Exchange for S-Axis Speed Reducer ............................. 9-8

9.3.1.1 Grease Replenishment............................................................................ 9-8

9.3.1.2 Grease Exchange ................................................................................... 9-9

9.3.2 Grease Replenishment/Exchange for L-Axis Speed Reducer............................ 9-11

9.3.2.1 Grease Replenishment.......................................................................... 9-11

9.3.2.2 Grease Exchange ................................................................................. 9-12

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9.3.3 Grease Replenishment/Exchange for U-Axis Speed Reducer ........................... 9-13

9.3.3.1 Grease Replenishment.......................................................................... 9-13

9.3.3.2 Grease Exchange.................................................................................. 9-14

9.3.4 Grease Replenishment/Exchange for R-Axis Speed Reducer ........................... 9-16

9.3.4.1 Grease Replenishment.......................................................................... 9-16

9.3.4.2 Grease Exchange.................................................................................. 9-17

9.3.5 Grease Replenishment/Exchange for B- and T-Axis Speed Reducers

and Gears ........................................................................................................... 9-18

9.3.5.1 Grease Replenishment.......................................................................... 9-18

9.3.5.2 Grease Exchange.................................................................................. 9-19

9.3.6 Notes for Maintenance........................................................................................ 9-20

9.3.6.1 Battery Pack Connection for Motors...................................................... 9-20

10 Recommended Spare Parts........................................................................................................ 10-1

11 Parts List ..................................................................................................................................... 11-1

Table of Contents

11.1 S-Axis Unit ..................................................................................................................... 11-1

11.2 L-Axis Unit...................................................................................................................... 11-3

11.3 U-Axis Unit ..................................................................................................................... 11-5

11.4 R-, B-, T-Axis Unit.......................................................................................................... 11-7

11.5 Wrist Unit ..................................................................................................................... 11-10

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CAUTION

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1 Product Confirmation

1.1 Contents Confirmation

1 Product Confirmation

• Confirm that the manipulator and the DX100 have the same order number. Special care must be taken when more than one manipulator is to be installed.

If the numbers do not match, manipulators may not perform as expected and cause injury or damage.

1.1 Contents Confirmation

Confirm the contents of the delivery when the product arrives.

Standard delivery includes the following four items (Information for the content of optional goods is given separately):

• Manipulator

• DX100

• Programming Pendant

• Manipulator cables (2 cables, between the DX100 and the manipulator)

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THE MANIPULATOR AND THE CONTROLLER SHOULD HAVE SAME ORDER NUMBER.

ORDER NO.

Check that the manipulator and the DX100 have the same order number.

Label (Enlarged View)

(a) DX 100 (Front View) (b) Manipulator (Side View)

X 8 1

PROGRAMMING PENDANT

TRIPPED

RESET

OFF

AVERAGE

PEAK

kVA

INTERRUPT CURRENT

ERDR-

POWER SUPPLY

TYPE

DX100

kVA

3PHASE

NJ2960-1

60Hz

SERIAL No.

DATE

AC220V

MADE IN JAPAN

50/60HzAC200V

ORDER NO.

NJ1529

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1 Product Confirmation

1.2 Order Number Confirmation

Check that the order number of the manipulator corresponds to the DX100. The order number is indicated on a label as shown below.

Fig. 1-1: Location of Order Number Label

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CAUTION

NOTE

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2 Transport

2.1 Transporting Method

• Sling and crane or forklift operations must be performed by authorized personnel only.

Failure to observe this caution may result in injury or damage.

• Avoid excessive vibration or shock during transport.

The system consists of precision components. Failure to observe this caution may adversely affect performance.

2.1 Transporting Method

• The mass of the manipulator is approximately 585 kg including the shipping bolts and brackets. Use a wire rope strong enough to withstand the mass.

• The attached eyebolts are designed to support the manipulator mass. Never use them for anything other than transporting the manipulator.

• Mount the shipping bolts and brackets before transporting the manipulator.

• With any transportation equipment, make sure to avoid external force on the arm or motor unit when transporting the manipulator.

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Shipping bolts and bracket (Fixed to the manipulator before shipment.)

Hexagon head screw M12 (8 screws)

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2 Transport

2.1 Transporting Method

2.1.1 Using a Crane

As a rule, when uncrating the manipulator and moving it, a crane should be used. Lift the manipulator with a four-leg bridle sling using the shipping bolts and brackets. Be sure that the manipulator is fixed with the shipping bolts and brackets before transport, and lift it in the posture as shown in

Fig. 2-1 “Transport Using a Crane”.

Fig. 2-1: Transport Using a Crane

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Pallet

Shipping bolts and bracket (Fixed to the manipulator before shipment.)

Screw M20 (8 screws)

Forklift claw entries

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2 Transport

2.1 Transporting Method

2.1.2 Using a Forklift

When using a forklift, the manipulator should be fixed on a pallet with shipping bolts and brackets as shown in Insert claws into the folklift claw entries of the pallet and lift it. The pallet must be strong enough to support the manipulator.

Transport the manipulator slowly with due caution in order to avoid overturn or slippage.

Fig. 2-2: Transport Using a Forklift

Fig. 2-2 “Transport Using a Forklift”.

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NOTE

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2 Transport

2.2 Shipping Bolts and Brackets

The manipulator is provided with shipping bolts and brackets at positions as shown in the figures in section 2.1 “Transporting Method” on page 2-1, to protect its driving units from various external force during transport.

The shipping brackets are painted yellow.

Before turning ON the power, check to be sure that the shipping bolts and brackets have been removed. The shipping bolts and brackets then must be stored for future use, in the event that the manipulator must be moved again for relocation.

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WARNING

CAUTION

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3 Installation

• Install the safeguarding.

Failure to observe this warning may result in injury or damage.

• Install the manipulator in a location where the manipulator’s tool or the workpiece held by the manipulator will not reach the wall, safeguarding, or DX100 when the arm is fully extended.

Failure to observe this warning may result in injury or damage.

• Do not start the manipulator or even turn ON the power before it is firmly anchored.

The manipulator may overturn and cause injury or damage.

• Do not install or operate a manipulator that is damaged or lacks parts.

Failure to observe this caution may cause injury or damage.

• Before turning ON the power, check to be sure that the shipping bolts and brackets explained in section 2.2 “Shipping Bolts and Brackets” on page 2-4 are removed.

Failure to observe this caution may result in damage to the driving parts.

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3 Installation

3.1 Installation of Safeguarding

To insure safety, be sure to install the safeguarding. They prevent unforeseen accidents with personnel and damage to equipment. The following is quoted for your information and guidance.

Responsibility for Safeguarding (ISO 10218)

The user of a manipulator or robot system shall ensure that safeguarding is provided and used in accordance with Sections 6, 7, and 8 of this standard. The means and degree of safeguarding, including any redundancies, shall correspond directly to the type and level of hazard presented by the robot system consistent with the robot application. Safeguarding may include but not be limited to safeguarding devices, barriers, interlock barriers, perimeter guarding, awareness barriers, and awareness signals.

3.2 Mounting Procedures for Manipulator Base

The manipulator should be firmly mounted on a baseplate or foundation strong enough to support the manipulator and withstand repulsion forces during acceleration and deceleration. Construct a solid foundation with the appropriate thickness to withstand maximum repulsion force of the manipulator. (Refer toTable 3-1 "Maximum Repulsion Force of the

Manipulator at Emergency Stop" andTable 3-2 "Endurance Torque in Operation".)

A baseplate flatness must be kept at 0.5 mm or less: insufficient flatness of installation surface may deform the manipulator shape and affect its functional abilities.

For installation, refer to Fig. 3-1 “Mounting the Manipulator on the

Baseplate” or Fig. 3-2 “Mounting the Manipulator on the Floor”.

Table 3-1:

Maximum torque in horizontal rotation (S-axis moving direction)

Maximum torque in vertical rotation (LU-axis moving direction)

Maximum Repulsion Force of the Manipulator at Emergency Stop

24500 N·m (2500 kgf·m)

45080 N·m (4600 kgf·m)

Table 3-2: Endurance Torque in Operation

Endurance torque in horizontal operation

Endurance torque in vertical operation

6125N·m (625 kgf·m)

11270 N·m (1150 kgf·m)

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Flatness: 0.5mm or less

Baseplate

Anchor bolt (M20 or more)

Manipulator base

Hexagon head screw M20 (8 screws)

Spring washer

Washer

Baseplate

50 30

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3 Installation

3.2 Mounting Procedures for Manipulator Base

3.2.1 Mounting the Manipulator on the Baseplate

The baseplate should be rugged and durable to withstand maximum repulsion force of the manipulator and to ensure that the manipulator and fixture are in the correct relative position. The thickness of the baseplate is 50 mm or more and an M20 size or larger anchor bolt is recommended. After anchoring the baseplate firmly on the floor, fix the manipulator base to the baseplate with the hexagon head screw M20 (8 screws, length of 70 mm or more is recommended) using mounting holes on the manipulator base. The manipulator base is tapped for eight mounting holes. Tighten the hexagon head bolts and anchor bolts securely so that they will not work loose during operation. For details, refer to Fig. 3-1

“Mounting the Manipulator on the Baseplate”.

Fig. 3-1: Mounting the Manipulator on the Baseplate

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28 dia.hole (4 holes) (Base B)

28 dia.hole (4 holes) (Base A)

Base B

Base A

Level the floor.

JA-type anchor bolt M24

Weld here after installation and adjustment .

Units: mm

Screw A: Screw M20 (length: 70) (8 screws); spring washer, flat washer Screw B: Screw M24 (length: 70) (4 screws); spring washer The fixing screws and bases are to be prepared by customer.

(length: 315)

Tapped hole M20 (8 holes);

Manipulator base

Tapped hole M24 (4 holes) (Base B); Screw B

Screw A

600

900

800

720

385

320

300300

400

230

36250

350

200

100

200

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3.2 Mounting Procedures for Manipulator Base

3.2.2 Mounting the Manipulator on the Floor

The floor should be strong enough to support the manipulator. Construct a solid foundation with the appropriate thickness to withstand maximum repulsion force of the manipulator shown in Table 3-1 "Maximum Repulsion Force of the Manipulator at Emergency Stop" . As a rough standard, if there is a concrete thickness (floor) of 200 mm or more, the manipulator base can be fixed directly to the floor with anchor bolts M20. Before mounting the manipulator, however, check that the floor is level and that all cracks, etc. are repaired. Any thickness less than 200 mm is insufficient for mounting, even if the floor is concrete.

Fig. 3-2: Mounting the Manipulator on the Floor

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NOTE

Manipulator base

Support for fall prevention

Hexagon socket head cap screw M20 (8 screws) (Tensile strength: 1200 N/mm

or more)

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3 Installation

3.3 Types of Mounting

The MOTOMAN-MH80 is available in three ways: floor-mounted (standard), wall-mounted and ceiling-mounted way. For wall-mounted and ceiling-mounted ways, the three points listed below are different from the floor-mounted way.

• S-axis Operating Range

• Fixing the Manipulator Base

• Precautions to Prevent the Manipulator from Falling

3.3.1 S-axis Operating Range

For wall-mounted way, the S-axis operating range is ±30°. (The range is adjusted prior to the shipment.)

3.3.2 Fixing the Manipulator Base

For wall- and ceiling-mounted ways, be sure to use eight hexagon socket head cap screws M20 (tensile strength: 1200 N/mm

or more) when fixing the manipulator base. Use a torque of 402 N•m (41 kgf•m) when tightening the screws.

3.3.3 Precautions to Prevent the Manipulator from Falling

For the wall- or ceiling-mounted ways, take appropriate measures to avoid the falling of the manipulator in case of emergency. Refer to Fig. 3-3

“Precaution Against Falling” for details.

Fig. 3-3: Precaution Against Falling

In case of using the wall-/ceiling-mounted way, inform Yaskawa of the matter when placing an order. Be sure to contact your Yaskawa representative (listed on the back cover of this instruction manual) to perform a wall/ceiling installation on site.

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(After)

View A

(Before)

Air Breather

Grease Cap

Motor base

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3 Installation

3.4 Notes in Mounting the Manipulators on the Ceiling

In the case if the manipulator shipped is the floor-mounted way, yet is to be mounted on the ceiling, mounting positions of each part on the view A in the figure below should be changed after installing the manipulator on the ceiling, to prevent a grease leakage from an air breather.

Change the mounting positions of the parts as shown in the figure below.

After installing the manipulator on the ceiling, replace the positions of the parts installed in the L-axes motor base, by switching the positions of the grease cap and the air breather.

Replace the positions of the grease cap and the air breather promptly, to prevent the grease leakage from a hole where a grease cap is to be installed.

Fig. 3-4: Parts Positions for Ceiling Mounted Manipulator

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NOTE

(After)

View A

(Before)

Air Breather

Grease Cap

Air Breather

Grease Cap

Motor base

Connector base

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3 Installation

3.4 Notes in Mounting the Manipulators on the Ceiling

3.5 Notes in Mounting the Manipulators on the Wall

In the case if the manipulator shipped is the floor-mounted way, yet is to be mounted on the wall, mounting positions of each part on the view A in the figure below should be changed after installing the manipulator on the wall, to prevent a grease leakage from an air breather.

Change the mounting positions of the parts as shown in the figure below.

After installing the manipulator on the wall, replace the positions of the parts installed in the motor base, by switching the positions of the grease cap and the air breather.

Replace the positions of the grease cap and the air breather promptly, to prevent the grease leakage from a hole where a grease cap is to be installed.

When used in the wall mounted position, install the manipulator so that a connector base becomes the top.

Fig. 3-5: Parts Positions for Wall Mounted Manipulator

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3 Installation

3.6 IP (International Protection)

For the standard type, environmental resistance for main part of the manipulator conforms to IP54; the wrist part conforms to IP67.

However, for wall-mounted or ceiling mounted ways, environmental resistance for main part of the manipulator does not conform to IP54; environmental resistance for IP65 is optionally available.

3.7 Location

When installing the manipulator, satisfy the following environmental conditions.

• Ambient temperature: 0° to 45°C

• Humidity: 20 to 80%RH at constant temperature

• Free from exposure to water, oil, or dust

• Free from corrosive gas or liquid, or explosive gas or liquid

• Free from excessive vibration (Vibration acceleration: 4.9 m/s [0.5 G] or less)

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• Free from large electrical noise (plasma)

• Flatness for installation is 0.5 mm or less

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WARNING

CAUTION

NOTE

5.5mm2 or more

Screw M8 (for grounding)

(Delivered with the manipulator)

View A

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4Wiring

4 Wiring

4.1 Grounding

• Ground resistance must be 100Ω or less.

Failure to observe this warning may result in fire or electric shock.

• Before wiring, make sure to turn OFF the primary power supply, and put up a warning sign. (ex. DO NOT TURN THE POWER ON.)

Failure to observe this warning may result in fire or electric shock.

• Wiring must be performed by authorized or certified personnel.

Failure to observe this caution may result in fire or electric shock.

4.1 Grounding

Follow local regulations for grounding line size. A line of 5.5 mm2 or more is recommended. Refer to Fig. 4-1 “Grounding Method” to connect the ground line directly to the manipulator.

Fig. 4-1: Grounding Method

• Do not use this line sharing with other ground lines or grounding electrodes for other electric power, motor power, welding devices, etc.

• Where metal ducts, metallic conduits, or distributing racks are used for cable laying, ground in accordance with local electric equipment technical standards.

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4 Wiring

4.2 Manipulator Cable Connection

Two manipulator cables are delivered with the manipulator: an encoder cable (1BC) and a power cable (2BC). Refer to Fig. 4-2 “Manipulator Cables” on page 4-3. Connect these cables to the connectors on the manipulator connector base and the DX100 board connectors.

4.2.1 Connection to the Manipulator

Before connecting the manipulator cables to the manipulator, verify the connector numbers: both the cables and the connectors on the manipulator base are marked with 1BC and 2BC. Connect the cables in the order of 2BC, 1BC, referring to Fig. 4-3(a) "Manipulator Cable Connection (To the Manipulator)" on page 4-4. When connecting, insert each cable connector adjusting its position to the main keys on the connector base of the manipulator, and then depress the lever until it clicks.

4.2.2 Connection to the DX100

Before connecting the manipulator cables to the DX100, verify the connector numbers: both the cables and the connectors on the DX100 are marked with X11 and X21. Connect the cables in the order of X21, X11, referring to Fig. 4-3(b) "Manipulator Cable Connection (To the DX100)" on page 4-4. When connecting, insert each cable connector adjusting its position to the main keys on the DX100, and then depress the lever until it clicks.

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2BC

1BC

Power Cable

DX100 Manipulator

Encoder Cable

X11

1BC

X21

2BC

X11

1BC

X21 2BC

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4 Wiring

4.2 Manipulator Cable Connection

Fig. 4-2: Manipulator Cables

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MH80 Manipulator

AIR

1BC

2BC

AIR

1BC

2BC

X11

X21

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4 Wiring

4.2 Manipulator Cable Connection

Fig. 4-3(a): Manipulator Cable Connection (To the Manipulator)

Fig. 4-3(b): Manipulator Cable Connection (To the DX100)

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5 Basic Specifications

5.1 Basic Specifications

5 Basic Specifications

5.1 Basic Specifications

Table 5-1: Basic Specifications

Item Model MOTOMAN-MH80

Configuration Vertically Articulated

Degree of Freedom 6

Payload 80 kg

Repeatability

Range of Motion

Maximum Speed S-axis 2.97 rad/s, 170°/s

Allowable Moment

Allowable Inertia (GD

Approx. Mass 555 kg

Ambient Conditions

Power Capacity 4.5 kVA

1 Conformed to ISO9283 2 For the limit switch specification (type: MOTOMAN-MH00080-A01),

the range of motion is limited with limit switch before shipment.

3 Refer to Table 6-1 "Allowable Total Moment of Wrist" on page 6-1" for details

on the allowable moment of inertia.

Note: SI units are used in this table. However, gravitational unit is used in ().

S-axis (turning) -180° - +180°

L-axis (lower arm) -90° - +135°

U-axis (upper arm) -170° - +251°

R-axis (wrist roll) -360° - +360°

B-axis (wrist pitch/yaw) -125° - +125°

T- axis (wrist twist) -360° - +360°

L-axis 2.44 rad/s, 140°/s

U-axis 2.79 rad/s, 160°/s

R-axis 4.01 rad/s, 230°/s

B-axis 4.01 rad/s, 230°/s

T-axis 6.11 rad/s, 350°/s

2.97 rad/s, 170°/s 392 N•m (40 kgf•m)

2.44 rad/s, 140°/s 392 N•m (40 kgf•m)

2.79 rad/s, 160°/s 196 N•m (20 kgf•m)

/4) R-Axis 28 kg•m

B-Axis 28 kg•m

T-Axis 11 kg•m

Temperature 0°C to 45°C

Humidity 20 to 80% RH at constant temperature

Vibration Acceleration Less than 4.9 m/s

Others Free from corrosive gas or liquid, or explosive gas.

±0.07 mm

(0.5G)

Free from water, oil, or dust. Free from excessive electrical noise (plasma).

5-1

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MH80 Manipulator

(S-head)

Base

(U-arm)

Wrist flange

Wrist

S+

S-

L+L-

U-

U+

R+

R-

B-

B+

T+

T-

Rotary head

(L-arm)

Lower arm

Upper arm

22 dia. hole (8 holes)

12 dia. hole (2 holes)

+0.018 0

View A

153

455

608

455

0.1

195

385

320

0.1

195

0.1

195

0.1

230

0.1

195

400

230

230±

0.1



Manipulator Base Dimensions

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5 Basic Specifications

5.2 Part Names and Working Axes

Fig. 5-1: Part Names and Working Axes

5.3 Manipulator Base Dimensions

Fig. 5-2: Manipulator Base Dimensions

5-2

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P-point maximum

envelope

P-point

R377

234 234

40 223.5

135

3578

1751025145

3832

R2061

R543

120

1807

187540 870

210

343

265

105105

118

1369

453

170

437

925

2456

460

1121

2061

543

530

213

605

1056

1771

248

View A

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5 Basic Specifications

5.4 Dimensions and P-Point Maximum Envelope

Fig. 5-3: Dimensions and P-Point Maximum Envelope

5-3

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5 Basic Specifications

5.5 Alterable Operating Range

The operating range of the S-axis can be altered according to the operating conditions as shown in Fig. 5-2 “S-Axis Operating Range”. If alteration is necessary, contact your Yaskawa representative in advance.

Table 5-2: S-Axis Operating Range

Item Specifications

S-Axis Operating Range -180° - +180°

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(standard)

-165° - +165°

-150° - +150°

-135° - +135°

-120° - +120°

-105° - +105°

-90° - +90°

-75° - +75°

-60° - +60°

-45° - +45°

-30° - +30°

-15° - +15°

5-4

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P-point

R-, T-axis center of rotation

B-axis center of rotation

LT(mm)

600

400

200

400

200

400 800

LB(mm)

80kg

70kg

60kg

50kg

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6 Allowable Load for Wrist Axis and Wrist Flange

6.1 Allowable Wrist Load

6 Allowable Load for Wrist Axis and Wrist Flange

6.1 Allowable Wrist Load

The allowable wrist load is 80 kg; however, consider the limitations shown in Table 6-1 "Allowable Total Moment of Wrist" to fulfill this condition. If force is applied to the wrist instead of the load, the forces on R-, B-, and TAxes should be within the values shown in Table 6-1.

Table 6-1: Allowable Total Moment of Wrist

Axis Moment N•m (kgf•m)

R-Axis 392 (40) 28

B-Axis 392 (40) 28

T-Axis 196 (20) 11

1 ( ): Gravitational unit

/4 Total Moment of Inertia kg•m

When the volume load is small, refer to the moment arm rating shown in Fig. 6-1 “Moment Arm Rating”.

The allowable total inertia is calculated when the moment is at the maximum. Contact your Yaskawa representative when only inertia, or load moment is small and inertia is large. Also, when the load mass is combined with an outside force, contact your Yaskawa representative.

Fig. 6-1: Moment Arm Rating

6-1

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MH80 Manipulator

P.C.D.80

Alignment mark

Units: mm

+0.015

8 dia. hole (depth: 14)

+0.012

6 dia. hole (depth: 10)

Tapped hole M8 (depth: 14) (pitch: 1.25) (6 holes)

-0.022

100 dia.

+0.025

50 dia. hole

NOTE

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6 Allowable Load for Wrist Axis and Wrist Flange

6.2 Wrist Flange

The wrist flange dimensions are shown in Fig. 6-2 “Wrist Flange”. To make the alignment mark visible and to enable an easy grease exchange for the B- and T-axis gears, mount the attachment inside the fitting. Fitting depth of inside and outside fittings must be 5 mm or less.

Fig. 6-2: Wrist Flange

Wash off anti-corrosive paint (Yellow) on the wrist flange surface with thinner or light oil before mounting the tools.

6-2

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(pitch:1.25)(4 holes)

Tapped hole M8(depth:16)

(pitch:1.75)(4 holes)

Tapped hole M12(depth:18)

(pitch:1.25)(4 holes)

Tapped hole M8(depth:16)

Mount the peripheral equipment within this range.

View A

Peripheral Equipment Mounuts and Tapped hole

187

22440

105105

200 513

100

180

100 98.5

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7 System Application

7.1 Peripheral Equipment Mounts

7 System Application

7.1 Peripheral Equipment Mounts

The peripheral equipment mounts are fixed on the upper arm for easier installation of the user's system application as shown in Fig. 7-1 “Installing Peripheral Equipment”. Observe the conditions in the figure and table below in mounting the peripheral equipment on the U-axis.

Fig. 7-1: Installing Peripheral Equipment

Table 7-1: Conditions for Installation

Section Application Note

A Cabling Up to 80 kg for attaching load

B Cabling

mass including wrist load.

Up to 10 kg.

N•m (5 kgf•m) max. for

Valve mounting

increased moment amount of upper arm

C Transformer, etc. mounting 30 kg or less

7-1

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MH80 Manipulator

AIR

1BC

2BC

Connector for internal user I/O wiring harness:

Prepare pin connector JL05-6A24-28P

JL05-2A24-28SC(socket connector with a cap)

Tapped hole PT3/8 with a pipe plug

Air inlet

Air inlet Tapped hole PT3/8 with a pipe plug

View B

View A

Connector for internal user I/O wiring harness: JL05-2A24-28PC(socket connector with a cap) Prepare pin connector JL05-6A24-28S

Pin Details for Internal User I/O Wiring Harness

Pin Used

Internal user I/O wiring harness:

0.5mm

, 23 wires

6517

11 121813

21 22 23

3 4

7 8 9 10

17 18

22 23

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7 System Application

7.2 Internal User I/O Wiring Harness and Air Lines

Internal user I/O wiring harness (0.5 mm2 x 23 wires) and an air line are incorporated in the manipulator for the drive of peripheral devices mounted on the upper arm as shown in Fig. 7-2 “Connectors for Internal User I/O Wiring Harness and Air Lines”

The Fig. 7-2 “Connectors for Internal User I/O Wiring Harness and Air Lines” also shows the connector pin (1 to 23) assignment. Perform wiring referring to the figure and the conditions below.

Items Conditions

The allowable current for internal user I/ O wiring harness

The maximum pressure for the air line 490 kPa (5 kgf/cm

Fig. 7-2: Connectors for Internal User I/O Wiring Harness and Air Lines

5.1A or less per a wire. The total current value for pins 1 to 23 must be 34.5A or less.

(The air line inside diameter: 8 mm.)

) or less

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The same numbered pins (1 to 23) of the two connectors are connected with a single lead wire of 0.5mm

7-2

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NOTE

S-axis overrun limit switch

(For limit switch specification YR-MH00080-A01)

L-axis overrun limit switch

(For limit switch specification YR-MH00080-A01)

LU-axis interference limit switch

AIRAIR

1BC1BC

2BC2BC

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8 Electrical Equipment Specification

8.1 Position of Limit Switch

8 Electrical Equipment Specification

8.1 Position of Limit Switch

8.1.1 Specification of Limit Switch

1. The interference limit switch at S-, L- and U-axes electrically limit the operating range of respective axes by adjusting the position of the dog using the limit switch. The positions of the mechanical limits (mechanical stoppers) at S-, Land U-axes are changeable. When the limit switch is activated, the power supply to the manipulator is interrupted, then the manipulator makes an emergency stop as a result. Refer to section 8.9 “Overrun/Tool Shock Sensor Releasing” in “DX100 INSTRUCTIONS” for releasing the status of this overrun.

2. The range of S-, L- and U-axes limit switches are set to the maximum operating range before shipping.

In case of re-adjusting the operating range of each subject axis, it is also required to change the dog location and limit values in software. Contact your Yaskawa representative if re-adjustment is required.

Fig. 8-1: location of Limit Switches

8.1.2 Location of Limit Switches

Limit switches are optional. The limit switches (the S- and L-axis overrun limit switches and the LU-axes interference limit switch) can be mounted only if the manipulator type is YR-MH00080-A01. For each location, refer to Fig. 8-1 “location of Limit Switches”.

8-1

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MH80 Manipulator

Negative side

Positive side

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8.1.3 Setting of Operation Range

8.1.3.1 S-Axis Operation Range

8.1.3.2 L-Axis Operation Range

8 Electrical Equipment Specification

8.1 Position of Limit Switch

By the S-axis limit switch, S-axis operation range can be set to those ranges mentioned in Table 5-2 "S-Axis Operating Range" on page 5-4.

By the L-axis limit switch, the L-axis operation range can be set to any angles within -91° to +136° as mentioned in the figure below.

Fig. 8-2: L-Axis Overrun Limit Switch Setting Range

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8-2

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8.1.3.3 Setting Range of LU-Axes Interference Angle

8 Electrical Equipment Specification

8.1 Position of Limit Switch

L- and U-axes interference limit switches are designed to check the interference angle of L- and U-axes.

As shown in Fig. 8-3 “LU-Axes Interference Angle”, the operation range of U-axis can be set to any angles within +9° to +297° as the interference angle with L-axis.

Fig. 8-3: LU-Axes Interference Angle

8-3

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MH80 Manipulator

AIR

1BC

2BC

1BC

2BC

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8 Electrical Equipment Specification

8.2 Internal Connections

Highly reliable connectors are equipped on each connection part of the manipulator to enable easy removal and installation for maintenance and inspection. For the numbers, types, and locations of connectors, see Fig. 8-4 “Location of Connectors” and Fig. 8-1 “List of Connector Types”.

Diagrams for internal connections of the manipulator are shown in

Fig. 8-5(a) "Internal Connection Diagram" on page 8-5 and Fig. 8-5(b) "Internal Connection Diagram" on page 8-6.

Fig. 8-4: Location of Connectors

Table 8-1: List of Connector Types

Name Type of Connector

Connector for internal user I/O wiring harness on base connector

Connector for internal user I/O wiring harness on U-arm

JL05-2A24-28PC Prepare JL05-6A24-28S (optional)

JL05-2A24-28SC Prepare JL05-6A24-28P (optional)

8-4

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S-AXIS OVERRUN L.S. Connected to A1

SLU-axes with Limit Switch Specification

S-axis with Limit Switch Specification

L- AND U-AXES INTERFERENCE L.S. Connected to A3

L-AXIS OVERRUN L.S. Connected to A2

S-AXIS OVERRUN L.S. Connected to B1

L-AXIS OVERRUN L.S. Connected to B2

L AND U-AXES INTERFERENCE L.S. Connected to B3

S-AXIS OVERRUN L.S. Connected to B1

S-AXIS OVERRUN L.S. Connected to A1

<Notes>

1.For the limit switch specification, the connection of the section A B are changed as follows:

S-axis

L-axis

U-axis

R-axis

B-axis

T-axis

Lamp (option)

CASINGBASE

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Fig. 8-5(a): Internal Connection Diagram

8 Electrical Equipment Specification

8.1 Internal Connections

8-5

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S-axis

L-axis

U-axis

R-axis

B-axis

T-axis

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8 Electrical Equipment Specification

8.1 Internal Connections

Fig. 8-5(b): Internal Connection Diagram

8-6

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DANGER

WARNING

CAUTION

NOTE

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9 Maintenance and Inspection

9.1 Inspection Schedule

9 Maintenance and Inspection

• Maintenance and inspection must be performed by specified personnel.

Failure to observe this caution may result in electric shock or injury.

• For disassembly or repair, contact your Yaskawa representative.

• Do not remove the motor, and do not release the brake.

Failure to observe these safety precautions may result in death or serious injury from unexpected turning of the manipulator's arm.

• Before maintenance or inspection, be sure to turn the main power supply OFF, and put up a warning sign. (ex. DO NOT TURN THE POWER ON.)

Failure to observe this warning may result in electric shock or injury.

• The battery pack must be connected before removing detection connector when maintenance and inspection.

Failure to observe this caution may result in the loss of home position data.

9.1 Inspection Schedule

Proper inspections are essential not only to assure that the mechanism will be able to function for a long period, but also to prevent malfunctions and assure safe operation. Inspection intervals are classified into six levels as shown in Table 9-1 "Inspection Items" on page 9-2. Conduct periodical inspections according to the inspection schedule in the table.

In Table 9-1 "Inspection Items" on page 9-2, the inspection items are categorized by three types of operations: operations which can be performed by personnel authorized by the user, operations which can be performed by personnel being trained, and operations which can be performed by service company personnel. Only specified personnel are to do the inspection work.

• The inspection interval depends on the total servo operation time.

• If axes are used very frequently (in handling applications, etc.), inspections may be required at shorter intervals. Contact your Yaskawa representative.

9-1

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Table 9-1: Inspection Items

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Items

1 Alignment marks

Schedule Method Operation Inspection

Charge

Daily

1000HCycle

6000HCycle

12000HCycle

24000HCycle

36000HCycle

••••••

Visual Check alignment mark accordance at the home position.

Check for damage.

Specified Personnel

Licensee

•••

MH80 Manipulator 9.1 Inspection Schedule

9 Maintenance and Inspection

Service Company

2 External cables

9-2

3 Working area

and whole exterior of manipulator

4 SLURBT-axis motors

5 Baseplate mounting bolts

6 Cover mounting screws

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7 SLURBT-axis motor

connectors

8 Connector base

••••••

Visual Check for damage and deterioration.

Visual Clean the work area if dust or spatter is present. Check for

damage and outside cracks.

Visual Check for grease leakage.

Wrench Tighten loose bolts. Replace if necessary.

Screwdriver, Wrench

Manual Check for loose connectors and tighten if necessary.

Manual Check for loose connectors.

Tighten loose bolts. Replace if necessary.

•••

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Table 9-1: Inspection Items

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Items

Schedule Method Operation Inspection

Charge

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MH80 Manipulator 9.1 Inspection Schedule

9 Wire harness in manipulator

9-3

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10 Limit switches and dogs

(For SLU-axes)

11 Battery pack in manipulator

12 S-axis speed reducer,

13 LU-axis speed reducers

Daily

1000HCycle

6000HCycle

12000HCycle

24000HCycle

36000HCycle

••••••

Visual, Multimeter

Check for conduction between the main connector of base and intermediate connector by manually shaking the wire. Check for wear of protective spring.

Specified Personnel

Licensee

Service Company

•••

•••••• • ••

••••••

Screwdriver, Wrench, Multimeter

Grease Gun Check for malfunction. (Replace if necessary.)

Check for dirt, damage, malfunction. Tighten loose bolts.

Replace the battery pack when the battery alarm occurs or when the manipulator has been operated for 36000H.

Supply grease 5) (6000H cycle). Exchange grease 4) (12000H cycle). See section 9.3.1 on page 9-8.

Supply grease4) (6000H cycle). Exchange grease4) (12000H cycle). See section 9.3.2 on page 9-11 and section 9.3.3 on page 9-13.

•••

9 Maintenance and Inspection

Page 46

Table 9-1: Inspection Items

46 of 77

Items

MH80 Manipulator 9.1 Inspection Schedule

Schedule Method Operation Inspection

Charge

14 R-axis speed reducer

15 BT-axis speed

reducers and gears

9-4

16 Overhaul

1 Inspection numbers correspond to the numbers in Fig. 9-1 “Inspection Parts and Inspection Numbers” on page 9-5. 2 The occurrence of a grease leakage indicates the possibility that grease has seeped into the motor. This can cause a motor

breakdown. Contact your Yaskawa representative.

3 When checking for conduction with multimeter, connect the battery to “BAT” and “OBT” of connectors on the motor side for each

axis, and then remove connectors on detector side for each axis from the motor. Otherwise, the home position may be lost. (Refer

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to section 9.3.6 “Notes for Maintenance” on page 9-20) 4 For the grease, refer to Table 9-2 "Inspection Parts and Grease Used" on page 9-6. 5 The application that requires highly frequent operation such as handling may cause grease leakage of air breather or the internal

pressure rise of speed reducer. Contact your Yaskawa representative.

Daily

1000HCycle

6000HCycle

12000HCycle

24000HCycle

36000HCycle

••••••

Grease Gun Check for malfunction. (Replace if necessary.)

Supply grease4) (6000H cycle). Exchange grease4) (12000H cycle). See section 9.3.4 on page 9-16.

Grease Gun Check for malfunction. (Replace if necessary.)

Supply grease 4) (6000H cycle). Exchange grease4) (12000H cycle). See section 9.3.5 on page 9-18.

Specified Personnel

Licensee

Service Company

•••

•••••• • ••

9 Maintenance and Inspection

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AIR

1BC

2BC

U-axis

L-axis

T-axis

B-axis

R-axis

S-axis

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9 Maintenance and Inspection

9.1 Inspection Schedule

Fig. 9-1: Inspection Parts and Inspection Numbers

9-5

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Battery pack

Connector base

(length: 8mm) (4 screws)

Cross head APS bolt M6

Cross head APS bolt M4

(length: 12mm) (8 bolts)

(HW0470360-A)

AIR

1BC

2BC

(a) Back View

(b) Top View

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9 Maintenance and Inspection

9.2 Notes on Maintenance Procedures

Table 9-2: Inspection Parts and Grease Used

No. Grease Used Inspected Parts

13, 14, 15, 16 Molywhite RE No.00 Speed reducers for all axes

B-, T-axis gears

Inspection numbers correspond to the numbers in Fig. 9-1 “Inspection Items” on page 9-2.

9.2 Notes on Maintenance Procedures

9.2.1 Battery Pack Replacement

The battery packs (type: HW0470360-A) are attached in the two locations as shown in Fig. 9-2 “Battery Location”.

Fig. 9-2: Battery Location

9-6

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Connector

Battery pack before replacement

See step 5 below.

See step 4 below.

New battery pack (HW0470360-A)

Circuit Board

(Type: SGDR-EFBA02A)

NOTE

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Fig. 9-3: Battery Connection

9 Maintenance and Inspection

9.2 Notes on Maintenance Procedures

1. Turn OFF the DX100 main power supply.

2. Remove the cover plate fastening screws M4 and from the connector base and pull out the battery pack to replace with a new battery pack.

3. Remove the old battery pack from the battery holder.

4. Connect the new battery pack to the unoccupied connector on the circuit boa

5. Remove the old battery pack from the circuit board.

6. Mount the new battery pack to the battery holder.

7. Reinstall the plate and fix it with the plate fastening screws M4.

rd.

Connect the new battery pack before removing the old one so that the encoder absolute data does not disappear.

Be sure not to pinch the cable when putting the plate back into place.

9-7

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NOTE

S-axis speed reducer

(Hexagon socket head plug PT1/4)

Grease inlet

(Hexagon socket head plug PT3/8)

Grease exhaust port

AIR

1BC

2BC

AIR

1BC

2BC

NOTE

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9 Maintenance and Inspection

9.3 Notes on Grease Replenishment/Exchange Procedures

Make sure to follow the instructions listed below at grease replenishment/ exchange. Failure to observe the following notes may result in damage to motor and speed reducer.

• If grease is added without removing the plug/screw from the 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/screw.

• Do not install a joint, a hose, etc. to the grease exhaust port. Failure to observe this instruction may result in damage to the motor due to coming off of an oil seal.

• Make sure to use a grease pump to inject grease. Set air supply pressure to the grease pump at 0.3 MPa or less, and the grease injection rate at 8 g/s or less.

9.3.1 Grease Replenishment/Exchange for S-Axis Speed Reducer

Fig. 9-4: S-Axis Speed Reducer

• Make sure to fill hoses, which are joined to the grease inlet, with grease beforehand to prevent air from intruding into the speed reducer.

9.3.1.1 Grease Replenishment

(Refer to Fig. 9-4 “S-Axis Speed Reducer”.)

1. Remove the hexagon socket head plug PT1/8 from the grease exhaust port.

• If grease is injected with the plug on, the grease will go inside the motor and may cause a damage. Make sure to remove the plug before the grease injection.

• Do not install a joint, a hose, etc. to the grease exhaust port. Failure to observe this instruction may result in damage to the motor due to coming off of an oil seal.

9-8

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NOTE

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9 Maintenance and Inspection

9.3 Notes on Grease Replenishment/Exchange Procedures

2. Remove the hexagon socket head plug PT1/4 from the grease inlet and install the grease zerk PT1/4. (The grease zerk is delivered with the manipulator.)

3. Inject grease into the grease inlet using a grease gun.

– Grease type: Molywhite RE No. 00

–

Amount of grease: 520 cc

(1040 cc for 1st supply)

– Air supply pressure of grease pump: 0.3 MPa or less

– Grease injection rate: 8 g/s or less

4. Move the S-axis for a few minutes to discharge excess grease.

5. Wipe the discharged grease with a cloth and reinstall the plug PT1/8 on

the grease exhaust port. Apply Three Bond 1206C to the thread

part of the plug, and tighten the plug with a tightening torque of 4.9

·m (0.5 kgf·m).

6. Remove the grease zerk from the grease inlet and reinstall the plug PT1/4

. Apply Three Bond 1206C to the thread part of the plug, and

tighten the plug with a tightening torque of 12 N

·m (1.2 kgf·m).

9.3.1.2 Grease Exchange

r to Fig. 9-4 “S-Axis Speed Reducer”.)

(Refe

1. Remove the hexagon socket head plug PT1/8 from the grease exhaust port.

• If grease is injected with the plug on, the grease will go inside the motor and may cause a damage. Make sure to remove the plug before the grease injection.

• Do not install a joint, a hose, etc. to the grease exhaust port. Failure to observe this instruction may result in damage to the motor due to coming off of an oil seal.

2. Remove the hexagon socket head plug PT1/4 from the grease inlet an

d install the grease zerk PT1/4. (The grease zerk is delivered with

the manipulator.)

3. Inject grease into the grease inlet using a grease gun.

– Grease type: Molywhite RE No. 00

–

Amount of grease: 2600 cc

– Air supply pressure of grease pump: 0.3 MPa or less

– Grease injection rate: 8 g/s or less

4. The grease exchange is completed when new grease appears in the exha

ust port. The new grease can be distinguished from the old

grease by color.

5. Move the S-axis for a few minutes to discharge excess grease.

9-9

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NOTE

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9 Maintenance and Inspection

9.3 Notes on Grease Replenishment/Exchange Procedures

6. Wipe the discharged grease with a cloth and reinstall the plug PT1/8 on the grease exhaust port. Apply Three Bond 1206C to the thread part of the plug, and tighten the plug with a tightening torque of 4.9 N·m (0.5 kgf·m).

If the plug is installed while the grease is being exhausted, the grease will go inside the motor and may cause a damage. Ensure that the grease has been completely exhausted before installing the plug.

7. Remove the grease zerk from the grease inlet and reinstall the plug

1/4.

9-10

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158813-1CD

(Hexagon socket head plug PT3/8)

Grease exhaust port

L-axis speed reducer

(Hexagon socket head plug PT1/8)

Grease Inlet

NOTE

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MH80 Manipulator

9.3.2 Grease Replenishment/Exchange for L-Axis Speed Reducer

Fig. 9-5: L-Axis Speed Reducer

9.3.2.1 Grease Replenishment

9 Maintenance and Inspection

9.3 Notes on Grease Replenishment/Exchange Procedures

(Refer to Fig. 9-5 “L-Axis Speed Reducer”.)

1. Tilt the L-arm vertical to the ground.

2. Remove the hexagon socket head plug PT1/8 from the grease exhaust port.

• If grease is injected with the plug on, the grease will go inside the motor and may cause a damage. Make sure to remove the plug before the grease injection.

• Do not install a joint, a hose, etc. to the grease exhaust port. Failure to observe this instruction may result in damage to the motor due to coming off of an oil seal.

3. Remove the hexagon socket head plug PT1/8 from the grease inlet d install the grease zerk PT1/8. (The grease zerk is delivered with

an the manipulator.)

4. Inject grease into the grease inlet using a grease gun.

– Grease type: Molywhite RE No. 00

–

Amount of grease: 250 cc

(500 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. Wipe the discharged grease with a cloth and reinstall the plug PT1/8

the grease exhaust port. Apply Three Bond 1206C to the thread

part of the plug, and tighten the plug with a tightening torque of 4.9

·m (0.5 kgf·m).

7. Remove the grease zerk from the grease inlet and reinstall the plug

PT1/8

. Apply Three Bond 1206C to the thread part of the plug, and

tighten the plug with a tightening torque of 4.9 N

·m (0.5 kgf·m).

9-11

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NOTE

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9.3.2.2 Grease Exchange

158813-1CD

9 Maintenance and Inspection

9.3 Notes on Grease Replenishment/Exchange Procedures

(Refer to Fig. 9-5 “L-Axis Speed Reducer”.)

1. Tilt the L-arm vertical to the ground.

2. Remove the hexagon socket head plug PT1/8 from the grease exhaust port..

• If grease is injected with the plug on, the grease will go inside the motor and may cause a damage. Make sure to remove the plug before the grease injection.

• Do not install a joint, a hose, etc. to the grease exhaust port. Failure to observe this instruction may result in damage to the motor due to coming off of an oil seal.

3. Remove the hexagon socket head plug PT1/8 from the grease inlet nd install the grease zerk PT1/8. (The grease zerk is delivered with

a the manipulator.)

4. Inject grease into the grease inlets using a grease gun.

– Grease type: Molywhite RE No. 00

–

Amount of grease: 1650 cc

– Air supply pressure of grease pump: 0.3 MPa or less

– Grease injection rate: 8 g/s or less

5. The grease exchange is completed when new grease appears in the

xhaust port. The new grease can be distinguished from the old

grease by color.

6. Move the L-axis for a few minutes t

7. Wipe the discharged grease with a clo

on the grease exhaust port. Apply Three Bond 1206C to the thread part of the plug, and tighten the plug with a tightening torque of 4.9

·m (0.5 kgf·m).

8. Remove the grease zerk from the grease inlet and reinstall the plug

1/8. Apply Three Bond 1206C to the thread part of the plug, and

PT tighten the plug with a tightening torque of 4.9 N

o discharge excess grease.

th and reinstall the plug PT1/8

·m (0.5 kgf·m).

9-12

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158813-1CD

U-arm

(Hexagon socket head plug PT1/8)

(Hexagon socket head plug PT3/8)

Grease inlet

Grease exhaust port

U-axis speed reducer

NOTE

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MH80 Manipulator

9.3.3 Grease Replenishment/Exchange for U-Axis Speed Reducer

Fig. 9-7: U-Axis Speed Reducer

9 Maintenance and Inspection

9.3 Notes on Grease Replenishment/Exchange Procedures

Fig. 9-6: U-Arm Posture in Grease Replenishment/Exchange for U-Axis Speed Reducer

9.3.3.1 Grease Replenishment

(Refer to Fig. 9-7 “U-Axis Speed Reducer”.)

1. Tilt the U-arm horizontal to the ground. (Refer to Fig. 9-6 “U-Arm

Posture in Grease Replenishment/Exchange for U-Axis Speed Reducer”.)

2. Remove the hexagon socket head plug PT1/8 from the grease exhaust port.

3. Remove the hexagon socket head plug PT1/8 from the grease inlet an the manipulator.)

• If grease is injected with the plug on, the grease will go inside the motor and may cause a damage. Make sure to remove the plug before the grease injection.

• Do not install a joint, a hose, etc. to the grease exhaust port. Failure to observe this instruction may result in damage to the motor due to coming off of an oil seal.

d install the grease zerk PT1/8. (The grease zerk is delivered with

9-13

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NOTE

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9 Maintenance and Inspection

9.3 Notes on Grease Replenishment/Exchange Procedures

4. Inject grease into the grease inlet using a grease gun.

– Grease type: Molywhite RE No. 00

–

Amount of grease: 140 cc

(280 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 U-axis for a few minutes to discharge excess grease.

9.3.3.2 Grease Exchange

6. Wipe the discharged grease with a clo on the grease exhaust port. Apply Three Bond 1206C to the thread part of the plug, and tighten the plug with a tightening torque of

·m (0.5 kgf·m).

4.9 N

7. Remove the grease zerk from the grease inlet and reinstall the plug PT

1/8. Apply Three Bond 1206C to the thread part of the plug, and

tighten the plug with a tightening torque of 4.9 N

Refer to Fig. 9-7 “U-Axis Speed Reducer”.)

(

1. Tilt the U-arm horizontal to the ground. (Refer to Fig. 9-6 “U-Arm

Posture in Grease Replenishment/Exchange for U-Axis Speed Reducer”.)

2. Remove the hexagon socket head plug PT1/8 from the grease ex

haust port.

• If grease is injected with the plug on, the grease will go inside the motor and may cause a damage. Make sure to remove the plug before the grease injection.

• Do not install a joint, a hose, etc. to the grease exhaust port. Failure to observe this instruction may result in damage to the motor due to coming off of an oil seal.

th and reinstall the plug PT1/8

·m (0.5 kgf·m).

3. Remove the hexagon socket head plug PT1/8 from the grease inlet nd install the grease zerk PT1/8. (The grease zerk is delivered with

a the manipulator.)

4. Inject grease into the grease inlet using a grease gun.

– Grease type: Molywhite RE No. 00

–

Amount of grease: 700 cc

– Air supply pressure of grease pump: 0.3 MPa or less

– Grease injection rate: 8 g/s or less

5. The grease exchange is completed when new grease appears in the

rease exhaust port. The new grease can be distinguished from the

old grease by color.

6. Move the U-axis for a few minutes to discharge excess grease.

9-14

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NOTE

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9 Maintenance and Inspection

9.3 Notes on Grease Replenishment/Exchange Procedures

7. Wipe the discharged grease with a cloth and reinstall the plug PT1/8 on the grease exhaust port. Apply Three Bond 1206C to the thread part of the plug, and tighten the plug with a tightening torque of

·m (0.5 kgf·m).

4.9 N

8. Remove the grease zerk from the grease inlet and reinstall the plug

. Apply Three Bond 1206C to the thread part of the plug, and

PT1/8 tighten the plug with a tightening torque of 4.9 N

·m (0.5 kgf·m).

9-15

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MH80 Manipulator

R-axis speed reducer

(Hexagon socket head plug PT3/8)

(Hexagon socket head plug PT1/8)

Grease exhaust port

Grease inlet

U-arm

NOTE

58 of 77

9.3.4 Grease Replenishment/Exchange for R-Axis Speed Reducer

9.3.4.1 Grease Replenishment

9 Maintenance and Inspection

9.3 Notes on Grease Replenishment/Exchange Procedures

Fig. 9-8: R-Axis Speed Reducer

158813-1CD

(Refer to Fig. 9-8 “R-Axis Speed Reducer”.)

1. Remove the hexagon socket head plug 1/8 from the grease exhaust port.

• If grease is injected with the plug on, the grease will go inside the motor and may cause a damage. Make sure to remove the plug before the grease injection.

• Do not install a joint, a hose, etc. to the grease exhaust port. Failure to observe this instruction may result in damage to the motor due to coming off of an oil seal.

2. Remove the hexagon socket head plug PT1/8 from the grease inlet and install the grease zerk PT1/8. (The grease zerk is delivered with the manipulator.)

3. Inject grease into the grease inlet using a grease gun.

– Grease type: Molywhite RE No. 00

–

Amount of grease: 700 cc

(1400 cc for 1st supply)

– Air supply pressure of grease pump: 0.3 MPa or less

– Grease injection rate: 8 g/s or less

4. Move the R-axis for a few minutes to discharge excess grease.

5. Wipe the discharged grease with a clo on the grease exhaust port. Apply Three Bond 1206C to the thread part of the plug, and tighten the plug with a tightening torque of 4.9 N·m (0.5 kgf·m).

6. Remove the grease zerk from the grease inlet and reinstall the plug

1/8. Apply Three Bond 1206C to the thread part of the plug, and

PT tighten the plug with a tightening torque of 4.9 N·m (0.5 kgf·m).

9-16

th and reinstall the plug PT1/8

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NOTE

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9.3.4.2 Grease Exchange

9 Maintenance and Inspection

9.3 Notes on Grease Replenishment/Exchange Procedures

(Refer to Fig. 9-8 “R-Axis Speed Reducer”

1. Remove the hexagon socket head plug PT1/8 from the grease exhaust port.

• If grease is injected with the plug on, the grease will go inside the motor and may cause a damage. Make sure to remove the plug before the grease injection.

• Do not install a joint, a hose, etc. to the grease exhaust port. Failure to observe this instruction may result in damage to the motor due to coming off of an oil seal.

2. Remove the hexagon socket head plug PT1/8 from the grease inlet and install the grease zerk PT1/8. (The grease zerk is delivered with the manipulator.)

3. Inject grease into the grease inlet using a grease gun.

– Grease type: Molywhite RE No. 00

–

Amount of grease: 3500 cc

– Air supply pressure of grease pump: 0.3 MPa or less

– Grease injection rate: 8 g/s or less

4. The grease exchange is completed when new grease appears from the g

rease exhaust port. The new grease is distinguished from the old

grease by color.

5. Move the R-axis for a few minutes to discharge excess grease.

6. Wipe the discharged grease with a cloth and reinstall the plug PT1/8 on

the grease exhaust port. Apply Three Bond 1206C to the thread part of the plug, and tighten the plug with a tightening torque of 4.9 N·m (0.5 kgf·m).

7. Remove the grease zerk from the grease inlet and reinstall the plug . Apply Three Bond 1206C to the thread part of the plug, and

PT1/8 tighten the plug with a tightening torque of 4.9 N·m (0.5 kgf·m).

9-17

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MH80 Manipulator

B-axis speed reducer and gear

T-axis speed reducer and gear

(Hexagon socket head plug PT1/8)

Grease exhaust port

Grease inlet

NOTE

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9.3.5 Grease Replenishment/Exchange for B- and T-Axis Speed Reducers

9.3.5.1 Grease Replenishment

9 Maintenance and Inspection

9.3 Notes on Grease Replenishment/Exchange Procedures

and Gears

Fig. 9-9: B- and T-Axis Speed Reducers and Gears

(Refer to Fig. 9-9 “B- and T-Axis Speed Reducers and Gears”.)

158813-1CD

1. Remove the hexagon socket head set screw M6 from the grease exhaust port.

• If grease is injected with the set screw on, the grease will go inside the motor and may cause a damage. Make sure to remove the plug before the grease injection.

• Do not install a joint, a hose, etc. to the grease exhaust port. Failure to observe this instruction may result in damage to the motor due to coming off of an oil seal.

2. Remove the hexagon socket head plug PT1/8 from the grease inlet and install the grease zerk PT1/8. (The grease zerk is delivered with the manipulator.)

3. Inject grease into the grease inlet using a grease gun.

– Grease type: Molywhite RE No. 00

–

Amount of grease: 300 cc

(600 cc for 1st supply)

– Air supply pressure of grease pump: 0.3 MPa or less

– Grease injection rate: 8 g/s or less

4. Move the B-axis for a few minutes to discharge excess grease.

5. Wipe the discharged grease with a cloth and reinstall the set screw M6 o

n the grease exhaust port. Apply Three Bond 1206C to the thread part of the set screw, and tighten the set screw with a tightening torque of 3.9 N·m (0.4 kgf·m).

6. Remove the grease zerk from the grease inlet and reinstall the plug 1/8. Apply Three Bond 1206C to the thread part of the plug, and

PT tighten the plug with a tightening torque of 4.9 N·m (0.5 kgf·m).

9-18

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NOTE

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9.3.5.2 Grease Exchange

9 Maintenance and Inspection

9.3 Notes on Grease Replenishment/Exchange Procedures

(Refer to Fig. 9-9 “B- and T-Axis Speed Reducers and Gears”.)

1. Remove the hexagon socket head set screw M6 from the grease

exhaust port.

• If grease is injected with the set screw on, the grease will go inside the motor and may cause a damage. Make sure to remove the plug before the grease injection.

• Do not install a joint, a hose, etc. to the grease exhaust port. Failure to observe this instruction may result in damage to the motor due to coming off of an oil seal.

2. Remove the hexagon socket head plug PT1/8 from the grease inlet and install the grease zerk PT1/8. (The grease zerk is delivered with the manipulator.)

3. Inject grease into the grease inlet using a grease gun.

– Grease type: Molywhite RE No. 00

–

Amount of grease: 1500 cc

– Air supply pressure of grease pump: 0.3 MPa or less

– Grease injection rate: 8 g/s or less

4. The grease exchange is completed when new grease appears from the g

rease exhaust port. The new grease is distinguished from the old

grease by color.

5. Move the B-axis for a few minutes to discharge excess grease.

6. Wipe the discharged grease with a cloth and reinstall the set screw M6 on

the grease exhaust port. Apply Three Bond 1206C to the thread part of the set screw, and tighten the set screw with a tightening torque of 3.9 N·m (0.4 kgf·m).

7. Remove the grease zerk from the grease inlet and reinstall the plug . Apply Three Bond 1206C to the thread part of the plug, and

PT1/8 tighten the plug with a tightening torque of 4.9 N·m (0.5 kgf·m).

9-19

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NOTE

0BT

BAT

BAT*

0BT*

Motor

Connector for battery backup

HW9470932-A (Battery pack)

Motor power connector

Connector for the motor encoder

a: Crimped contact-pin (pin) b: Crimped contact-pin (socket)

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9 Maintenance and Inspection

9.3 Notes on Grease Replenishment/Exchange Procedures

9.3.6 Notes for Maintenance

When performing maintenance such as replacement of a wire harness in the manipulator, the encoder connector may be necessary to be removed. In this case, be sure to connect the battery pack to 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.

For the battery pack connection, refer to Fig. 9-10 “Battery Pack Connection for Motors”.

9.3.6.1 Battery Pack Connection for Motors

The connectors (crimped contact-pin) for battery backup are installed at the end point of each motor (marked as BAT and OBT). Connect the battery pack according to the following procedure.

158813-1CD

1. Remove a cap attached to battery backup connectors of the motor.

2. Connect a battery pack (HW9470932-A) to the battery backup connectors (BAT and OBT are marked) located at the end point of an encoder cable. With the battery pack connected to the battery backup connectors, perform maintenance check.

3. After the maintenance check, confir

m all connectors are connected and remove the battery pack. Reinstall the cap onto the battery backup connectors of the motor.

Do not remove battery pack in the connector base.

Fig. 9-10: Battery Pack Connection for Motors

9-20

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NOTE

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MH80 Manipulator

10 Recommended Spare Parts

It is recommended to keep the parts and components in the following table in stock as spare parts for the MOTOMAN-MH80. Product performance can not be guaranteed when using spare parts from any company other than Yaskawa. The spare parts are ranked as follows:

• Rank A: Expendable and frequently replaced parts

• Rank B: Parts for which replacement may be necessary as a result of frequent operation

• Rank C: Drive Unit

To replace parts in Rank B or Rank C, contact your Yaskawa representative.

Table 10-1: Spare Parts for the MOTOMAN-MH80 (Sheet 1 of 2)

Rank Parts

A 1 Grease Molywhite RE No. 00 Yaskawa 16 kg - For all axis

A 2 Liquid Gasket Three Bond 1206C ThreeBond Co.,

A 3 Battery Pack HW9470932-A Yaskawa 1 1 For replacing

A 4 Battery Pack HW0470360-A Yaskawa 1 1

B5S-axis

B 6 S-axis Input Gear HW0313741-1 Yaskawa 1 1

B7L-axis

B 8 L-axis Input Gear HW0409103-1 Yaskawa 1 1

B9U-axis

B 10 U-axis Input Gear HW0313740-1 Yaskawa 1 1

B 11 R-axis

B 12 B-axis

B13T-axis

C 14 AC Servomotor

Name Type Manufacturer Qty Qty

No.

Ltd.

HW0387752-A Yaskawa 1 1

Speed Reducer

for S-axis

HW1382898-A Yaskawa 1 1 For the

HW9381465-A Yaskawa 1 1

HW0387753-A Yaskawa 1 1

HW0387754-A Yaskawa 1 1

HW0387737-B Yaskawa 1 1

HW0389043-A Yaskawa 1 1

SGMRV-30ANA-YR1* HW0388669-A

Yaskawa 1 1

Remarks

per

Unit

speed reducers and wrist units

the wire harness in the manipulator

manipulator assembled after Apr.2, 2014

10-1

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10 Recommended Spare Parts

Table 10-1: Spare Parts for the MOTOMAN-MH80 (Sheet 2 of 2)

158813-1CD

Rank Parts

C 15 AC Servomotor

C 16 AC Servomotor

C 17 AC Servomotors

C 18 Wire Harness in

C 19 Connector base

C 20 Limit switch set

C 21 Limit switch set

C 22 Limit switch set

C 23 Circuit Board SGDR-EFBA02A Yaskawa 1 1

Name Type Manufacturer Qty Qty

No.

for L-axis

for U-axis

for R-, B-, and Taxes

Manipulator

Unit

for S-axis

for L-axis

for U-axis

SGMRV-44ANA-YR2* HW0388671-A

SGMRV-20ANA-YR1* HW0388668-A

SGMRV-09ANA-YR1* HW0388665-A

HW0174688-A Yaskawa 1 1

HW0374034-B Yaskawa 1 1

HW0472853-B Yaskawa 1 1 Treatment of

HW0472854-A Yaskawa 1 1 Treatment of

HW0472854-B Yaskawa 1 1 Treatment of

Yaskawa 1 1

Yaskawa 1 3

Remarks

per

Unit

-A01 lead terminal is done

10-2

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158813-1CD

1019

1001

1002

1003

1004

1005

1007

1009

1008

1010

1011

1013

1014

1016

1018

1020

1017

1021

1022

1025

1026

1028

1023

1024

1012

1030

1033

1029

1032

1031

1034

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11 Parts List

Fig. 11-1: S-Axis Unit

11 Parts List

11.1 S-Axis Unit

11-1

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11 Parts List

11.1 S-Axis Unit

Table 11-1: S-Axis Unit

No. DWG No. Name Pcs

1001 HW0387752-A Speed reducer 1

HW1382898-A (For the manipulator assembled after Apr.2, 2014)

1002 SGMRV-30ANA-YR1* Motor 1

1003 HW9404486-1 Shaft 1

1004 HW0400405-1 Stopper 1

1005 6310 Bearing 1

1007 M8X45 Socket screw 1

1008 2H-8 Spring washer 1

1009 HW0102237-2 S head 1

1010 M12X45 Socket screw 15

M12X45 (For the manipulator assembled after Apr.2, 2014)

1011 2H-12 Spring washer 15

2H-12 (For the manipulator assembled after Apr.2, 2014)

1012 C-30-SG-22A Glomet 1

1013 M12X55 Socket screw 3

1014 2H-12 Spring washer 3

1016 STW-50 Retaining Ring-C

1017 M8X100 Socket screw 1

1018 2H-8 Spring washer 1

1019 PT3/8

(STAINLESS coating)

1020 MSTH10-25 Parallel pin 1

1021 M12X55 Socket screw 12

1022 2H-12 Spring washer 12

1023 HW9405875-1 Coller 1

1024 M20X40 Socket screw 1

1025 HW0102236-1 Base 1

1026 KQ2L10-01S Elbow 1

1028 NB-1075-0.43 Tube 1

1029 HW0314010-1 M base 1

1030 Y507212.5 Oil seal 1

1031 M6X20 Socket screw 2

1032 2H-6 Spring washer 2

1033 HW0313741-1 Gear 1

1034 M12X35

(For the manipulator assembled after Apr.2, 2014)

Speed reducer 1

Socket screw 16

Spring washer 16

type

Plug 1

GT-SAbolt 2

11-2

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158813-1CD

2002

2005

2016

2004

2003

2026 2009 2008

2006

2007

2026

2027

2017

2011

2013

2014

2010

2019

2020

1009

2001

2021

2022

2024

2023

2018

2012

2025

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11 Parts List

11.2 L-Axis Unit

Fig. 11-2: L-Axis Unit

11-3

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11 Parts List

11.2 L-Axis Unit

Table 11-2: L-Axis Unit

No. DWG No. Name Pcs

2001 SGMRV-44ANA-YR2* Motor 1

2002 HW0102644-1 L arm 1

2003 M12X55 Socket screw 16

2004 2H-12 Spring washer 16

2005 HW9381465-A Speed reducer 1

2006 M10X40 Socket screw 18

2007 2H-10 Spring washer 18

2008 M16X45 Socket screw 6

2009 2H-16 Spring washer 6

2010 HW9481343-A Shaft 1

2011 HW0409103-1 Gear 1

2013 HW0483473-B Socket screw 1

2014 HW0408806-2 Spring washer 1

2016 G270 O ring 1

2017 EZ0094-A0 Air breather 1

2018 HW0314011-1 M base 1

2019 HW0312815-2 Shaft 1

2020 Y507212.5 Oil seal 1

2021 M12X65 Socket screw 4

2022 2H-12 Spring washer 4

2023 M6X30 Socket screw 2

2024 2H-6 Spring washer 2

2025 EZ5002A0 Cap 3

2026 PT3/8

(STAINLESS coating)

2027 PT1/8

(STAINLESS coating)

1009 HW0102237-2 S head 1

Plug 2

Plug 4

158813-1CD

11-4

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158813-1CD

2002

3014

3015

3028

3023

3024

3007

3027

3017

3022

3001

3016

3021

3026

3025

3018

3008

3011

3010

3005

3006

3020

3019

3002

3004

3003

3012

3013

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11 Parts List

11.3 U-Axis Unit

Fig. 11-3: U-Axis Unit

11-5

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11 Parts List

11.3 U-Axis Unit

Table 11-3: U-Axis Unit

No. DWG No. Name Pcs

3001 SGMRV-20ANA-YR1* Motor 1

3002 HW0413914-1 Stopper 1

3003 M6X55 Socket screw 1

3004 2H-6 Spring washer 1

3005 M8X55 Socket screw 4

3006 2H-8 Spring washer 4

3007 HW0387753-A Speed reducer 1

3008 HW0313740-1 Gear 1

3010 M8X115 Socket screw 1

3011 2H-8 Spring washer 1

3012 M12X30 Socket screw 12

3013 SW-2H-12 Washer 12

3014 M10X30 Socket screw 6

3015 2H-10 Spring washer 6

3016 HW9405257-1 Collar 1

3017 HW0102239-2 Casing 1

3018 Y426012.5 Oil seal 1

3019 M6X30 Socket screw 2

3020 2H-6 Spring washer 2

3021 HW0314012-1 M base 1

3022 G195 O ring 1

3023 M10X40 Socket screw 16

3024 2H-10 Spring washer 16

3025 TSH6-01M Union 2

3026 UB-0640-0.1C Tube 2

3027 PT1/8

(STAINLESS coating)

2028 PT3/8

(STAINLESS coating)

2002 HW0102425-1 L arm 1

Plug 1

11-6

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158813-1CD

4029

4030

4001

R axis

B axis

T axis

4003

4004

4005

4006

4007

4008

4009

4010

4011

4012

4013

4014

4015

4016

4017

4018

4019

4021

4022

4023

4024

4025

4026

4027

4028

4031

4033

4035

4034

4048

4036

4037

4039

4038

4040

4041

4043

4042

4044

4046

4047

4049 4050

4045

3017

4007

4031

4020

4002

4046

4047

4046

4047

4002

4049 4050

71 of 77

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11.4 R-, B-, T-Axis Unit

Fig. 11-4: R-, B-, T-Axis Unit

11 Parts List

11.4 R-, B-, T-Axis Unit

11-7

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11 Parts List

11.4 R-, B-, T-Axis Unit

Table 11-4: R-, B-, T-Axis Unit

No. DWG No. Name Pcs

4001 HW0387754-A Speed reducer 1

4002 SGMRV-09ANA-YR1* Motor 3

4003 AC1306-G00X6 Oil seal 1

4004 AE1017Q0 Oil seal 1

4005 ISTW-17 Retaining Ring 1

4006 HR32913J Bearing 1

4007 HR32005XJ Bearing 2

4008 HR32909J Bearing 1

4009 6003 Bearing 1

4010 HW0312823-1 Gear 1

4011 HW0312822-1 Gear 1

4012 HW0312824-1 Gear 1

4013 HW0312826-1 Gear 1

4014 HW0404196-8 Washer 1

4015 HW0312821-1 Gear 1

4016 MSTH8-20 Parallel pin 1

4017 HW0312834-1 Shaft 1

4018 HW0312832-1 Shaft 1

4019 HW0312831-1 Gear 1

4020 HW0312833-1 Shaft 1

4021 HW0312835-1 Shaft 1

4022 HW0312838-1 Flange 1

4023 MSTH6-15 Parallel pin 1

4024 HW0200768-1 Shaft 1

4025 HW0312837-1 Housing 1

4026 HW9405662-1 Washer 1

4027 HW0312825-1 Gear 1

4028 HW0412720-1 B nut 1

4029 PT1/8

(STAINLESS coating)

4030 PT3/8

(STAINLESS coating)

4031 M5X16 GT-SA bolt 18

4033 M4X6 H set screw 1

4034 M6X25 Socket screw 1

4035 2H-6 Spring washer 1

4036 M8X25 Socket screw 18

4037 2H-8 Spring washer 19

4038 M6X20 Socket screw 1

4039 2H-6 Spring washer 1

4040 M6X25 Socket screw 6

4041 2H-6 Spring washer 6

4042 M6X50 Socket screw 1

4043 2H-6 Spring washer 1

Plug 1

11-8

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MH80 Manipulator

11 Parts List

11.4 R-, B-, T-Axis Unit

Table 11-4: R-, B-, T-Axis Unit

No. DWG No. Name Pcs

4044 M6X35 GT-SA bolt 16

4045 M8X30 GT-SA bolt 8

4046 M8X25 Socket screw 10

4047 2H-8 Spring washer 10

4048 M8X20 Socket screw 1

4049 M4X6 Socket screw 2

4050 2H-4 Spring washer 2

3017 HW0102239-2 Casing 1

11-9

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MH80 Manipulator

5001

5002

5003

5004

5006

5007

5008

5009

5010

5013

5014

5047

5048

5053

5054

5055

5056

5057

5058

5060

5075

5082

5002A

5093

5094

5113

5015

5016

5027

5028

5029

5032

5033

5034

5035

5036

5037

5039

5040

5041

5044

5046

5022

5095

5096

5002B

5108 5107

5112

5111

3017

5091

5090

5049

5099

5092

5030

5038

5097

5098

5045

5068

5092

5011

5017

5012

5043

5110

5109

5059

5092

5031

5042

5093

5094

5105

5106

5035

5102

5100

5039

5005

5115

5005

5039

5114

5115

74 of 77

Fig. 11-5: Wrist Unit

158813-1CD

11 Parts List

11.5 Wrist Unit

11-10

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MH80 Manipulator

11 Parts List

11.5 Wrist Unit

Table 11-5: Wrist Unit

No. DWG No. Name Pcs

5001 HW0387737-B Speed reducer 1

5002 HW0389043-A Speed reducer 1

5002A HW0389043-A Washer 1

5002B HW0389043-A Fine U nut 1

5003 HW9405880-1 B cover 1

5004 HW9405445-1 B nut 1

5005 HW9405881-1 B nut 2

5006 HW9405882-1 B nut 1

5007 S34 O ring 1

5008 AE3092E2 Oil seal 1

5009 SC15247F585 Oil seal 1

5010 SC39528F585 Oil seal 1

5011 HW9405883-1 Coller 1

5012 HW9381667-A Gear 1

5013 HW9381668-A Gear 1

5014 HW9381669-A Gear 1

5015 HW9381672-A Gear 1

5016 WR60 Sirclip 1

5017 HW9405888-* Sim *

5022 HW9405885-* Sim *

5027 HW9482772-A Shaft 1

5028 HW9482765-A Shaft 1

5029 HW9381675-A Shaft 1

5030 RTW42 Retaining Ring 1

5031 STW-25 Retaining Ring-C type 1

5032 ISTW40 Retaining Ring 1

5033 HW9405891-1 Housing 1

5034 PT3/8 Plug 2

5035 PT1/8(STAINLESS

coating)

5036 HW9405892-1 Flange 1

5037 HW9481234-A Bearing 1

5038 6004LBD2PX24V1 Bearing 1

5039 HW9480086-A Bearing 4

5040 6912DU Bearing 1

5041 6808LLU Bearing 2

5042 6905 Bearing 1

5043 HW9405901-1 Washer 1

5044 BG3000-15X19 Ring 1

5045 HW0312827-1 Gear 1

5046 HW0312828-1 Gear 1

5047 HW0312830-1 Gear 1

5048 HW0312829-1 Gear 1

5049 HW0201159-A Shaft 1

Plug 3

11-11

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11 Parts List

11.5 Wrist Unit

Table 11-5: Wrist Unit

No. DWG No. Name Pcs

5053 HW0312773-1 Flange 1

5054 HW0312775-1 Flange 1

5055 HW9302630-3 Housing 1

5056 HW0102233-1 U arm 1

5057 HW0102491-1 Wrist 1

5058 HW0201226-1 Cover 1

5059 HW0414884-1 Cover 1

5060 HW0412694-* Sim *

5068 HW0412683-* Sim *

5075 HW0412695-* Sim *

5082 HW0412696-* Sim *

5090 M8X85 Socket screw 12

5091 2H-8 Spring washer 12

5092 M4X12 GT-SA bolt 17

5093 M5X16 Socket screw 10

5094 2H-5 Spring washer 10

5095 M5X35 Socket screw 6

5096 2H-5 Spring washer 6

5097 M4X25 Socket screw 6

5098 2H-4 Spring washer 6

5099 M4X6 H set screw 1

5100 M8X18 Socket screw 8

5102 M6X30 GT-SA bolt 10

5105 M6X25 Socket screw 16

5106 2H-6 Spring washer 16

5107 M8X25 Socket screw 12

5108 2H-8 Spring washer 20

5109 M6X16 Socket screw 1

5110 2H-6 Spring washer 1

5111 M8X20 Socket screw 16

5112 2H-8 Spring washer 16

5113 M4X14 Socket screw 4

5114 2H-4 Spring washer 4

5115 M5X7 Magic screw 6

3017 HW0102239-2 Casing 1

11-12

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MOTOMAN-MH80

77 of 77

INSTRUCTIONS

HEAD OFFICE 2-1 Kurosakishiroishi, Yahatanishi-ku, Kitakyushu 806-0004, Japan Phone +81-93-645-7703 Fax +81-93-645-7802

YASKAWA America Inc. (Motoman Robotics Division) 100 Automation Way, Miamisburg, OH 45342, U.S.A. Phone +1-937-847-6200 Fax +1-937-847-6277

YASKAWA Europe GmbHRobotics Divsion ) Yaskawastrasse 1, 85391 Allershausen, Germany Phone +49-8166-90-100 Fax +49-8166-90-103

YASKAWA Nordic AB Bredbandet 1 vån. 3 varvsholmen 392 30 Kalmar, Sweden Phone +46-480-417-800 Fax +46-480-417-999

YASKAWA Electric (China) Co., Ltd. 22/F One Corporate Avenue No.222, Hubin Road, Huangpu District, Shanghai 200021, China Phone +86-21-5385-2200 Fax 㧗86-21-5385-3299

YASKAWA SHOUGANG ROBOT Co. Ltd. No7 Yongchang North Road, Beijing E&T Development AreaChina 100176 Phone

+86-10-6788-2858

Fax

+86-10-6788-2878

YASKAWA India Private Ltd. (Robotics Division) #426, Udyog Vihar, Phase- IV,Gurgaon, Haryana, India

YASKAWA Electric Korea Co., Ltd 9F, KyoboSecuritiesBldg., 26-4, Yeouido-dong,Yeongdeungpo-gu, Seoul 150-737, Korea Phone +82-2-784-7844 Fax +82-2-784-8495

YASKAWA Electric Taiwan Corporation 12F, No.207, Sec. 3, Beishin Rd., Shindian District, New Taipei City 23143, Taiwan

YASKAWA Electric (Singapore) PTE Ltd. 151 Lorong Chuan, #04-02A, New Tech Park, Singapore 556741 Phone +65-6282-3003 Fax +65-6289-3003

YASKAWA Electric (Thailand) Co., Ltd. 252/125-126 27th Floor, Tower B Muang Thai-Phatra Complex Building, Rachadaphisek Road㧘Huaykwang, Bangkok 10320, Thailand Phone

PT. YASKAWA Electric Indonesia Secure Building-Gedung B Lantai Dasar & Lantai 1 JI. Raya Protokol Halim Perdanakusuma, Jakarta 13610, Indonesia

+66-2693-2200

Fax +91-124-475-8542Phone +91-124-475-8500

Fax +886-2-8913-1513Phone +886-2-8913-1333

Fax

+66-2693-4200

Fax +62-21-2982-6741Phone +62-21-2982-6470

Specifications are subject to change without notice for ongoing product modifications and improvements.

MANUAL NO.

HW1480080

Yaskawa MH80 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

1 Product Confirmation

1.1 Contents Confirmation

1.2 Order Number Confirmation

2 Transport

2.1 Transporting Method

2.1.1 Using a Crane

2.1.2 Using a Forklift

2.2 Shipping Bolts and Brackets

3 Installation

3.1 Installation of Safeguarding

3.2 Mounting Procedures for Manipulator Base

3.2.1 Mounting the Manipulator on the Baseplate

3.2.2 Mounting the Manipulator on the Floor

3.3 Types of Mounting

3.3.1 S-axis Operating Range

3.3.2 Fixing the Manipulator Base

3.3.3 Precautions to Prevent the Manipulator from Falling

3.4 Notes in Mounting the Manipulators on the Ceiling

3.6 IP (International Protection)

3.7 Location

4 Wiring

4.1 Grounding

4.2 Manipulator Cable Connection

4.2.1 Connection to the Manipulator

4.2.2 Connection to the DX100

5 Basic Specifications

5.1 Basic Specifications

5.2 Part Names and Working Axes

5.3 Manipulator Base Dimensions

5.4 Dimensions and P-Point Maximum Envelope

5.5 Alterable Operating Range

6 Allowable Load for Wrist Axis and Wrist Flange

6.1 Allowable Wrist Load

6.2 Wrist Flange

7 System Application

7.1 Peripheral Equipment Mounts

7.2 Internal User I/O Wiring Harness and Air Lines

8 Electrical Equipment Specification

8.1 Position of Limit Switch

8.1.1 Specification of Limit Switch

8.1.2 Location of Limit Switches

8.1.3 Setting of Operation Range

8.1.3.1 S-Axis Operation Range

8.1.3.2 L-Axis Operation Range

8.1.3.3 Setting Range of LU-Axes Interference Angle

8.2 Internal Connections

9 Maintenance and Inspection

9.1 Inspection Schedule

9.2 Notes on Maintenance Procedures

9.2.1 Battery Pack Replacement

9.3 Notes on Grease Replenishment/Exchange Procedures

9.3.1 Grease Replenishment/Exchange for S-Axis Speed Reducer

9.3.1.1 Grease Replenishment

9.3.1.2 Grease Exchange

9.3.2 Grease Replenishment/Exchange for L-Axis Speed Reducer

9.3.2.1 Grease Replenishment

9.3.2.2 Grease Exchange

9.3.3 Grease Replenishment/Exchange for U-Axis Speed Reducer

9.3.3.1 Grease Replenishment

9.3.3.2 Grease Exchange

9.3.4 Grease Replenishment/Exchange for R-Axis Speed Reducer

9.3.4.1 Grease Replenishment

9.3.4.2 Grease Exchange

9.3.5.1 Grease Replenishment

9.3.5.2 Grease Exchange

9.3.6 Notes for Maintenance

9.3.6.1 Battery Pack Connection for Motors

10 Recommended Spare Parts

11 Parts List

11.1 S-Axis Unit

11.2 L-Axis Unit

11.3 U-Axis Unit

11.4 R-, B-, T-Axis Unit

11.5 Wrist Unit