MOTOMAN-MPP3
MAINTENANCE MANUAL
TYPE: YR-MPP0003-A00
Upon receipt of the product and prior to initial operation, read these instructions thoroughly, and retain
for future reference.
MOTOMAN INSTRUCTIONS
MOTOMAN-MPP3 INSTRUCTIONS
FS100 INSTRUCTIONS
FS100 OPERATOR’S MANUAL
FS100 MAINTENACE MANUAL
The FS100 operator’s manual above corresponds to specific usage.
Be sure to use the appropriate manual.
Part Number:
Revision:
160478-1CD
1
MANUAL NO.
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Table of Contents
1 Introduction ..................................................................................................................................... 1-1
2 Notes for Maintenance .................................................................................................................... 2-1
2.1 Battery Pack Connection ................................................................................................... 2-1
3 Home Position Return ..................................................................................................................... 3-1
3.1 S-, L-, and U-axes Positioning ........................................................................................... 3-2
3.2 T-axis Positioning............................................................................................................... 3-2
4 Grease Replenishment and Exchange ........................................................................................... 4-1
4.1 Notes on Grease Replenishment Procedures ................................................................... 4-1
4.1.1 Grease Replenishment for S-, L-, and U- axes Speed Reducer
(For before June 20, 2013 shipment) ................................................................... 4-2
4.1.1.1 Grease Replenishment............................................................................ 4-2
4.1.2 Grease Replenishment for S-, L-, and U- axes Speed Reducer
(For after June 20, 2013 shipment) ...................................................................... 4-4
4.1.2.1 Grease Replenishment............................................................................ 4-5
4.1.3 Grease Replenishment for T- axis Speed Reducer .............................................. 4-6
4.1.3.1 Grease Replenishment............................................................................ 4-6
5 Disassembly and Reassembly of the Motor.................................................................................... 5-1
5.1 Disassembly and Reassembly of the S-, L-, and U-axes Motor ........................................ 5-1
5.1.1 For before June 20, 2013 shipment...................................................................... 5-1
5.1.2 For after June 20, 2013 shipment......................................................................... 5-4
5.2 Disassembly and Reassembly of T-axis Motor.................................................................. 5-9
6 Disassembly and Reassembly of Speed Reducer .......................................................................... 6-1
6.1 Disassembly and Reassembly of S-, L-, and U-axes Speed Reducer............................... 6-1
6.2 Disassembly and Reassembly of T-axis Speed Reducer .................................................. 6-4
7 Adjustment of S-, L-, and U-axes Timing Belt ................................................................................. 7-1
7.1 Disassembly and Reassembly of S-, L-, and U-axes Timing Belt...................................... 7-1
7.2 Adjustment of Timing Belt .................................................................................................. 7-3
8 Battery Pack Replacement.............................................................................................................. 8-1
8.1 Battery Pack Replacement ................................................................................................ 8-1
9 Relay Lead Cable Replacement ..................................................................................................... 9-1
9.1 Relay Lead Cable Replacement ........................................................................................ 9-1
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Table of Contents
10 Parts List ..................................................................................................................................... 10-1
10.1 Drive Unit (For before June 20, 2013 shipment)............................................................ 10-1
10.2 Drive Unit (After June 20, 2013 shipment)..................................................................... 10-4
10.3 Wiring and Piping Assy (Before June 20, 2013 shipment) ............................................ 10-7
10.4 Wiring and Piping Assy (After June 20, 2013 shipment) ............................................... 10-9
10.5 L-, U-Arms and T-Axis Unit.......................................................................................... 10-11
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1
Introduction
Introduction
MANDATORY
•
This maintenance manual is intended to explain maintenance
procedures primarily for the MOTOMAN-MPP3.
•
General items related to safety are listed in Chapter 1: Safety of the
FS100 Instructions. To ensure correct and safe operation, carefully
read the FS100 instructions before reading this manual.
CAUTION
•
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 and maintenance this product.
•
The drawings and photos in this manual are representative
examples and differences may exist between them and the
delivered product.
•
YASKAWA may modify this 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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Introduction
Notes for Safe Operation
Read this manual carefully before installation, operation, maintenance, or
inspection of the FS100.
In this manual, the Notes for Safe Operation are classified as
"WARNING", "CAUTION", "MANDATORY", or "PROHIBITED".
WARNING
CAUTION
MANDATORY
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.
PROHIBITED
Even items described as "CAUTION" may result in a serious
accident in some situations. At any rate, be sure to follow these
important items.
NOTE
To ensure safe and efficient operation at all times, be sure
to follow all instructions, even if not designated as
“CAUTION” and “WARNING”.
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Introduction
WARNING
•
Before operating the manipulator, check that servo power is turned
OFF pressing the emergency stop buttons on the programming
pendant.
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 the servo power ON.
Injury may result from unintentional or unexpected manipulator motion.
Figure 2: Release of Emergency Stop
TURN
•
Observe the following precautions when performing teaching
operations within the P-point maximum envelope of the
manipulator:
– View the manipulator from the front whenever possible.
– Always follow the predetermined operating procedure.
– Keep in mind the emergency response measures against the
manipulator’s unexpected motion toward you.
– 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 person is present in the P-point maximum envelope
of the manipulator and that you are in a safe location before:
– Turning ON the power for the FS100.
– Moving the manipulator with the programming pendant.
– Running the system in the check mode.
– 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 buttons are located on the right of the
programming pendant.
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Introduction
CAUTION
•
Perform maintenance inspection with the specific person who took
the maintenance training course in Yaskawa.
Failure to observe this may result in electric shock or injury.
•
When the maintenance inspection is performed, be sure to mount
the battery pack before removing the motor encoder connector.
Failure to observe this caution may result in disappearance of the home
position data.
•
Perform the following inspection procedures prior to conducting
manipulator teaching. If problems are found, 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 cabinet
of the FS100 after use.
The programming pendant can be damaged if it is left in the
manipulator's work area, on the floor, or near fixtures.
•
Read and understand the Explanation of Warning Labels in the
FS100 Instructions before operating the manipulator:
Definition of Terms Used Often in This Manual
The MOTOMAN manipulator is the YASKAWA industrial robot product.
The manipulator usually consists of the controller, the programming
pendant, and supply cables.
In this manual, the equipment is defined as follows:
Equipment
Manual Definition
FS100 Controller
FS100
FS100 Programming Pendant
Programming pendant
Cable between the manipulator and the
controller
Manipulator cable
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Introduction
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.
WARNING label A
A
A
WARNING label B
Nameplate
View B
WARNING label B
WARNING label A
B
View A
WARNING label A:
WARNING
Moving parts
may cause
injury
WARNING label B:
WARNING
Do not enter
robot
work area.
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Notes for Maintenance
2.1
Battery Pack Connection
Before removing the encoder connector (with CAUTION label), connect
the battery pack referring to the following figures.
Fig. 2-1: Battery Pack Connector Diagram for S-, L-, U-, and T-axes
Encoder
Motor
Motor cable etc.
Internal wire
2
2 Notes for Maintenance
2.1 Battery Pack Connection
Power connector
Connect
OBT
BAT
b OBT4
a BAT4
a
b
CAUTION
Connect battery to encoder
to save the data before
removing connector.
Encoder connector
Battery pack
CAUTION label
OBT
a
BAT
b
b OBT4
a BAT4
CAUTION label (Enlarged view)
CAUTION
a: Crimped contact-pin (socket)
b: Crimped contact-pin (pin)
Connect battery to encoder
to save the data before
removing connector.
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3
Home Position Return
Home Position Return
In the following cases, perform calibration and set the
manipulator geometrical position.
• Change in the combination of the MOTOMAN and the
control unit
• Replacement of the motor or encoder
• Clearing stored memory
NOTE
• Home position deviation caused by hitting the MOTOMAN
against a workpiece, etc.
• Replacement, disassembly, and reassembly of the main
parts such as speed reducers etc.
Before the calibration, be sure that the manipulator satisfies
the following conditions.
• No external force is exerted on the manipulator.
The hand and other parts attached to the wrist unit are
removed.
Table 3-1: List of Required Parts
Name
Type
Manufacturer
Qty
Positioning
key
HW1402030-1
Yaskawa
1
Configuration
Remarks
Product
accessories
50
4.5
00
10
13.5 16.5
70
R5
Indicate the range 12
of tolerance for
5 -0.010/-0.022.
10
46
4
15f7
The parts in Table 3-1 List of Required Partsis required for calibration.
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3 Home Position Return
3.1 S-, L-, and U-axes Positioning
3.1
S-, L-, and U-axes Positioning
•
To return the manipulator to the home position, refer to Fig.3-1 S-, L-,
and U-axes Home Position Calibration while performing the following
procedure.
1. Place the positioning key in the axis positioning area on the base unit,
and then perform a temporary home position registration with the arm
against the positioning key. (Repeat for each axis.)
2. Rotate the arm "+16062 pulse" from the position registered in step (1),
and then register the home position again. (Position where the
rotational center and ball joint are horizontal)
Fig. 3-1: S-, L-, and U-axes Home Position Calibration
A
°
20
For L-axis
positioning
1
Manipulator base
Positioning
key
A
For S-axis
positioning
(2)
120°
(1)
A
A
A
View A-A
12
0°
A
For U-axis
positioning
3.2
T-axis Positioning
As shown in Fig.3-2 T-axis Home Position Calibration, insert the
positioning key (HW1402030-1) in the keyways in the base unit and turn
the flange to the + side at a low (or inching) speed.
Register the position where the positioning key is fixed with the keyways
as a home position.
Fig. 3-2: T-axis Home Position Calibration
A
Keyway
View A
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4 Grease Replenishment and Exchange
4.1 Notes on Grease Replenishment Procedures
Grease Replenishment and Exchange
4.1
Notes on Grease Replenishment Procedures
Make sure to follow the instructions listed below at grease replenishment.
Failure to observe the following notes may result in damage to motor and
speed reducer.
• For before June 20, 2013 shipment
• If grease is added without removing the plug/screw from
the grease exhaust port, the 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.
NOTE
• 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 hand grease pump to inject grease.
• Make sure to fill hoses, which are joined to the grease
inlet, with grease beforehand to prevent air from intruding
into the speed reducer.
• For after June 20, 2013 shipment
NOTE
• If grease is added without removing the plug/screw from
the grease exhaust port, the 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.
• Use a hand grease gun or an injector to inject grease.
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4 Grease Replenishment and Exchange
4.1 Notes on Grease Replenishment Procedures
4.1.1
Grease Replenishment for S-, L-, and U- axes Speed Reducer
(For before June 20, 2013 shipment)
Fig. 4-1: S-, L-, and U- axes Speed Reducer Diagram
Hexagon socket
head cap screw M5
Connector base
Hexagon socket
Cover 2
head cap screw M4
Grease inlet
(Hexagon socket head plug PT1/8)
Radiator plate unit
Hexagon socket
head cap screw M6
S-, L- and U-axis speed reducer
Exhaust port
(Hexagon socket
head plug PT1/8)
Hexagon socket
head cap screw M8
U-arm
Cover 1
4.1.1.1 Grease Replenishment
(Refer to Fig. 4-1 S-, L-, and U- axes Speed Reducer Diagram on page 42.)
Replenish the grease according to the following procedure:
NOTE
• Since you must remove the U arm when replenishing
grease on the S-, L-, and U-axes, after the work is
complete you must then calibrate the home position.
• For more information about calibrating the home position,
see "Chapter 3 Home Position Return on page 3-1.
1. Turn off the power to the control panel.
2. Remove the manipulator cables from the manipulator.
3. Remove cover 1.
(Use a torque wrench (Tohnichi QL50N) with a 9.5 drive.)
4. Remove the U arm. (6 M8 × 55 fixing bolts)
5. Remove the connector base and cover 2.
(14 M4 × 10, and 13 M5 × 16 fixing bolts)
(Lower the connector base into the connector base opening in cover 2,
and then remove cover 2.)
6. Unscrew the hexagon socket head cap screw fixing the radiator plate
unit to the S-, L-, and U-axes drive unit and remove the radiator plate
unit.
7. Remove the vinyl cover protecting the connector (encoder cables)
parts of the internal wiring harness connected to the motor. Then
connect the backup battery. (Refer to Chapter 2 Notes for
Maintenance on page 2-1.)
8. Remove the vinyl cover protecting the connector (power cables) parts
of the internal wiring harness connected to the motor. Then disconnect
the cables (both power and encoder cables) of the internal wiring
harness.
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4 Grease Replenishment and Exchange
4.1 Notes on Grease Replenishment Procedures
9. Remove each axis drive unit. (3 M6 × 30, and 2 M6 × 40 fixing bolts)
10. Remove the PT1/8 plugs from the grease inlet and from the grease
exhaust port.
11. Install a grease zerk A-PT1/8 to the grease inlet. (The grease zerk is
delivered with the manipulator.)
12. Inject the grease through the grease inlet using a hand grease gun.
– Grease type:
Synaxreme FG-0
– Amount of grease:
5 cc (10 cc for 1st supply)
13. Remove the grease zerk from the grease inlet, and reinstall the PT1/8
hexagon socket head plugs in the grease inlet and the grease exhaust
port. Tighten the plugs to 4.9 Nm (0.5 kgfm).
Before installing the plugs, apply Three Bond 1206C on the thread part
of each plug.
14. Install each axis drive unit.
15. Connect the cables (both power and encoder cables) of the internal
wiring harness to the motor and disconnect the backup battery. Then
protect the connector parts with the vinyl covers.
16. Install the radiator plate unit with hexagon socket head cap screws
(3 M6 × 30, and 2 M6 × 40).
(Tighten the mounting bolts on to the radiator plate to a torque of
16.5 Nm (1.7 kgfm).)
17. Install cover 2.
(Tighten the 13 M5 × 16 mounting bolts on cover 2 to a torque of
6 Nm (0.6 kgfm).)
18. Install the connector base.
(Tighten the 14 M4 × 10 mounting bolts on the connector base to a
torque of 2.8 Nm (0.29 kgfm).)
19. Install the U arm.
(Tighten the 6 M8 × 55 mounting bolts on the U arm to a torque of
40 Nm (4.1 kgfm).)
20. Install cover 1.
(When installing cover 1, tighten it to a torque of 24.5 Nm (2.5 kgfm).)
21. Calibrate the home positions of the axis that have been replaced.
(Refer to Chapter 3 Home Position Return on page 3-1.)
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4 Grease Replenishment and Exchange
4.1 Notes on Grease Replenishment Procedures
4.1.2
Grease Replenishment for S-, L-, and U- axes Speed Reducer
(For after June 20, 2013 shipment)
Fig. 4-2: S-, L-, and U-Axes Grease inlet
Exhaust port
for U-axis
5
Grease inlet
for U-axis 6
Grease inlet
for S-axis
6
5
Exhaust port
for L-axis
5
Exhaust port
for S-axis
A
Grease inlet 6
for L-axis
2
3
5
4
6
1
B
View A
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4.1 Notes on Grease Replenishment Procedures
Table 4-1: S-, L-, and U-Axes Grease inlet Checklist
No Item
Qty Remark
Socket screw M5  16
Spring washer 2H-5
13
Tightening torque: 6.0 Nm (0.6 kgfm)
Socket screw M4  10
Spring washer 2H-4
14
Tightening torque: 2.8 Nm (0.29 kgfm)
3
C base HW1370413-A
1
4
Cover 1301062-1
1
5
Plug KQP-10
3
6
Plug KQP-08
3
1
2
4.1.2.1 Grease Replenishment
(Refer to Fig. 4-2 S-, L-, and U-Axes Grease inlet on page 4-4.)
Replenish the grease according to the following procedure:
1. Turn OFF the power supply to the FS100.
2. Remove the manipulator cables.
3. Unscrew the hexagon socket head cap screws 1 and 2 to remove
the cover 4 and the connector base 3 .
(Rotate to down the connector base 3 into the connector base fitting
hole on the cover 4 (see View B in the figure above), and then remove
the cover 4 .)
4. Remove the plug
inlet.
5
from the exhaust port and plug
6
from the grease
5. Install a hand grease gun or an injector to the grease inlet.
6. Inject grease through the grease inlet.
– Grease type:
Synaxreme FG-0
– Amount of grease:
5 cc (10 cc for 1st supply)
7. Remove the grease gun or the injector from the grease inlet, and then
reinstall the plug 5 to the exhaust port and plug 6 to the grease inlet.
8. Pull up the connector base 3 from the connector base fitting hole on
the cover 4 . (Opposite direction to view B in the figure above)
9. Reinstall the cover 4 with the hexagon socket head cap
screws 1 .Tighten the screw with the tightening torque of 6.0 Nm
(0.6kgfm).
10. Reinstall the connector base 3 with the hexagon socket head cap
screws 2 .Tighten the screw with the tightening torque of
2.8 Nm (0.29 kgfm).
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4 Grease Replenishment and Exchange
4.1 Notes on Grease Replenishment Procedures
4.1.3
Grease Replenishment for T- axis Speed Reducer
Fig. 4-3: T- axis Speed Reducer Diagram
Cover
Grease inlet
(Hexagon socket head
cap screw M6)
T-axis speed reducers
Grease exhaust port
(Plug LP-M5)
4.1.3.1 Grease Replenishment
(Refer to Fig.4-3 T- axis Speed Reducer Diagram.)
Replenish the grease according to the following procedure:
1. Remove the cover, and then remove the M6 bolts and LP-M5 plugs
from the grease inlet and from the grease exhaust port.
2. Install a grease zerk A-MT6 x 1 to the grease inlet. (The grease zerk is
delivered with the manipulator.)
3. Inject the grease through the grease inlet using a hand grease gun.
– Grease type:
Synaxreme FG-0
– Amount of grease:
1 cc (2 cc for 1st supply)
4. Remove the grease zerk from the grease inlet, and install an M6 bolt in
the grease inlet.
Before installing the bolt, apply Three Bond 1206C on the thread part
of the plug.
5. Before installing the plug in the grease exhaust port, operate the T-axis
for 20 or 30 minutes to purge all grease from the exhaust port.
6. Wipe away any grease that was discharged, and then install the LPM5 plug in the grease exhaust port.
Before installing the plugs, apply Three Bond 1206C on the thread part
of each plug.
7. Install the cover.
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5 Disassembly and Reassembly of the Motor
5.1 Disassembly and Reassembly of the S-, L-, and U-axes Motor
Disassembly and Reassembly of the Motor
5.1
5.1.1
Disassembly and Reassembly of the S-, L-, and U-axes
Motor
For before June 20, 2013 shipment
• Refer to Fig. 7.1 Disassembly and Reassembly of S-, L-, and U-axes
Timing Belt on page 7-1.
NOTE
Refer to Chapter 3 Home Position Return on page 3-1,
Chapter 4 Grease Replenishment and Exchange on page
4-1 and Chapter 7 Adjustment of S-, L-, and U-axes Timing
Belt on page 7-1 in this manual.
If you replace the motor, you don’t need to insert the backup
battery.
Remove old sealing from each parts before starting
assembling.

Disassembly
1. Turn off the power supply to the FS100.
2. Remove the manipulator cables from the manipulator.
3. Remove the cover 2 . Unscrew the hexagon socket head cap screw
4 to remove the U-arm 3 .
4. Unscrew the hexagon socket head cap screws 5 and 6 to remove the
cover 7 and the connector base 8 .
(Lower the connector base 8 into the connector base opening in the
cover 7 , and then remove the cover 7 .)
5. Unscrew the hexagon socket head cap screws
radiator plate unit 11 .
9
and 10 to remove the
6. Remove the vinyl cover protecting the connector (encoder cables)
parts of the internal wiring harness connected to the motor 1 . Then
connect the backup battery.
(Refer to Chapter 2 Notes for Maintenance on page 2-1.)
7. Remove the vinyl cover protecting the connector (power cables) parts
of the internal wiring harness connected to the motor 1 . Then
disconnect the cables (both power and encoder cables).
8. Remove the S-, L-, and U-axes drive unit 12 .
9. Unscrew the bolts 13 and 14 to remove the motor 1 from the drive unit.
10. Unscrew the hexagon socket head cap screw 15 to remove the
pulley 16 . (To fix the pulley 16 , use the two 3.2 dia. holes located in the
surface of the pulley 16 .)
11. Unscrew the hexagon socket head cap screw 17 to remove the
M-base 18 and the motor 1 .
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5 Disassembly and Reassembly of the Motor
5.1 Disassembly and Reassembly of the S-, L-, and U-axes Motor

Reassembly
1. Install the motor 1 to the M-base 18 by tightening the hexagon socket
head cap screw 17 with the tightening torque shown in Table 5-2 S-, L-,
and U-axes Motor Parts Checklist.
2. Install the motor 1 to the pulley 16 .
3. Apply LOCTITE 242 to the thread part of the hexagon socket head cap
screw 15 . Tighten the screw with the tightening torque shown in Table
5-2.
(To fix the pulley 16 , use the two 3.2 dia. holes located in the surface of
the pulley 16 .)
4. Hook the belt on the pulley 16 .
5. Install the motor 1 to the drive unit 12 by tightening the hexagon socket
head cap screw 14 with the tightening torque shown in table Table 5-2.
(Refer to Chapter 7 Adjustment of S-, L-, and U-axes Timing Belt on
page 7-1 to adjust the tension of the belt.)
6. Install the drive unit 12 .
7. Connect the cables (both encoder and power cables) of the internal
wiring harness to the motor 1 , disconnect the backup battery, and
then protect the connector parts with the vinyl covers.
8. Install the radiator plate unit 11 with the hexagon socket head cap
screws 9 and 10 .
(Apply the tightening torque shown in Table 5-2.)
9. Install the cover 7 with the hexagon socket head cap screw 5 and the
connector base 8 with the hexagon socket head cap screw 6
respectively.
(Apply the tightening torque shown in Table 5-2.)
10. Install the U-arm 3 with the hexagon socket head cap screw 4 . Then
install the cover 2 .
(Refer to 9.2.4 "U-Arm Removal Procedures" in Chapter 9 " in the
MOTOMAN-MPP3 INSTRUCTIONS.)
11. Calibrate the home positions of the axes that have been replaced.
(Refer to Section 3.1 “S-, L-, and U-axes Positioning” on page 3-2.)
Table 5-1: S-, L-, and U-axes Motor Parts Checklist (Sheet 1 of 2)
No Item
Qty Remark
1
Motor of each axis
HW13801060-1
1
SGMAV-10ANA-YR11
2
Cover HW1401164-1
1
Tightening torque: 24.5 Nm (2.5 kgfm)
3
U arm HW1200100-1
1
4
Socket screw M8 × 55
GT-LH Washer M8
6
Tightening torque: 40 Nm (4.1 kgfm)
5
Socket screw M5 × 16
Spring washer 2H-5
13
Tightening torque: 6.0 Nm (0.6 kgfm)
6
Socket screw M4 × 10
Spring washer 2H-4
14
Tightening torque: 2.8 Nm (0.29 kgfm)
7
Cover 1301062-1
1
8
C base HW1370413-A
1
9
Socket screw M6 × 30
GT-LH Washer M6
3
Tightening torque: 16.5 Nm (1.7 kgfm)
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5.1 Disassembly and Reassembly of the S-, L-, and U-axes Motor
Table 5-1: S-, L-, and U-axes Motor Parts Checklist (Sheet 2 of 2)
No Item
Qty Remark
2
Tightening torque: 16.5 Nm (1.7 kgfm)
10
Socket screw M6 × 40
GT-LH Washer M6
11
Plate HW1402322-1
1
Radiator plate unit
12
M base HW1200063-1
1
Drive unit
13
Socket screw M5 × 30
Spring washer 2H-5
Nut M5
2
Tightening torque: 6.0 Nm (0.6 kgfm)
14
Socket screw M5 × 30
Spring washer 2H-5
Washer M5
Washer HW8411125-3
4
Tightening torque: 6.0 Nm (0.6 kgfm)
15
Socket screw M6 × 20
Spring washer 2H-6
1
Tightening torque: 16.5 Nm (1.7 kgfm)
16
Pulley HW1401219-A
1
17
Socket screw M5 × 20
Spring washer 2H-5
Nut M5
4
18
M base HW1401298-1
1
Tightening torque: 8.4 Nm (0.85 kgfm)
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5.1 Disassembly and Reassembly of the S-, L-, and U-axes Motor
Fig. 5-1: Disassembly and Reassembly of S-, L-, and U-axes Motor
10
9
11
View A-A
13
12
14
1
6
8
7
A
5
A
15
16
2
18
5.1.2
17
4
3
For after June 20, 2013 shipment
• Refer to Fig. 5-2 Disassembly and Reassembly of S-, L-, and U-axes
Motor on page 5-8.
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5.1 Disassembly and Reassembly of the S-, L-, and U-axes Motor
NOTE
Refer to chapter Chapter 3 Home Position Return on page
3-1, Chapter 4 Grease Replenishment and Exchange on
page 4-1 and Chapter 7 Adjustment of S-, L-, and U-axes
Timing Belt on page 7-1 in this manual.
If you replace the motor, you don’t need to insert the backup
battery.
Remove old sealing from each parts before starting
assembling.

Disassembly
1. Turn off the power supply to the FS100.
2. Remove the manipulator cables from the manipulator.
3. Remove the cover 2 . Unscrew the hexagon socket head cap screw
4 to remove the U-arm 3 .
(Refer to 9.2.4 "U-Arm Removal Procedures" in Chapter 9
"Maintenance and Inspection" in the MOTOMAN-MPP3
INSTRUCTIONS.)
4. Unscrew the hexagon socket head cap screws 5 and 6 to remove the
cover 7 and the connector base 8 .
(Rotate to down the connector base 8 into the connector base fitting
hole on the cover 7 see View B in the figure above), and then remove
the cover 7 .)
5. Unscrew the hexagon socket head cap screws
radiator plate unit 11 .
9
and 10 to remove the
6. Remove the vinyl cover protecting the connector (encoder cables)
parts of the internal wiring harness connected to the motor 1 . Then
connect the backup battery.
(Refer to Chapter 2 Notes for Maintenance on page 2-1.)
7. Remove the vinyl cover protecting the connector (power cables) parts
of the internal wiring harness connected to the motor 1 . Then
disconnect the cables (both power and encoder cables).
8. Remove the S-, L-, and U-axes drive unit 12 .
9. Unscrew the bolts 13 and 14 to remove the motor 1 from the drive unit.
10. Unscrew the hexagon socket head cap screw 15 to remove the
pulley 16 . (To fix the pulley 16 , use the two 3.2 dia. holes located in the
surface of the pulley 16 .)
11. Unscrew the hexagon socket head cap screw 17 to remove the
M-base 18 and the motor 1 .

Reassembly
1. Install the motor 1 to the M-base 18 by tightening the hexagon socket
head cap screw 17 with the tightening torque shown in Table 5-2 S-, L-,
and U-axes Motor Parts Checklist.
2. Install the motor 1 to the pulley 16 .
3. Apply LOCTITE 242 to the thread part of the hexagon socket head cap
screw 15 . Tighten the screw with the tightening torque shown in Table
5-2.
(To fix the pulley 16 , use the two 3.2 dia. holes located in the surface of
the pulley 16 .)
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5.1 Disassembly and Reassembly of the S-, L-, and U-axes Motor
4. Hook the belt on the pulley 16 .
5. Install the motor 1 to the drive unit 12 by tightening the hexagon socket
head cap screw 14 with the tightening torque shown in table Table 5-2.
(Refer to Chapter 7 Adjustment of S-, L-, and U-axes Timing Belt on
page 7-1 to adjust the tension of the belt.)
6. Install the drive unit 12 .
7. Connect the cables (both encoder and power cables) of the internal
wiring harness to the motor 1 , disconnect the backup battery, and
then protect the connector parts with the vinyl covers.
8. Install the radiator plate unit 11 with the hexagon socket head cap
screws 9 and 10 .
(Apply the tightening torque shown in Table 5-2.)
9. Pull up the connector base 8 from the connector base fitting hole on
the cover 7 . (Opposite direction to view B in the figure above)
10. Install the cover 7 with the hexagon socket head cap screw 5 and the
connector base 8 with the hexagon socket head cap screw 6
respectively.
(Apply the tightening torque shown in Table 5-2.)
11. Install the U-arm 3 with the hexagon socket head cap screw 4 . Then
install the cover 2 .
(Refer to 9.2.4 "U-Arm Removal Procedures" in Chapter 9
"Maintenance and Inspection"in MOTOMAN-MPP3 INSTRUCTIONS.)
12. Calibrate the home positions of the axes that have been replaced.
(Refer to Section 3.1 “S-, L-, and U-axes Positioning” on page 3-2.)
Table 5-2: S-, L-, and U-axes Motor Parts Checklist (Sheet 1 of 2)
No Item
Qty Remark
1
Motor of each axis
HW13801060-1
1
SGMAV-10ANA-YR11
2
Cover HW1401164-1
1
Tightening torque: 24.5 Nm (2.5 kgfm)
3
U arm HW1200153-1
1
4
Socket screw M8 × 55
GT-LH Washer M8
6
Tightening torque: 40 Nm (4.1 kgfm)
5
Socket screw M5 × 16
Spring washer 2H-5
13
Tightening torque: 6.0 Nm (0.6 kgfm)
6
Socket screw M4 × 10
Spring washer 2H-4
14
Tightening torque: 2.8 Nm (0.29 kgfm)
7
Cover HW1301062-1
1
8
C base HW1370413-A
1
9
Socket screw M6 × 30
GT-LH Washer M6
3
Tightening torque: 16.5 Nm (1.7 kgfm)
10
Socket screw M6 × 40
GT-LH Washer M6
2
Tightening torque: 16.5 Nm (1.7 kgfm)
11
Plate HW1402322-1
1
Radiator plate unit
12
M base HW1200063-1
1
Drive unit
13
Socket screw M5 × 30
Spring washer 2H-5
Nut M5
2
Tightening torque: 6.0 Nm (0.6 kgfm)
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5.1 Disassembly and Reassembly of the S-, L-, and U-axes Motor
Table 5-2: S-, L-, and U-axes Motor Parts Checklist (Sheet 2 of 2)
No Item
Qty Remark
14
Socket screw M5 × 30
Spring washer 2H-5
Washer M5
Washer HW8411125-3
4
Tightening torque: 6.0 Nm (0.6 kgfm)
15
Socket screw M6 × 20
Spring washer 2H-6
1
Tightening torque: 16.5 Nm (1.7 kgfm)
16
Pulley HW1401219-A
1
17
Socket screw M5 × 20
Spring washer 2H-5
Nut M5
4
18
M base HW1401298-1
1
Tightening torque: 8.4 Nm (0.85 kgfm)
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5.1 Disassembly and Reassembly of the S-, L-, and U-axes Motor
Fig. 5-2: Disassembly and Reassembly of S-, L-, and U-axes Motor
10
9
A
11
9
6
8
7
5
B
12 13
14
1
15
16
18
17
View A
4
3 2
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5 Disassembly and Reassembly of the Motor
5.2 Disassembly and Reassembly of T-axis Motor
5.2
Disassembly and Reassembly of T-axis Motor
Refer to Fig. 5-3 Disassembly and Reassembly of T-axis Motor on
page 5-10.

Disassembly
1. Place the T-axis unit on a working table carefully so that the unit does
not fall off the table.
2. Turn off the power supply to the FS100.
3. Remove the L-arm 2 .
(Refer to 9.2.3 "L-Arm Removal/Installation and T-axis Cable Fixing
Procedures" in Chapter 9 "Maintenance and Inspection" in
MOTOMAN-MPP3 INSTRUCTIONS.)
4. Remove the cover
3
.
5. Remove the vinyl cover protecting the connector (encoder cables)
parts of the relay lead connected to the T-axis motor 1 . Then
disconnect the backup battery.
(Refer to Chapter 2 Notes for Maintenance on page 2-1.)
6. Remove the vinyl cover protecting the connector (power and
application cables) parts of the relay lead connected to the T-axis
motor 1 . Then disconnect the cables (encoder, power and application
cables) of the internal wiring harness.
7. Unscrew the hexagon socket head cap screws
8. Remove the flange
6
4
and
5
.
(with the circular spline 10 attached).
9. Unscrew the hexagon socket head cap screw 7 to remove the wave
generator 8 .
(To fix the wave generator 8 , use the two 2.3 dia. holes located in the
surface of the wave generator 8 .)

Reassembly
1. Install the wave generator
placed in between.
8
to the T-axis motor 1 with the base
9
2. Apply LOCTITE 242 to the thread part of the hexagon socket head cap
screw 7 . Tighten the screw with the tightening torque shown in Table
5-3 T-axis Motor Parts Checklist on page 5-10."
(To fix the wave generator 8 , use the two 2.3 dia. holes located in the
surface of the wave generator 8 .)
3. Apply ThreeBond 1206C to the matching surface 10 between the
circular spline and the base 9 .
4. Install the flange 6 (with the circular spline 10 attached) with the
hexagon socket head cap screw 5 .
(Apply the tightening torque shown in Table 5-3.)
(Apply ThreeBond 1206C to the matching surface between the circular
spline 10 and the base 9 .)
5. Install the T-axis motor 1 with the hexagon socket head cap screw
(Apply the tightening torque shown in Table 5-3.)
4
.
6. Connect the cables (encoder, power and application cables) of the
relay lead to the T-axis motor 1 , disconnect the backup battery, and
then protect the connector parts with the vinyl covers.
7. Install the cover
3
.
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5.2 Disassembly and Reassembly of T-axis Motor
8. Install the L-arm 2 .
(Refer to 9.2.3 "L-Arm Removal/Installation and T-axis Cable Fixing
Procedures" in Chapter 9 "Maintenance and Inspection" in
MOTOMAN-MPP3 INSTRUCTIONS.)
9. Turn on the power supply to the FS100.
Table 5-3: T-axis Motor Parts Checklist
No Item
Qty Remark
1
T-axis Motor HW1381061-1
1
2
L arm HW13001663-A
6
SGMAV-01ANA-YR21
3
Cover HW1301550-1
1
4
GT-SA bolt M3 × 10
2
Tightening torque: 1.4 Nm (0.14
kgfm)
5
Socket screw M3 × 25
Spring washer 2H-3
14
Tightening torque: 1.4 Nm (0.14
kgfm)
6
Flange HW1301665-1
1
7
Socket screw M3 × 12
Spring washer 2H-3
1
8
Speed reducer HW1380868- 1
A
Wave generator
9
Base HW1200113-1
1
For before June 20, 2013 shipment
Base HW1200157-1
1
For after June 20, 2013 shipment
10
Speed reducer HW1380868- 1
A
Tightening torque: 2.25 Nm (0.23
kgfm)
Circular spline
Fig. 5-3: Disassembly and Reassembly of T-axis Motor
3
2
1
5
4
10
9
8
6
7
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6
6 Disassembly and Reassembly of Speed Reducer
6.1 Disassembly and Reassembly of S-, L-, and U-axes Speed Reducer.
Disassembly and Reassembly of Speed Reducer
NOTE
6.1
Refer to chapter Chapter 3 Home Position Return on page
3-1, Chapter 4 Grease Replenishment and Exchange on
page 4-1, Chapter 5 Disassembly and Reassembly of the
Motor on page 5-1. Remove old sealing from each parts
before assembling.
Disassembly and Reassembly of S-, L-, and U-axes Speed
Reducer.
• Refer to Fig. 6-1 Disassembly and Reassembly of S-, L-, and U-axes
Speed Reducer on page 6-3.

Disassembly
1. Turn OFF the power supply to the FS100.
2. Follow steps from (2) to (9) in Section 5.1 “Disassembly and
Reassembly of the S-, L-, and U-axes Motor” on page 5-1
“Disassembly” .
3. Loosen the hexagon socket head cap screws
belt 4 .
2
and
4. Unscrew the hexagon socket head cap screw
reducer. 1
5
to remove the speed
3
to remove the
5. Unscrew the hexagon socket head cap screw 6 to remove the pulley
7 . (To fix the pulley 7 , use the two areas located in the surface of the
pulley 7 .)

Reassembly
1. Install the speed reducer 1 to the pulley
7
.
2. Apply LOCTITE 242 to the thread part of the hexagon socket head cap
screw 6 . Tighten the screw with the tightening torque shown in Table
6-1 S-, L-, and U-axes Motor Parts Checklist on page 6-2."
3. Install the speed reducer 1 to the drive unit 8 with the hexagon socket
head cap screw 5 .
(Apply the tightening torque shown in table Table 6-1.)
4. Hook the belt
4
on the pulley
7
.
5. Install the motor 1 to the drive unit 8 by tightening the hexagon socket
head cap screw 3 with the tightening torque shown in Table 6-1.
Refer to Chapter 7 Adjustment of S-, L-, and U-axes Timing Belt on
page 7-1 to adjust the tension of the belt.
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6 Disassembly and Reassembly of Speed Reducer
6.1 Disassembly and Reassembly of S-, L-, and U-axes Speed Reducer.
6. Follow step (5) through step (10) in Section 5.1 “Disassembly and
Reassembly of the S-, L-, and U-axes Motor” on page 5-1
“Reassembly” .
Table 6-1: S-, L-, and U-axes Motor Parts Checklist
No
Item
Qty Remark
1
Speed reducer
HW13801062-A
1
2
Socket screw M5 × 30
Spring washer 2H-5
Nut M5
2
Tightening torque: 6.0 N•m (0.6 kgf•m)
3
Socket screw M5 × 30
Spring washer 2H-5
Washer M5
Washer HW8411125-3
4
Tightening torque: 6.0 N•m (0.6 kgf•m)
4
Belt 250HP-S5M560
1
5
Socket screw M10 × 40
Spring washer 2H-10
4
Tightening torque: 68 N•m (6.9 kgf•m)
6
Socket screw M6 × 20
Spring washer 2H-6
1
Tightening torque: 16.5 N•m (1.7kgf•m)
7
Pulley HW1401218-A
1
8
M base HW1200063-1
1
Drive unit
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6 Disassembly and Reassembly of Speed Reducer
6.1 Disassembly and Reassembly of S-, L-, and U-axes Speed Reducer.
Fig. 6-1: Disassembly and Reassembly of S-, L-, and U-axes Speed
Reducer
3
2
3
2
8
8
4
4
7
7
6
6
1
5
1
5
8
2
For before June 20, 2013 shipment
For before June 20, 2013 shipment
3
4
7
6
1
5
For after June 20, 2013 shipment
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6 Disassembly and Reassembly of Speed Reducer
6.2 Disassembly and Reassembly of T-axis Speed Reducer
6.2
Disassembly and Reassembly of T-axis Speed Reducer
• Refer to Fig. 6-2 Disassembly and Reassembly of the T-axis Speed
Reducer on page 6-5.

Disassembly
1. Follow step (1) through step (9) in Section 5.2 “Disassembly and
Reassembly of T-axis Motor” on page 5-9 “Disassembly” .
2. Remove the built-up grease inside the flange
1 attached).
2
3. Unscrew the hexagon socket head cap screw
2 and the circular spline 1 .

(with the circular spline
3
to remove the flange
Reassembly
1. Apply ThreeBond 1206C to the matching surface between the flange
2 and the circular spline 1 , and then attach the circular spline 1 to the
flange 2 .
2. Install by tightening the hexagon socket head cap screw
tightening torque shown in Table 6-2.
3. Fill LUBRI FG-0 up to the mark
4
3
with the
inside the circular spline 1 .
4. Follow steps from (1) to (9) in Section 5.2 “Disassembly and
Reassembly of T-axis Motor” on page 5-9 “Reassembly”
.
Table 6-2: T-axis Motor Parts Checklist
No Item
Qty Remark
1
Speed reducer HW1380868- 1
A
Circular spline
2
Flange HW1301665-1
1
3
Socket screw M3 × 25
Spring washer 2H-3
14
Tightening torque: 1.4 N•m (0.14 kgf•m)
4
LUBRIPLATE SYNXTREME
FG-0
1
Limit of Grease Replenishment Volume
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6 Disassembly and Reassembly of Speed Reducer
6.2 Disassembly and Reassembly of T-axis Speed Reducer
Fig. 6-2: Disassembly and Reassembly of the T-axis Speed Reducer
3
1
4
2
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7
7 Adjustment of S-, L-, and U-axes Timing Belt
7.1 Disassembly and Reassembly of S-, L-, and U-axes Timing Belt
Adjustment of S-, L-, and U-axes Timing Belt
7.1
Disassembly and Reassembly of S-, L-, and U-axes
Timing Belt
• Refer to Fig. 7-1 Disassembly and Reassembly of S-, L-, and U-axes
Timing Belt on page 7-2 and Table 7-1 S-, L-, and U-axes Timing
Belt Parts Checklist on page 7-1.
• Refer to Section 5.1 “Disassembly and Reassembly of the S-, L-, and
U-axes Motor” on page 5-1.


Disassembly
1. Remove the S-, L-, and U-axes motor
axes timing belt 1 .
2
and unhook the S-, L-, and U-
Reassembly
1. Hook the S-, L-, and U-axes timing belt 1 and install the S-, L-, and Uaxes motor 2 .
Table 7-1: S-, L-, and U-axes Timing Belt Parts Checklist
No Item
Qty Remark
1
Motor of each axis
HW13801060-1
1
SGMAV-10ANA-YR11
2
Belt 250HP-S5M560
1
3
Socket screw M5 × 30
Spring washer 2H-5
Washer M5
Washer HW8411125-3
4
Tightening torque: 6.0 N•m (0.6 kgf•m)
4
Socket screw M5 × 30
Spring washer 2H-5
Nut M5
2
Tightening torque: 6.0 N•m (0.6 kgf•m)
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7 Adjustment of S-, L-, and U-axes Timing Belt
7.1 Disassembly and Reassembly of S-, L-, and U-axes Timing Belt
Fig. 7-1: Disassembly and Reassembly of S-, L-, and U-axes Timing Belt
4
3
2
1
For before June 20, 2013 shipment
4
3
2
1
For after June 20, 2013 shipment
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7 Adjustment of S-, L-, and U-axes Timing Belt
7.2 Adjustment of Timing Belt
7.2
Adjustment of Timing Belt
1. Refer to Fig. 7-1 Disassembly and Reassembly of S-, L-, and U-axes
Timing Belt on page 7-2 . Loosen the hexagon socket head cap
screw 3 . Adjust the tension of the timing belt 1 by tightening the
hexagon socket head cap screw 4 to the direction that the timing
belt 1 is stretched.
2. Using a tension meter, adjust the tension of the timing belt to fall within
the initial tension range shown in Table 7-2 Initial Tension of Timing
Belt.
3. Tighten the hexagon socket head cap screw 3 with the specified
tightening torque. Double-check that the initial tension of the timing
belt falls within the initial tension range shown in Table 7-2.
(Set a tension meter as follows: belt mass as 38g (10 mm (W) x 1m (L)),
belt width as 25 mm, and distance between axes as 191 mm.)
Table 7-2: Initial Tension of Timing Belt
Initial Tension
S-, L-, and U-axes
169 to 291 N (17.2 to 29.7 kgf)
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8
8 Battery Pack Replacement
8.1 Battery Pack Replacement
Battery Pack Replacement
8.1
Battery Pack Replacement
The battery packs are installed in the position shown in Fig.8-1 Battery
Location. If the battery alarm occurs in the FS100, replace the battery in
accordance with the following procedure:
Fig. 8-1: Battery Location
Battery cover
A
A
Battery cover
Fixing bolt (8 bolts)
Battery
Battery holder
View A-A
Battery holder
Fixing screw (4 screws)
NOTE
Remove the old battery pack after connecting the new one
so that the encoder absolute data does not disappear.
1. Turn OFF the FS100 main power supply.
2. Remove the fixing screws (4) from the battery holder, and then pull the
battery holder out.
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8 Battery Pack Replacement
8.1 Battery Pack Replacement
3. Connect the new battery connector to the unoccupied connector on
the board.
Connect the new battery
New battery
Circuit board
Old battery
4. Remove the old battery connector from the board.
Circuit board
New battery
Old battery
Remove the old battery
5. Remove the old battery from the battery holder, mount the new battery
to the holder.
6. Mount the battery holder in its original position.
NOTE
Do not allow plate to pinch the cables when reinstalling the
holder.
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8.1 Battery Pack Replacement
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9
9 Relay Lead Cable Replacement
9.1 Relay Lead Cable Replacement
Relay Lead Cable Replacement
9.1
Relay Lead Cable Replacement
• Refer to Fig.9-1 Relay Lead Cable Replacement.

Disassembly
1. Place the T-axis unit on a working table carefully so that the unit does
not fall off the table.
2. Turn OFF the power supply to the FS100.
3. Remove the cover
3
from the T-axis unit.
4. Remove the vinyl cover from the connector (encoder cables) parts of
the relay lead connected to the T-axis motor 1 . Then disconnect the
backup battery. (Refer to Fig.9-1 Relay Lead Cable Replacement.)
5. Remove the cable ties tying the relay lead cables which are wired to Uarm and L-arm of the S-axis. There are twelve cable-tied parts; 6 parts
at each side of the L-arm.
6. Separate the T-axis unit by removing the L-arm 2 . At this time, treat
the axis unit with caution so that it does not fall off. Also, avoid the
relay lead from stretching. (Refer to Section 9.2.3.1 “L-arm Removal”
in the MOTOMAN-MPP3 INSTRUCTIONS.)
7. Manually loosen the hexagon cap nut 6 on the cable connector 5 ,
remove Multi-Opening Packing 7 and from the cable, pull out the
connector, which is at the cable-relay part, and then remove the
connector.
NOTE
• The battery pack must be connected before removing the
detection connector to avoid home position data from
loosing.
• Place the T-axis unit (relay lead are equipped) on an
appropriate place for working.
8. Refer to chapter 5.2 “Disassembly and Reassembly of T-axis Motor”
in the Disassembly 6.
9. Unscrew the hexagon socket head cap screw (stainless) 4 . Use a
short type tapered head socket set screw wrench to unscrew the
screws.
10. Separate the relay lead from the T-axis unit.
Table 9-1: Relay Lead Cable Replacement
No Item
Qty Remark
1
Motor of T-axis
HW13801061-1
1
2
L arm HW1301663-A
6
3
Cover HW1301550-1
1
4
Socket screw M3 × 8(SUS) 6
Seal washer W-3(SUS)
5
Connector
E2MBG20 7x3P-28
1
6
hexagon cap nut
1
7
Multi-Opening Packing
EMGP20 7x3P
1
SGMAV-01ANA-YR21
(
5
accessories)
9-1
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9 Relay Lead Cable Replacement
9.1 Relay Lead Cable Replacement
Fig. 9-1: Relay Lead Cable Replacement
Left side
of the L-arm
T-PG,T-PW
4
L-Axis
L-Axis
T-PW
Relaying part
of the cable
Left side
of the L-arm
1
T-PG,T-PW
T-PG
Relaying
part of
the cable
$,
5
%
6
&
%
&
S-Axis
$,
5
4
4
%$7
S-Axis
S1-1,S1-2
Relaying part
4 of the cable
S1-1,S1-2
Right side
of the L-arm
U-Axis
pin for battery
S1-1,S1-2
Right side
of the L-arm
A-A
U-Axis
<Disassembly and Assembly
of Cable Relaying Part>
Relaying part
of the cable
Cable fixing part
5
2
Cable fixing part
Blue tube
7
Cable fixing part
6
3
A
2.5
A
95
°
4 Screwing jig:
6
Short type tapered head socket set screw wrench
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9 Relay Lead Cable Replacement
9.1 Relay Lead Cable Replacement

Assembly
1. Connect the relay lead to the T-axis unit. (By referring to Fig.9-1 Relay
Lead Cable Replacement, connect two relay leads (encoder and
power) to the left side of the L-arm and connect one relay lead
(application) to the right side of the L-arm.)
2. Mount the hexagon socket head cap screw (stainless) 4 . Use short
type tapered head socket set screw wrench to unscrew the screws.
3. Refer to chapter 5.2 “Disassembly and Reassembly of T-axis Motor”
Reassembly.
4.
Store the connectors and the cables into the T-axis base.
5. Connect the relay lead connectors of the base-axis side, and then
store them into the T-axis base. At this time, set and fix the MultiOpening Packing to the position shown in the Fig.9-1 Relay Lead
Cable Replacement. (A thermal compressed tube (black) is attached
to one relay lead of the three as a fixing position for the Multi-Opening
Packing.)
Fig. 9-2: Multi-Opening Packing Fixing Positio
Basic axis relay
lead cable connector
Multi-Opening Packing
fixing position
Thermal compressed
tube (black)
Mark for fixing position
6. Disconnect the backup battery, and then protect the connector parts
with the vinyl cover.
NOTE
The battery pack must be connected before removing the
detection connector to avoid home position data from
loosing. Place the T-axis unit (relay lead are equipped) on a
appropriate place for working.
7. Wipe away any old grease adhered to the L-arm and the ball joint, and
then apply new grease to the bush part. (Refer to Section 9.2.5 “Bush
Grease Application” in the MOTOMAN-MPP3 INSTRUCTIONS.)
8.
Mount the L-arm. (Refer to Section 9.2.3.2 “L-arm Installation” in the
MOTOMAN-MPP3 INSTRUCTIONS.)
9. Wire the relay lead to the U-arm and the L-arm of the S-axis. (This
wiring helps differentiate each axis.) For the wiring method, refer to
Section 9.2.3.3 “Relay Lead Fixing in MOTOMAN-MPP3 instructions.
10. Perform a low-speed operation check to confirm that there is no
interference or no excess tension to the relay lead, and then start the
normal operation.
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10 Parts List
10.1 Drive Unit (For before June 20, 2013 shipment)
10 Parts List
10.1
Drive Unit (For before June 20, 2013 shipment)
Fig. 10-1: Drive Unit
1051
1052
1053
1050
1042
1047
1049
1048
1046
1051
1052
1053
1050
1042
1048
1047
1020
1023 1024
1054
1054
1006
1007
1005
1004
1030
1031
1029
1028
1049
1021
1019
1015
1017
1018
1016
1046
1054
1022
1043
1041
1042
1008
1041
1042
1032
1009 1010 1011
1025
1014
1043
1004
1005 1007
1006
1028
1029 1031
1030
1020
1021
1026
1027
1025
1019
1024
1023
1022
1003
1032
1018
1017
1016
1015
1014
1027 1026
1051
1052
1053
1048
1011
1010
1009
1003
1008
1001
1047
1054
1034
1035
1049
1050
1042
1020
1021
1019
1036
1043
1041
1042
1046
1023
1024
1009
1010
1011
1054
1008
1022
1014
1015
1017
1016
1018
1037
1054
1003
1002
1004
1007
1005
1025
1006
1028
1032
1027
1026
10311029
1030
10-1
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MPP3
10 Parts List
10.1 Drive Unit (For before June 20, 2013 shipment)
Table 10-1: Drive Unit (Sheet 1 of 2)
No.
DWG No.
Name
Pcs
1001
HW1100155-1
Base
1
1002
HW1100154-1
Cover
1
1003
HW1200063-1
M base
3
1004
HW1401219-A
Pulley
3
1005
HW1400768-1
Washer
3
1006
M6X20
Socket screw
3
1007
2H-6
Spring washer
3
1008
HW1381060-A
Motor
3
1009
M5X20
Socket screw
12
1010
2H-5
Spring washer
12
1011
M5
Washer
12
1014
HW1401298-1
M base
3
1015
M5X30
Socket screw
12
1016
2H-5
Spring washer
12
1017
M5
Washer
12
1018
HW8411125-3
Washer
12
1019
HW1401299-1
Block
3
1020
M5X30
Socket screw
6
1021
2H-5
Spring washer
6
1022
M5
Nut
6
1023
M5X30
Socket screw
6
1024
2H-5
Spring washer
6
1025
HW1381062-A
Speed reducer
3
1026
M10X40
Socket screw
12
1027
2H-10
Spring washer
12
1028
HW1401218-A
Pulley
3
1029
HW1400768-2
Washer
3
1030
M6X20
Socket screw
3
1031
2H-6
Spring washer
3
1032
250HP-S5M560
Belt
3
1034
M6X40
(STAINLESS coating)
Socket screw
21
1035
2H-6
(STAINLESS coating)
Spring washer
21
1036
MSTH6-15
Pin
2
1037
VC851009
Oil seal
3
1041
M6X30
Socket screw
9
1042
GT-LH-6
Washer
15
1043
MSTH6-15
Pin
6
1046
HW1402322-1
Plate
3
1047
Cooler H417-70
Fin
6
1048
HW0301131-2
Clamp
6
1049
HW9482408-A
Thermal conductive
sheet
78
10-2
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10 Parts List
10.1 Drive Unit (For before June 20, 2013 shipment)
Table 10-1: Drive Unit (Sheet 2 of 2)
No.
DWG No.
Name
Pcs
1050
M6X40
Socket screw
6
1051
M6X15
Socket screw
6
1052
2H-6
Spring washer
6
1053
M6
Washer
6
1054
HW9482404-A
Thermal conductive
sheet
24
10-3
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10 Parts List
10.2 Drive Unit (After June 20, 2013 shipment)
10.2
Drive Unit (After June 20, 2013 shipment)
Fig. 10-2: Drive Unit
1066
1050
1066
1051
1042
1065
1052
1053
1047
1065
1052
1053
1051
1067
1046
1050
1047
1054-2
1042
1054-2
1067
2002
2003
2001
1062
1054-1
1054-3
1060
1054-3
1064
1046
1006
1020
1024
1023
1007
1005
1063
1054-3
1004
1021
1019
1017
1018
1061
1058
1022
1059
1016
1030
1031
1029
1032
1054-3
1028
1009
1011
1010
1041
1043
1015
1008
1004 1005
1007
1006
1003
1014
1057
1027
1056
1057
1026
1032
1042
1026
1027
1041
1042
1055
1025
1043
1056
1025
1055
1058
1028
1030
1029
1031
1003
1020
1001
1021
1019
1061
1059
1022
1063
1062
1024
1014
1060
1023
1064
1018
1017
1016
1015
1054-1
1011
1010
1009
1008
1037
1020
1024
1061
1021
1063
1059
1023
1064
1062
1019
1060
1022
1041
1042
1008
1014
1043
1051
1054-1
1052
1053
1009
1010
1011
1015
1016
1017
1018
1057
1066
1065
1067
1047
1054-2
1050
1042
1003
1046
1058
1055
1054-3
1025
1054-3
1004
1005
1006 1007
1056
1027
1026
1032
1029
1031
1030
1028
10-4
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10 Parts List
10.2 Drive Unit (After June 20, 2013 shipment)
Table 10-2: Drive Unit (Sheet 1 of 2)
No.
DWG No.
Name
Pcs
1001
HW1100228-1
Base
1
1003
HW1200063-1
M base
3
1004
HW1401219-A
Pulley
3
1005
HW1400768-1
Washer
3
1006
M6X20
Socket screw
3
1007
2H-6
Spring washer
3
1008
HW1381060-A
Motor
3
1009
M5X20
Socket screw
12
1010
2H-5
Spring washer
12
1011
M5
Washer
12
1014
HW1401298-1
M base
3
1015
M5X30
Socket screw
12
1016
2H-5
Spring washer
12
1017
M5
Washer
12
1018
HW8411125-3
Washer
12
1019
HW1401299-1
Block
3
1020
M5X30
Socket screw
6
1021
2H-5
Spring washer
6
1022
M5
Nut
6
1023
M5X30
Socket screw
6
1024
2H-5
Spring washer
6
1025
HW1381062-A
Speed reducer
3
1026
M10X40
Socket screw
12
1027
2H-10
Spring washer
12
1028
HW1401218-A
Pulley
3
1029
HW1400768-2
Washer
3
1030
M6X20
Socket screw
3
1031
2H-6
Spring washer
3
1032
250HP-S5M560
Belt
3
1037
VC851009
Oil seal
3
1041
M6X30
Socket screw
9
1042
GT-LH-6
Washer
15
1043
MSTH6-15
Pin
6
1046
HW1402322-1
Plate(LU-Axis)
2
1046
HW1402322-2
Plate(S-Axis)
1
1047
Cooler H417-70
Fin
6
1050
M6X30
Socket screw
6
1051
M6X15
Socket screw
6
1052
2H-6
Spring washer
6
1053
M6
Washer
6
1054-1
HW1481624-C
Thermal conductive
sheet
3
1054-2
HW1481626-A
Thermal conductive
sheet
6
10-5
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10 Parts List
10.2 Drive Unit (After June 20, 2013 shipment)
Table 10-2: Drive Unit (Sheet 2 of 2)
No.
DWG No.
Name
Pcs
1054-3
HW1481625-C
Thermal conductive
sheet
3
1055
KQ2L10-01S
Male elbow
3
1056
KQ2L08-01S
Male elbow
3
1057
TU1065
Tubing
3
1058
TU0805
Tubing
3
1059
KQ2H10-00A
Straight union
3
1060
KQ2L08-00
Union elbow
3
1061
KQP-10
Plug
3
1062
KQP-08
Plug
3
1063
HW1404440-2
Bracket
3
1064
HW1404440-1
Bracket
3
1065
HW1402966-1
Clamp
3
1066
M4X45
Socket screw
3
1067
M4
Nut
3
2001
HW1401415-1
Support
1
2002
M4X10
Socket screw
2
2003
2H-4
Spring washer
2
10-6
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10 Parts List
10.3 Wiring and Piping Assy (Before June 20, 2013 shipment)
10.3
Wiring and Piping Assy (Before June 20, 2013 shipment)
Fig. 10-3: Wiring and Piping Assy
2006
2007
2004
2025
2005
2010
2011
2008
2009
2023
2028
2002
2003
2001
2021
2020
2019
2016
2018
2014
2015
2012
1040
2013
2026
1038 1039
3020
1040
1038
1039
3020
3020
1039
1038
1040
2024
2027
2022
2022
*"No.2027" used S-axis only
10-7
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10 Parts List
10.3 Wiring and Piping Assy (Before June 20, 2013 shipment)
Table 10-3: Wiring and Piping Assy
No.
DWG No.
Name
Pcs
2001
HW1401415-1
Support
1
2002
M4X10
Socket screw
2
2003
2H-4
Spring washer
2
2004
HW1370413-A
C base assy
1
2005
HW1401334-1
Packing
1
2006
M4X10
(STAINLESS coating)
Socket screw
14
2007
2H-4
(STAINLESS coating)
Spring washer
14
2008
HW1301062-1
Cover
1
2009
HW1301066-1
Packing
1
2010
M5X16
(STAINLESS coating)
Socket screw
13
2011
2H-5
Spring washer
13
2012
HW1401307-1
N-Base
1
2013
HW1401308-1
Packing
1
2014
M4X12
(STAINLESS coating)
Socket screw
7
2015
2H-4
(STAINLESS coating)
Spring washer
7
2016
KQ2E08-01
Union
2
2018
E2MBG20-7X3P-28
Keigrand
1
2019
TA1-S8
Clamp
3
2020
M4X8
Pan-head sems
screw
3
2021
M4X8
APS bolt
6
2022
MCTS200-BLU
Cable tie
12
2023
HW1170334-A
Wire harness in
manipulator
1
2024
HW1370677-A
Relay wire
1
2025
M16 *SUS*
Eye bolt
3
2026
PT1/8 *SUS*
Plug
2
2027
HW1402152-1
Support
2
2028
T50R
Cable tie
3
1038
M8X55
Socket screw
18
1039
GT-LH-8
Washer
18
1040
HW1401164-1
U-arm cover
3
10-8
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10 Parts List
10.4 Wiring and Piping Assy (After June 20, 2013 shipment)
10.4
Wiring and Piping Assy (After June 20, 2013 shipment)
Fig. 10-4: Wiring and Piping Assy
2006
2007
2004
2025
2005
2010
2011
2008
2009
2023
2028
2020
2019
2021
2016
2018
2014
2015
2012
2013
1040
2026
1038
1039
3020
1040
1038
1039
3020
3020
1039
1038
1040
2027
2024
2022
2022
10-9
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10 Parts List
10.4 Wiring and Piping Assy (After June 20, 2013 shipment)
Table 10-4: Wiring and Piping Assy
No.
DWG No.
Name
Pcs
2004
HW1370413-A
C base assy
1
2005
HW1401334-1
Packing
1
2006
M4X10
(STAINLESS coating)
Socket screw
14
2007
2H-4
(STAINLESS coating)
Spring washer
14
2008
HW1301062-1
Cover
1
2009
HW1301066-1
Packing
1
2010
M5X16
(STAINLESS coating)
Socket screw
13
2011
2H-5
(STAINLESS coating)
Spring washer
13
2012
HW1401307-1
N-Base
1
2013
HW1401308-1
Packing
1
2014
M4X12
(STAINLESS coating)
Socket screw
7
2015
2H-4
(STAINLESS coating)
Spring washer
7
2016
KQ2E08-01
Union
2
2018
E2MBG20-7X3P-28
Keigrand
1
2019
TA1-S8
Clamp
3
2020
M4X8
Pan-head sems
screw
3
2021
M4X8
APS bolt
6
2022
MCTS200-BLU
Cable tie
12
2023
HW1170334-A
Wire harness in
manipulator
1
2024
HW1370677-A
Relay wire
1
2025
M16 *SUS*
Eye bolt
3
2026
PT1/8 *SUS*
Plug
2
2027
HW1402152-1
Support
2
2028
T50R
Cable tie
3
1038
M8X55
Socket screw
18
1039
GT-LH-8
Washer
18
1040
HW1401164-1
U-arm cover
3
10-10
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10 Parts List
10.5 L-, U-Arms and T-Axis Unit
10.5
L-, U-Arms and T-Axis Unit
Fig. 10-5: L-, U-Arms and T-Axis Unit
3020
3030
3015
3021
3012
3029
3015
3012
3015
3029
3002
3030 3021
3014
3015
3003
3013
3001
3031
3015
3030
3015
3029
3019
2024
3036
3017
2024
3036
3011
3013
3030
3015
3029
3028
3034
3035
3033
3035
3034
3012
3004
3032
3034
3035
3015
3012
3008
3009
3026
3007
3006
3022
3023
3027
3010
3024
3005
3025
10-11
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10 Parts List
10.5 L-, U-Arms and T-Axis Unit
Table 10-5: L-, U-Arms and T-Axis Unit
No.
DWG No.
Name
Pcs
3001
HW1381061-A
(SGMAV-01ANA-YR21)
Motor
1
3002
HW1301550-1
Cover
1
3003
HW1401881-1
Packing
1
3004
HW1200157-1
Base
1
3005
HW1301665-1
Flunge
1
3006
HW1401882-1
Washer
1
3007
HW1380868-A
Speed reducer
1
3008
SC12.67 x 22.22 x 4.7 *NOK*
Oil seal
1
3009
M3X25
Socket screw
12
3010
M3X12
Socket screw
1
3011
M3X25
Socket screw
14
3012
HW1402017-1
Ball joint
12
3013
HW1402846-1
Spring unit
6
3014
EZ5013B0 *NOK*
Bore plug
3
3015
HW1402785-5
Roller
24
3017
LP-M5
Plug
1
3019
M6X6
Socket screw
1
3020
HW1200100-1
U arm
3
3021
HW1301663-1
L arm
6
3022
M4X12
Socket screw
8
3023
2H-4
Spring washer
8
3024
M4
Washer
8
3025
HW1401970-1
Flunge
1
3026
2H-3
Spring washer
12
3027
2H-3
Spring washer
1
3028
2H-3
Spring washer
14
3029
HW1402084-1
Bush
12
3030
HW1402832-1
Pin
12
3031
M3X10
GT-SA bolt
2
3032
HW1470432-A
Relay lead assy
1
3033
HW1402098-1
Packing
1
3034
W-3 *SUS*
Seal washer
6
3035
M3X8 *SUS*
Socket screw
6
3036
HW1402097-1
Packing
2
10-12
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MOTOMAN-MPP3
MAINTENANCE MANUAL
Specifications are subject to change without notice
for ongoing product modifications and improvements.
MANUAL NO.
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