MANUAL NO.

1HW1480794

Part Number: 164044-1CDRevision: 0

MOTOMAN-MH165INSTRUCTIONSSUPPLEMENTARY FOR YR-MH00165-C00 (IP65 SPECIFICATION) YR-MH00165-C10 (IP65 SPECIFICATION)

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

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MH165 2.1 Transport Method (page 2-1)

IntroductionThis supplementary instruction manual describes how YR-MH00165-C00 (here in after referred to as MH00165-C00) and YR-MH00165-C10 (here in after referred to as MH00165-C10) are different from the YR-MH00165-A00 (hereinafter referred to as MH00165-A00) and MH00165-A10 (hereinafter referred to as MH00165-A10).

Read this supplementary instruction manual thoroughly together with the following instruction manuals:

For operating YR-MH00165-C00,

Read “MOTOMAN-MH165 INSTRUCTIONS” (Type: YR-MH00165-A00 for standard specification and YR-MH00165-A10 for SLU-axes with limit switches Manual Part No. 164043-1CD)

For operating YR-MH00165-C10,

Read “MOTOMAN-MH165-100 INSTRUCTIONS” (Type: YR-MH00165-100 A10 for standard specification and YR-MH00165-100-A11 for SLU-axes with limit switches, Manual Part No. 164052-1CD)

Points of DifferencesThe MH00165-C00 and MH00165-C10 are different from the MH00165-A00 and MH00165-A10 in the following point:

• Environmental resistance : IP65 (for the main part of the manipulator)

The differences are described based on “MOTOMAN-MH165 INSTRUCTIONS” (Manual Part No. 164043-1CD) and “MOTOMAN-MH165-100 INSTRUCTIONS” (Manual Part No. 164052-1CD). Read this manual thoroughly replacing the subject matters for changes with this supplementary instruction manual.

2.1 Transport Method (page 2-1)

The weight (mass) of the manipulator described as “1180 kg” in the NOTE column shall be changed to “1190 kg”.

3.3 Location (page 3-3)

• Free from dust, soot, oil, or water

Please replace the above sentence with the following one.

• Free from dust or soot; free from substances that may reduce the efficacy of sealant materials such as nitrile rubber oil seal, O-ring, gasket, and liquid gasket used in the manipulator.

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MH165

4.2.2 Connection to the DX100 (page 4-4)

Fig. 4-3(a): Manipulator Cable Connectors (Manipulator Side)

Key position Key position

Key position

AIR

2BC

AIR1BC

4BC3BC

B

2BC

A1BC

4BC3BC

Connector details(Manipulator side)

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MH165 5 Basic Specifications (page 5-1)5.3 Manipulator Base Dimensions (page 5-2)

5 Basic Specifications (page 5-1)

The MH00165-C00 manipulator differs from the MH00165-A00 in the following items listed on Table 5-1 “Basic Specifications” on page 5-1.

• Mass

The mass indicated as “1100 kg” shall be changed to “1110 kg”.

• Others (in Ambient Conditions)

• Free from dust, soot, or water

Please replace the above sentence with the following one.

• Free from dust or soot; free from substances that may reduce the efficacy of sealant materials such as nitrile rubber oil seal, O-ring, gasket, and liquid gasket used in the manipulator.

5.3 Manipulator Base Dimensions (page 5-2)

Fig. 5-2: Manipulator Base Dimensions

126

200 35

0 0

.1

290 0.1

640

290 0.1

893

54029

0 0

.1

290 0.1353 0.1

290 0.1

View A

540

640

735

290

0.140

A

Fitting surface

22 dia. (8 holes)(For fixing the manipulator)

20 dia. (2 holes)(Pin hole for manipulator positioning)

+0.021 0

16 dia. (2 holes)(Pin hole for manipulator positioning)

+0.018 0

Units: mm

Fitting surface

5 Basic Specifications (page 5-1)5.4 Dimensions and P-Point Maximum Envelope (page 5-4)

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5.4 Dimensions and P-Point Maximum Envelope (page 5-4)

Fig. 5-3: Dimensions and P-Point Maximum Envelope (MH00165-C00)

1307

0

687

126

945

0 52

4

70

15

82

72

77

29

16

322

0

650

1024

348495

3050

294491

40

650

50

42

609.2 76

9.2

9.2

1825

142.5

1150

153

250

2203

1225285 225

1961 26514612

R2651

R728

R608

491

264

180�

180�

P-point maximumenvelope

P-point

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MH165 5 Basic Specifications (page 5-1)5.4 Dimensions and P-Point Maximum Envelope (page 5-4)

Fig. 5-4: Dimensions and P-Point Maximum Envelope (MH00165-C10)

491

650

914

B

894

0

681

238

45

13312

0 9216 60

R914

73

344

R3010

255 40

3010

3410

410

491

23205330

27.5

12.5R608

2251590

82

285

153

250

50°

137.5

85

75

5

C

650

1150

864

292

0

A

1215

40

2203

154

443

0

1541

644

134

P-point

P-point maximumenvelope

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MH165 7.2 Internal User I/O Wiring Harness and Air Line (page 7-3)

7.2 Internal User I/O Wiring Harness and Air Line (page 7-3)

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

View A

B

2BC

A1BC

4BC3BC

A

Exhaust port A (air flow)Tapped hole PT3/8with pipe plug

Exhaust port B (air flow)Tapped hole PT3/8with pipe plug

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

Air inlet A (air flow)Tapped hole PT3/8with pipe plug

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

Air inlet B (air flow)Tapped hole PT3/8with pipe plug

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MH165 8.2 Internal Connections (page 8-2)

8.2 Internal Connections (page 8-2)

High reliability connectors which can be easily put on and removed are used with each connector part. For the numbers, types, and locations of connectors, see Fig.8-2 Locations and Numbers of Connectors and Table 8-1 List of Connector Types.

Fig. 8-2: Locations and Numbers of Connectors

1BC

3BC 2BC

Connector for internal user I/O wiring harness (Casing)

Connector forinternal user I/Owiring harness(Base)

Table 8-1: List of Connector Types

Name Type of Connector

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

JL05-2A24-28PC(JL05-6A24-28S: Optional)

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

JL05-2A24-28SC(JL05-6A24-28P: Optional)

8 Electrical Equipment SpecificationMH165 8.2 Internal Connections (page 8-2)

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Fig. 8-3(a): Internal Connection Diagram (page 8-3)

A1

B1

A2B2

A3

B3

SPG-6

CN4-4 SPG-7

CN3-4 5V

5V0VCN3-5

CN3-9CN3-10

0VCN2-10CN2-9CN2-5CN2-4CN4-9CN4-5 FG7

SPG+7

AL2BC2CN4-3

CN4-8

AL1SS2

CN4-7CN4-2

LB1+24V

CN4-6CN4-1

FG6CN3-8

CN3-7

FG5

SPG+6

CN3-3

CN3-6

SPG-5SPG+5

CN3-2CN3-1

FG4CN2-8

SPG-4SPG+4

CN2-7CN2-6

FG3CN2-3

SPG+3SPG-3CN2-2

CN2-1

SPG-2

FG2CN1-8

CN1-7

SPG+2

FG1

CN1-6

CN1-3

Controller

SPG+1SPG-1CN1-2

CN1-1

+24V

+24V0V

0V

CN1-9CN1-10

CN1-4CN1-5

CN1-3

DATA-6-2CN3-7P SPG-6 P

MANIPULATOR

P CN4-5

CN3-4

CN3-10CN3-9CN3-5

CN4-9CN2-4CN2-5CN2-9CN2-10

E

E

CN4-2CN4-7

CN4-3CN4-8

CN4-4

P

P

BC2

SS2

CN4-1CN4-6

CN3-8

P+24VLB1

FG6

LD1LD2

SS2

LB2LB1

SS1

LB1

P

P

LC2LD2

BC2BC1

LB2LA2

OBTBAT

FG6

+5VOBT

0V

BAT

-10

FOR LAMP(OPTION)

PG T-AXIS

CN3-1CN3-2

CN3-3

CN3-6

P

FG5

SPG+6

SPG+5SPG-5

CN2-8

CN2-6CN2-7P

FG4

SPG-4SPG+4

P

P

P

P

P

P

CN2-1CN2-2

CN2-3

P

FG3

SPG+3SPG-3

CN1-8

CN1-6CN1-7P SPG-2

FG2

SPG+2

FG1

P

P

P

P

P

P

BAT

No.5CN

No.6CN6CN-1

FG5

BATOBT

-10

DATA+6

5CN-1

+5VOBTBAT

0V

-2 DATA-5DATA+5

+5V0VFG4

BATOBT

-10

No.4CN4CN-1

BATOBT

-2 DATA-4DATA+4

PG B-AXIS

PG R-AXIS

OBT

+5V

OBTFG30V

OBT

-10

No.3CN3CN-1

BAT

BAT-2

DATA+3DATA-3

DATA-2-2

OBT+5V

FG20V

BAT

-10

No.2CN2CN-1

-10OBTBAT

FG1

DATA+2

PGU-AXIS

PG L-AXIS

CN1-4

CN1-10CN1-9

CN1-1CN1-2

CN1-5

P

P

P

SPG+1SPG-1

+24V0V

+24V0V

24

13

1BC(10P�4)

678

345

21

PG5V510

13141516

1112

PG0V6PG5V6

P

P

P

PG5V24

6

87

9

5PG5V3

PG5V4PG0V4

PG0V5

PG0V3

32123

3130

PG0V1PG5V1PG0V2

BAT6

0BT 1 0BAT11

BAT210BAT22BAT22

0BAT215

78

6P BAT

P BAT0BT

0BT

BAT120BAT12BAT11

32

4P

P

BAT0BTBAT

0BAT117

23

2627

2928

2524

BAT4

BAT50BAT6

0BAT5

0BAT4

20

2221

1918 BAT1

BAT3

BAT20BAT3

0BAT2

No.1CN1CN-1

+5VOBTBAT

0V

-2DATA+1DATA-1

PG S-AXIS

E

E

LA1

-6-5-4-9

-9-4-5-6

-9-4-5-6

-9-4-5-6

-9-4-5-6

-9-4-5-6

-3-1

-4-2

No.22CN+24V0V

+24V0V

X

No.16CN

-4-3-2-1

PG0V1PG5V1

BAT10BAT1

S

No.17CN-1-2-3-4

BAT2

PG5V2PG0V2

0BAT2

L

No.18CN-1-2-3-4

BAT3

PG5V3PG0V3

0BAT3

U

No.19CN-1-2-3-4

BAT4

PG5V4PG0V4

0BAT4

R

PG0V5-4

No.20CN

-3-2-1

B

PG5V5

BAT50BAT5

PG0V6-4

No.21CN

-3-2-1

T

PG5V6

BAT60BAT6

P

P

P

0VCN4-10 CN4-10

LC3LD3

LB3LA3

LD2LD1

LB1LB2

LD1LC1

0V

+24LD1

E E E E E E

+24LD1

E E

10

214BC-214BC-224BC-23

2223

4BC-154BC-164BC-174BC-18

4BC-194BC-20

4BC-104BC-114BC-12

4BC-134BC-14

18

2019

1617

12

13

1514

11

4BC(24-28)

4BC-44BC-54BC-6

4BC-74BC-84BC-9

4BC-24BC-3

4BC-14BC

5

7

6

98

E

4321

10

4BC-114BC-12

4BC-134BC-144BC-154BC-164BC-174BC-18

4BC-194BC-204BC-214BC-224BC-23

4BC-10

212223

18

2019

1617

12

13

1514

11

4BC4BC-14BC-24BC-34BC-44BC-54BC-6

4BC-74BC-84BC-9

4BC(24-28)

5

7

6

98

E

43214BC-1

No.26CN

-2

-4-3

-1-2-3-4

-6 -6-5-5

-11-12

4BC-7No.27CN

-10-9-8

-17-18

4BC-13No.28CN

-16-15-14

No.29CN4BC-19

-23

-20-21-22

A

B

D

C

-18

-20-21

-23-22

4BC-19No.25CN D

-11-12

-10-9

-17-16-15-14

4BC-13No.24CN C

-2-3-4

-6

-8

-5

4BC-1

4BC-7

-5

No.23CN

-6

No.22CN

-2

-4-3

-1

B

A

-6-5

-2

-4-3

-1

-3-4-5-6

-1-2

-2-1

-5-4-3

-6

-4-5

-3

-1-2

-2-1

-5-4-3

-3-4-5-6

-1-2

S-AXIS OVERRUN L.S.

L-AXIS OVERRUN L.S.

L AND U-AXIS INTERFERENCE L.S.

LA1LB1

LB2 LB2LA2

LB1

S-AXIS OVERRUN L.S.

L-AXIS OVERRUN L.S.

L AND U-AXIS INTERFERENCE L.S.

LC1LD1

LD2 LD2LC2

LD1LC1

LD1

LD1LD2

LD3LC3

LA1

LB1

LB1LB2

LB3LA3

SLU-Axes with L.S. Specification

2. For the limit switch specification, the connection of the section A and B parts are changed as follows:1. This diagram is for the MOTOMAN-MH165 (with 23-wire internal user I/O wiring harness and 2 air lines).

Notes

A1Connected to

A2Connected to

A3Connected to

B1Connected to

B2Connected to

B3Connected to

CASINGBASE

8 Electrical Equipment SpecificationMH165 8.2 Internal Connections (page 8-2)

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Fig. 8-3(b): Internal Connection Diagram (page 8-4)

PE

CN3-6 ME5

CN4-1 MV6

ME6ME6

MW6MW6

MV6

CN4-6

CN4-2CN4-3

CN4-4

CN4-5

MU6MU6

CN3-4CN3-5

CN2-4 MU5

ME5

MW5

MV5MU5

MV5

MW5

CN2-3CN2-5

CN2-6

CN3-3CN3-2CN3-1

ME4ME4

CN1-6CN1-3

CN2-7 MU2

CN5-2 MW3

BB5CN6-10

MU4

MV4

MW4

MU4

MV4

MW4

CN1-1

CN1-4CN1-2

CN2-1CN1-5

CN2-2

BB6BA6

CN6-12CN6-11

CN6-5 BA3BB3

BA4BB4

BA5

CN6-6

CN6-8CN6-7

CN6-9

ME3ME3ME3

MW3

CN5-4CN4-8CN4-4

CN5-3

CN6-3 BA2

CN4-3 MU3

MW3

MV3MV3MV3

CN5-1

CN4-6CN4-5

CN4-7

BB2

MU3MU3

CN6-4

CN4-2CN4-1

CN3-6 MW2

ME2ME2ME2

MW2

CN3-8CN3-4CN2-8

CN3-7

MW2

MV2MV2MV2

CN3-5

CN3-2CN3-1

CN3-3

CN2-2 MW1

CN6-1 BA1

MU2MU2

BB1

CN2-5CN2-6

CN6-2

ME1ME1ME1

MW1

CN2-4

CN1-4CN1-8

CN2-3

CN1-3 MU1

MW1

MV1MV1MV1

CN2-1

CN1-5CN1-6CN1-7

MU1MU1

E

CN1-2CN1-1

ME5CN3-6

CN3-4CN3-5CN4-1CN4-4CN4-2CN4-3CN4-5CN4-6

MV6MV6

MW6MW6

ME6ME6

MU6MU6

CN2-4CN2-5CN2-3CN2-6

CN3-2CN3-3

CN3-1

CN1-3CN1-6

MU5

MV5

MU5MV5

MW5ME5

MW5

ME4ME4

MU2CN2-7

MW3CN5-2

BB5CN6-10

CN6-12CN6-11

CN1-1CN1-2CN1-4CN1-5CN2-1CN2-2

3BC(6PX6)

MU4MV4

MU4

MW4

MV4MW4

BB6BA6

CN6-9

CN6-8CN6-7

CN4-4CN4-8CN5-4

CN6-5

CN5-3

CN6-6BA3

BA5

BB4BA4

BB3

ME3ME3ME3

MW3

BA2CN6-3

CN4-3

CN4-5CN4-6CN4-7

CN5-1

CN6-4

CN4-1CN4-2

MU3

MV3MV3MV3

MW3

MU3MU3

BB2

CN3-1CN3-2CN3-3

CN3-5CN3-6CN3-7

CN2-8CN3-4CN3-8

MW2MW2

ME2ME2ME2

MV2MV2MV2

MW2

MW1CN2-2

CN6-1

CN1-8CN1-4

CN2-4

CN2-3

CN2-5CN2-6

CN6-2BA1

MU2MU2

BB1

ME1ME1ME1

MW1

CN1-1CN1-2CN1-3

CN2-1

CN1-5CN1-6CN1-7

2BC(8PX5+12PX1)

MU1

MV1MV1MV1

MW1

MU1MU1

E

E E

-5-6

BA4-1

-4-3

-2 BB4

BA5BB5

BA6BB6

No.30CN Z

BA5-1

No.14CN

MV6MW6

MU6

BA6BB6

ME6

-B-C

-2-1

-D

14CN-A

BB5-2

SM

YB

T-AXIS

YB

MU5

MW5ME5

MV5

-D-C-B

No.13CN13CN-A

ME4

BA4BB4

-1

-D

-2

SMB-AXIS

YB

R-AXIS

MV4MW4

MU4

-C-B

No.12CN12CN-A

SM

BA3BB3

ME3

-1-2

-D

YB

L-AXIS

No.10CN

-C

-1-2

-D

10CN-A-B

SMMW2

BA2BB2

ME2

YB

MU2MV2

MU3

MW3MV3-B

-C

No.11CN11CN-A

SM U-AXIS

S-AXIS

-1-2

-D

BA1BB1

ME1

YB

No.9CN9CN-A

-C-B

MW1MV1MU1

SM

S-AXIS OVERRUN L.S.LA1

LB1LB1

S-AXIS OVERRUN L.S.LC1

LD1LD1LC1

LA1

S-AXIS OVERRUN L.S.

L-AXIS OVERRUN L.S.

LA1LB1

LB2 LB2LA2

LB1

S-AXIS OVERRUN L.S.

L-AXIS OVERRUN L.S.

LC1LD1

LD2 LD2LC2

LD1LC1

LD1

LA1

LB1

SL-axes with Limit Switch Specification

A1Connected to

A2Connected to

B1Connected to

B2Connected to

A1Connected to

B1Connected to

S-axis with Limit Switch Specification

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MH165 9 Maintenance and Inspection9.1 Inspection Schedule (page 9-3)

9 Maintenance and Inspection

9.1 Inspection Schedule (page 9-3)

Add the following item to the Table 9-1 Inspection Items.

The inspection interval depends on the total servo operation time.

Add the following figure to Fig. 9-1 “Inspection Items” on page 9-5.

Fig. 9-1: Inspection Items (Additional)

Table 9-1: Inspection Items

Items Schedule Method Operation Inspection

Charge

Dai

ly

10

00H

Cy

cle

60

00H

Cy

cle

12

000

HC

ycle

24

000

H

36

000

H

Sp

ecif

ied

P

ers

on

ne

lL

icen

see

Se

rvic

e

Co

mp

an

y

18

Drain plug • Screwdriver,Wrench

Drain condensation water from the robot. • • •

1818

9 Maintenance and Inspection9.2 Notes on Maintenance Procedures (page 9-6)

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9.2 Notes on Maintenance Procedures (page 9-6)

9.2.1 Battery Pack Replacement

The battery packs are installed in the position shown in Fig.9-2 Battery Location. If the battery alarm occurs in the DX100, replace the battery in accordance with the following procedures.

Fig. 9-2: Battery Location

Fig. 9-3: Battery Connection

B

2BC

A1BC

4BC3BC

Cover Mounting screw M4

Battery pack

Plate Mounting screw M4

Connector

Battery pack before replacementSee the step 6.

New battery pack

Circuit boardSee the step 5.

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MH165 9 Maintenance and Inspection9.2 Notes on Maintenance Procedures (page 9-6)

1. Turn OFF the DX100 main power supply.

2. Remove the cover of the connector base.

3. Remove the plate fixing screws and the plate, then pull the battery pack out to replace it with the new one.

4. Remove the battery pack from the battery holder.

5. Connect the new battery pack to the unoccupied connector on the board.

6. Remove the old battery pack from the board.

7. Mount the new battery pack on the battery holder.

8. Reinstall the plate with plate fixing screws.

9. The battery replacing procedure completes after reassembling the cover. Apply liquid gasket (Three Bond 1206C: refer to table 10-1 “Spare Parts for the YR-MH00165-C00, YR-MH00165-C10” at page 15) to the cover and sealing bond to the thread part of the screws.

NOTE Remove the old battery pack after connecting the new one so that the encoder absolute data does not disappear.

NOTE Do not allow the plate to pinch the cables when reinstalling the plate.

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9.3.1 Grease Replenishment/Exchange for S-Axis Speed Reducer (page 9-8)

Fig. 9-4: S-Axis Speed Reducer Diagram

9.3.1.1 Grease Replenishment

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

1. Remove the hexagon socket head plugs from the grease inlet.

2. Install a grease zerk A-PT1/4 to the grease inlet. (The grease zerk is delivered with the manipulator.)

3. Inject grease through the grease inlet by using a grease gun.

– Grease type: Molywhite RE No. 00

– Amount of grease: 1200 cc (2400 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. Before installing the plug, apply Three Bond 1206C on the thread part of the plug, then tighten the plug with a tightening torque of 24.5 N•m (2.5 kgf•m).

6. Remove the grease zerk from the grease inlet and reinstall the hexagon socket head plug.Before installing the plug, apply Three Bond 1206C on the thread part of the plug, then tighten the plug with a tightening torque of 12 N•m (1.2 kgf•m).

B

2BC

A1BC

4BC3BC

Grease exhaust portHexagon socket head plug PT1/8

Hexagon socket head plug A-PT1/4 Grease inlet

S-axis speed reducer

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

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MH165

9.3.7 Drainage Procedures of Dew Condensation Water (page 9-23)

Add this section to “9.3 Notes on Grease Replenishment/Exchange Procedures”.

Fig. 9-10: Dew Condensation Water Drainage

1. Make the U-axis horizontal to the ground as shown in Fig.9-10 Dew Condensation Water Drainage.

2. Remove the plug from the water drainage port 1 and 2.

3. Drain the dew condensation water.

4. Reinstall the plug on the water drainage port 1 and 2.

5. Tighten the plug to 5 N•m (0.51 kgf•m). Apply Three Bond 1206C to screwed parts of the plug.

Dew condensation water drainage port2:(hexagon socket head plug PT1/8)

Dew condensation water drainage port1:(hexagon socket head plug PT1/8)

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MH165 10 Recommended Spare Parts (page 10-2)

10 Recommended Spare Parts (page 10-2)

Replace the following items with the items in Table 10-1 ”Spare Parts for the YR-MH00165-A00, YR-MH00165-A10” in “MOTOMAN-MH165 INSTRUCTIONS”

Table 10-1: Spare Parts for the YR-MH00165-C00, YR-MH00165-C10

Rank PartsNo.

Name Type Manufacturer Qty QtyperUnit

Remarks

C 19 Internal Wire Harness

HW1170222-A Yaskawa 1 1

C 20 Connector Base Set

HW1370180-A Yaskawa 1 1

1HW1480794MANUAL NO.

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

MOTOMAN-MH165INSTRUCTIONSSUPPLEMENTARY FOR YR-MH00165-C00 (IP65 SPECIFICATION)SUPPLEMENTARY FOR YR-MH00165-C10 (IP65 SPECIFICATION)