This guide describes how to replace the MiR500/MiR1000 motor and bogie. The motor and bogie are attached and come as a combined package as spare parts. The illustrations in this guide show the right-side motor being replaced on a MiR500, but the process is the same if you need to replace the motor on a MiR1000 or the left-side motor on either robot.

If your MiR500 is a hardware version 1.0 (with serial number U0159 or lower), you need the Motor upgrade kit to change both motors because the motors on version 1.0 have a different gearing (28:1) than the newer models (23:1). You also need to:

• Replace the motor controller carrier board—see the guide How to replace the motor controller carrier board on MiR500 and MiR1000. You can find this guide on MiR Support Portal.

• Update the SICK configuration—see the guide How to apply the default SICK configuration on MiR250, MiR500, MiR600, MiR1000, and MiR1350. You can find this guide on MiR Support Portal.

• Change the gearing settings in the robot interface System > Settings > Motor controller > Advanced Settings > Gearing ratio to 22.89:1 instead of 28:1

Things you will need

• A new bogie with a motor from MiR

• The Motor upgrade kit from MiR (only for MiR500 HW version 1.0)

• A socket wrench set with 13 mm and 17 mm hex sockets

• A 43 Nm torque wrench

• A flat-head screwdriver
  

• A piece of wood to levitate the wheel

• A screwdriver or wrench with the following exchangeable bits:

  • 4 mm hex

  • 5 mm hex

• Loctite 2400 threadlocking adhesive, or other adhesive with same properties—see Loctite 2400 specifications

Before replacing the motor

Turn off the robot, and disconnect the battery. To disconnect the battery, open the rear compartment, and turn the Battery disconnect switch to the Off position.

Removing the front compartment hatch

1. Press the two buttons on the front hatch, and pull open the hatch.

    

2. Remove the compartment hatch. To do this, disconnect the status light cable, and turn the two hinges in the bottom corners.

   

Removing the corner shield

Only remove the front corner shield on the side of the robot where you are replacing the bogie.

1. Press the Emergency stop button on the corner shield you are going to remove. After reassembling, remember to release the button again.

2. Disconnect the cables plugged into the corner shield. Mark which cables should be plugged into which sockets, or take a picture to make sure you plug in the cables correctly when reassembling the robot.

3. Remove the four screws from the corner shield. Use a 4 mm hex bit.

   

4. Remove the corner shield. It may require some force to disconnect the shield from the corner bumper. Pull it downward firmly to remove it from the bumper.

   

Removing the side compartment hatch

1. Turn the two screws 90˚ with a flat-head screwdriver, and pull open the hatch.

   

2. Remove the compartment hatch. To do this, disconnect the status light cable, and turn the two hinges in the bottom corners.

    

Pulling out the bogie arm

1. Raise the robot above ground, and use a piece of wood or other firm material to keep it lifted. The drive wheel must not be in contact with the floor.

   

2. Remove the bogie bolt. Use a 17 mm wrench. When reassembling, apply Loctite 2400 to the bolt, and tighten it to 43 Nm.

   Loctite and many other threadlocking adhesives are toxic substances that can cause skin, eye, throat, or digestive tract irritation to personnel upon contact, inhalation, or ingestion.

   • Read the safety data sheet for the adhesive product before applying it.

   • Avoid direct contact with the adhesive.

   • Apply the adhesive in a well-ventilated area.

   

3. Pull out the wheel and bogie arm slightly. Pull out the bogie arm enough to make it possible to gain access behind the wheel gearing.

   Be careful not to pull any wires while pulling out the bogie arm. If necessary, unplug any wires that are not long enough to let you pull out the bogie far enough for you to reach behind it.

    

4. Disconnect the following cables located behind the bogie, beneath the center compartment:

   Pos.	Description	Pos.	Description
   1	Brake feedback cable	2	Brake power cable
   3	Motor encoder cable

   

5. Disconnect the motor power cable and the hall sensor cable. The bogie arm with the motor is now detached.

   

6. Pull the bogie free of the robot completely. You have now removed the bogie arm and can replace it with a new one.

   

Replacing the bogie

To install the new bogie into the robot, complete all of the dissasembly steps in the reverse order with the new bogie.