MOTOMAN-HP20D MAINTENANCE MANUAL...not copy the s to another website, blog, cloud storage site or...

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Part Number: 159281-1CDRevision: 1

MOTOMAN-HP20DMAINTENANCE MANUAL

TYPE:YR-HP0020D-A00 (STANDARD SPECIFICATION FOR DX100)YR-HP0020D-B00 (ZEROING SPECIFICATIONS FOR DX100)YR-HP0020D-A10 (LONG U-ARM, 6kg PAYLOAD SPECIFICATION)Procedures described in this maintenance manual should be carried out by the person who took the maintenance-relevant trainings offered by YASKAWA.

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

MOTOMAN INSTRUCTIONS

MOTOMAN-HP20D INSTRUCTIONSDX100 INSTRUCTIONSDX100 OPERATOR’S MANUALDX100 MAINTENACE MANUALThe DX100 operator’s manual above corresponds to specific usage. Be sure to use the appropriate manual.

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Copyright © 2018, 2011 Yaskawa America, Inc.

Terms of Use and Copyright NoticeAll rights reserved. This manual is freely available as a service to Yaskawa customers to assist in the operation of Motoman robots, related equipment and software This manual is copyrighted property of Yaskawa and may not be sold or redistributed in any way. You are welcome to copy this document to your computer or mobile device for easy access but you may not copy the PDF files to another website, blog, cloud storage site or any other means of storing or distributing online content.

Printed in the United States of America

First Printing, 2011

Yaskawa America, Inc.Motoman Robotics Division100 Automation WayMiamisburg, OH 45342Phone: 937-847-6200

www.motoman.com

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HP20D Table of Contents

Table of Contents

1 Introduction ..................................................................................................................................... 1-1

1.1 National Safety Standard for Industrial Robots and Robot Systems ................................. 1-2

1.2 Notes for Safe Operation ................................................................................................... 1-3

1.3 Definition of Terms Used Often in This Manual ................................................................. 1-5

1.4 Registered Trademark ....................................................................................................... 1-5

1.5 Explanation of Warning Labels.......................................................................................... 1-6

1.6 Safeguarding Tips.............................................................................................................. 1-7

1.7 Mechanical Safety Devices................................................................................................ 1-7

1.8 Programming, Operation, and Maintenance Safety........................................................... 1-8

1.9 Maintenance Safety ........................................................................................................... 1-9

1.10 Summary of Warning Information.................................................................................... 1-9

1.11 Customer Support Information....................................................................................... 1-10

2 Notes for Maintenance.................................................................................................................... 2-1

2.1 Wrist Unit ........................................................................................................................... 2-1

2.2 Encoder Connector (with CAUTION Label) ....................................................................... 2-2

2.2.1 Battery Pack Connection for S-, L-, and U-axis Motors........................................ 2-2

2.2.2 Battery Pack Connection for R-, B-, and T-axis Motors........................................ 2-2

3 Home Position Return..................................................................................................................... 3-1

3.1 Home Position Return after Motor Replacement ............................................................... 3-1

3.1.1 Home Position Return by Zeroing Function.......................................................... 3-1

3.1.2 Home Position Return by Robot Calibration (MOTOCALV EG) ........................... 3-1

3.1.3 Home Position Return by Setting Teaching Point for Home Position Setting before Motor Replacement ......................................... 3-23.1.3.1 Preparation before Motor Replacement .................................................. 3-23.1.3.2 Motor Replacement ................................................................................. 3-43.1.3.3 Home Position Adjustment ...................................................................... 3-5

3.2 Home Position Return in Case of Exhaustion of Robot-Axis Motor Battery ...................... 3-6

3.2.1 Home Position Return at the Time of Battery Backup by Using the Function: Home Position Calibration Function for Restoration....................... 3-6

3.2.2 Home Position Return by Keys (for S-, L-, U-, and R-Axes)................................. 3-63.2.2.1 Calibration Operation .............................................................................. 3-6

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4 Grease Replenishment and Exchange ...........................................................................................4-1

4.1 Notes on Grease Replenishment and Exchange Procedures ........................................... 4-1

4.2 Grease Replenishment and Exchange for S-Axis Speed Reducer.................................... 4-2

4.2.1 Grease Replenishment .........................................................................................4-2

4.2.2 Grease Exchange................................................................................................. 4-3

4.3 Grease Replenishment and Exchange for L-Axis Speed Reducer .................................... 4-4


4.3.2 Grease Exchange................................................................................................. 4-5

4.4 Grease Replenishment and Exchange for U-Axis Speed Reducer ...................................4-6


4.4.2 Grease Exchange................................................................................................. 4-7

4.5 Grease Replenishment for R-Axis Speed Reducer ...........................................................4-8

4.6 Grease Replenishment for B- and T-Axis Speed Reducers ..............................................4-9

4.7 Grease Replenishment for T-Axis Gear...........................................................................4-10

4.8 Grease Replenishment for R-Axis Cross Roller Bearing .................................................4-11

5 Disassembly and Reassembly of Motors ........................................................................................ 5-1

5.1 Disassembly and Reassembly of S-Axis Motor .................................................................5-1

5.2 Disassembly and Reassembly of L-Axis Motor..................................................................5-4

5.3 Disassembly and Reassembly of U-Axis Motor .................................................................5-6

5.4 Disassembly and Reassembly of R-Axis Motor .................................................................5-8

5.5 Disassembly and Reassembly of B-Axis Motor ...............................................................5-11

5.6 Disassembly and Reassembly of T-Axis Motor ...............................................................5-13

6 Disassembly and Reassembly of Speed Reducer .......................................................................... 6-1

6.1 Disassembly and Reassembly of S-Axis Speed Reducer .................................................6-1

6.2 Disassembly and Reassembly of L-Axis Speed Reducer.................................................. 6-3

6.3 Disassembly and Reassembly of U-Axis Speed Reducer .................................................6-5

6.4 Disassembly and Reassembly of R-Axis Speed Reducer .................................................6-7

6.5 Disassembly and Reassembly of B-Axis Speed Reducer .................................................6-9

6.6 Disassembly and Reassembly of T-Axis Speed Reducer................................................ 6-12

7 Disassembly and Reassembly of Wrist Unit ................................................................................... 7-1

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8 Disassembly, Reassembly, and Adjustment of B- and T-axis Timing Belts.................................... 8-1

8.1 Disassembly and Reassembly of B- and T-axis Timing Belts ........................................... 8-1

8.2 Adjustment of Timing Belts ................................................................................................ 8-3

8.2.1 B-Axis ................................................................................................................... 8-3

8.2.2 T-Axis ................................................................................................................... 8-3

9 Battery Pack Replacement ............................................................................................................. 9-1

10 Cable Wiring ............................................................................................................................... 10-1

10.1 Disconnecting Cables.................................................................................................... 10-1

10.1.1 Cables in Wrist Unit .......................................................................................... 10-1

10.1.2 Cables in U-Arm ............................................................................................... 10-3

10.1.3 Cables in S-Head ............................................................................................. 10-6

10.2 Connecting Cables ........................................................................................................ 10-9

10.2.1 Cables in S-Head ............................................................................................. 10-9

10.2.2 Cables in U-Arm ............................................................................................. 10-10

10.2.3 Cables in Wrist Unit ........................................................................................ 10-11

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

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

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

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

11.4 R-Axis Unit..................................................................................................................... 11-7

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

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1 Introduction

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1 Introduction

MANDATORY

• This maintenance manual is intended to explain maintenance procedures primarily for the MOTOMAN-HP20D.

• 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.

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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HP20D 1 Introduction1.1 National Safety Standard for Industrial Robots and Robot Systems

1.1 National Safety Standard for Industrial Robots and Robot Systems

We suggest that you obtain and review a copy of the ANSI/RIA National Safety Standard for Industrial Robots and Robot Systems (ANSI/RIA R15.06-2012). You can obtain this document from the Robotic Industries Association (RIA) at the following address:

Robotic Industries Association900 Victors WayP.O. Box 3724

Ann Arbor, Michigan 48106TEL: (734) 994-6088FAX: (734) 994-3338

www.roboticsonline.com

Ultimately, well-trained personnel are the best safeguard against accidents and damage that can result from improper operation of the equipment. The customer is responsible for providing adequately trained personnel to operate, program, and maintain the equipment. NEVER ALLOW UNTRAINED PERSONNEL TO OPERATE, PROGRAM, OR REPAIR THE EQUIPMENT!

We recommend approved Yaskawa training courses for all personnel involved with the operation, programming, or repair of the equipment.

This equipment has been tested and found to comply with the limits for a Class A digital device, pursuant to part 15 of the FCC rules. These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial environment. This equipment generates, uses, and can radiate radio frequency energy and, if not installed and used in accordance with the instruction manual, may cause harmful interference to radio communications.

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1 Introduction1.2 Notes for Safe Operation

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1.2 Notes for Safe Operation

Read this manual carefully before installation, operation, maintenance, or inspection of the DX100.

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

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

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

CAUTIONIndicates 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.

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

PROHIBITEDMust never be performed.

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

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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HP20D 1 Introduction1.2 Notes for Safe Operation

WARNING• Before operating the manipulator, check that servo power is turned

OFF pressing the emergency stop buttons.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:– 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.– 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 DX100.– 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.

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1 Introduction1.3 Definition of Terms Used Often in This Manual

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1.3 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 supply cables.

In this manual, the equipment is designated as follows:

1.4 Registered Trademark

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

CAUTION

• 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.

• For the DX100, always return the programming pendant to the hook on the cabinet of the DX100 after use. For the FS100, always return the programming pendant to a safe place 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 DX100 Instructions before operating the manipulator:

Equipment Manual DesignationDX100 controller DX100DX100 programming pendant Programming pendantCable between the manipulator and the controller

Manipulator cable

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HP20D 1 Introduction1.5 Explanation of Warning Labels

1.5 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 Label Locations

Warning label B

Warning label B

Nameplate

Warning label A

WARNINGDo not enterrobotwork area.

WARNINGMoving partsmay causeinjury

Warning Label A:

Warning Label B:

Nameplate

MADE IN JAPAN

YASKAWA ELECTRIC CORPORATION

Kitakyushu 806-0004 Japan2-1 Kurosakishiroishi, Yahatanishi-ku,

SERIAL NO.

PAYLOADkg

TYPE

MASS

NJ3247

DATEORDER NO.kg

MOTOMAN-MODEL

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1 Introduction1.6 Safeguarding Tips

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1.6 Safeguarding Tips

All operators, programmers, maintenance personnel, supervisors, and anyone working near the system must become familiar with the operation of this equipment. All personnel involved with the operation of the equipment must understand potential dangers of operation. General safeguarding tips are as follows:

• Improper operation can result in personal injury and/or damage to the equipment. Only trained personnel familiar with the operation of this equipment, the operator's manuals, the system equipment, and options and accessories should be permitted to operate this equipment.

• Improper connections can damage the equipment. All connections must be made within the standard voltage and current ratings of the equipment.

• The system must be placed in Emergency Stop (E-Stop) mode whenever it is not in use.

• In accordance with ANSI/RIA R15.06-2012, section 4.2.5, Sources of Energy, use lockout/tagout procedures during equipment maintenance. Refer also to Section 1910.147 (29CFR, Part 1910), Occupational Safety and Health Standards for General Industry (OSHA).

1.7 Mechanical Safety Devices

The safe operation of this equipment is ultimately the users responsibility. The conditions under which the equipment will be operated safely should be reviewed by the user. The user must be aware of the various national codes, ANSI/RIA R15.06-2012 safety standards, and other local codes that may pertain to the installation and use of this equipment.

Additional safety measures for personnel and equipment may be required depending on system installation, operation, and/or location. The following safety equipment is provided as standard:

• Safety barriers

• Door interlocks

• Emergency stop palm buttons located on operator station

Check all safety equipment frequently for proper operation. Repair or replace any non-functioning safety equipment immediately.

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HP20D 1 Introduction1.8 Programming, Operation, and Maintenance Safety

1.8 Programming, Operation, and Maintenance Safety

All operators, programmers, maintenance personnel, supervisors, and anyone working near the system must become familiar with the operation of this equipment. Improper operation can result in personal injury and/or damage to the equipment. Only trained personnel familiar with the operation, manuals, electrical design, and equipment interconnections of this equipment should be permitted to program, or maintain the system. All personnel involved with the operation of the equipment must understand potential dangers of operation.

• Inspect the equipment to be sure no potentially hazardous conditions exist. Be sure the area is clean and free of water, oil, debris, etc.

• Be sure that all safeguards are in place. Check all safety equipment for proper operation. Repair or replace any non-functioning safety equipment immediately.

• Check the E-Stop button on the operator station for proper operation before programming. The equipment must be placed in Emergency Stop (E-Stop) mode whenever it is not in use.

• Back up all programs and jobs onto suitable media before program changes are made. To avoid loss of information, programs, or jobs, a backup must always be made before any service procedures are done and before any changes are made to options, accessories, or equipment.

• Any modifications to the controller unit can cause severe personal injury or death, as well as damage to the robot! Do not make any modifications to the controller unit. Making any changes without the written permission from Yaskawa will void the warranty.

• Some operations require standard passwords and some require special passwords.

• The equipment allows modifications of the software for maximum performance. Care must be taken when making these modifications. All modifications made to the software will change the way the equipment operates and can cause severe personal injury or death, as well as damage parts of the system. Double check all modifications under every mode of operation to ensure that the changes have not created hazards or dangerous situations.

• This equipment has multiple sources of electrical supply. Electrical interconnections are made between the controller and other equipment. Disconnect and lockout/tagout all electrical circuits before making any modifications or connections.

• Do not perform any maintenance procedures before reading and understanding the proper procedures in the appropriate manual.

• Use proper replacement parts.

• Improper connections can damage the equipment. All connections must be made within the standard voltage and current ratings of the equipment.

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1 Introduction1.9 Maintenance Safety

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1.9 Maintenance Safety

Turn the power OFF and disconnect and lockout/tagout all electrical circuits before making any modifications or connections.

Perform only the maintenance described in this manual. Maintenance other than specified in this manual should be performed only by Yaskawa-trained, qualified personnel.

1.10 Summary of Warning Information

This manual is provided to help users establish safe conditions for operating the equipment. Specific considerations and precautions are also described in the manual, but appear in the form of Dangers, Warnings, Cautions, and Notes.

It is important that users operate the equipment in accordance with this instruction manual and any additional information which may be provided by Yaskawa. Address any questions regarding the safe and proper operation of the equipment to Yaskawa Customer Support.

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HP20D 1 Introduction1.11 Customer Support Information

1.11 Customer Support Information

If you need assistance with any aspect of your HP20D system, please contact YASKAWA Customer Support at the following 24-hour telephone number:

For routine technical inquiries, you can also contact YASKAWA Customer Support at the following e-mail address:

When using e-mail to contact YASKAWA Customer Support, please provide a detailed description of your issue, along with complete contact information. Please allow approximately 24 to 36 hours for a response to your inquiry.

Please have the following information ready before you call Customer Support:

[email protected]

NOTEPlease use e-mail for routine inquiries only. If you have an urgent or emergency need for service, replacement parts, or information, you must contact YASKAWA Customer Support at the telephone number shown above.

• System HP20D

• Robots ___________________________

• Primary Application ___________________________

• Controller DX100

• Software Version Access this information on the Programming Pendant’s LCD display screen by selecting {MAIN MENU} - {SYSTEM INFO} - {VERSION}

• Robot Serial Number Located on the robot data plate

• Robot Sales Order Number Located on the DX100 controller data plate

(937) 847-3200

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2 Notes for Maintenance2.1 Wrist Unit

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2 Notes for Maintenance

2.1 Wrist Unit

• Refer to Fig. 2-1 “Wrist Unit”.

The motor and encoder unit are provided to the wrist unit. The matching surfaces of the wrist cover and the wrist unit are sealed with sealing bond to prevent fumes from penetrating into the wrist unit.

After removing the wrist cover, make sure to reapply sealing bond (ThreeBond 1206C).

Fig. 2-1: Wrist Unit

NOTE

• 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.

• Do not remove the battery pack in the connector base.

Cover

Cover Cover matching surface

Cover matching surface

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HP20D 2 Notes for Maintenance2.2 Encoder Connector (with CAUTION Label)

2.2 Encoder Connector (with CAUTION Label)

Before disconnecting the encoder connector (with CAUTION label), connect the battery pack to the motor referring to Fig. 2-2 “Battery Pack Connection”.

2.2.1 Battery Pack Connection for S-, L-, and U-axis Motors

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

1. Remove the caps attached to the battery backup connectors of the motor.

2. Connect the battery pack (HW9470932-A) with the battery backup connectors located at the end point of the encoder cable. (Under this condition, remove the encoder connector and carry out the maintenance checks.)

3. After the maintenance check, confirm that all the connectors are connected, then remove the battery pack. Install the caps attached to the battery backup connectors of the motor.

2.2.2 Battery Pack Connection for R-, B-, and T-axis Motors

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

1. Connect the battery pack (HW9470932-A) with the battery backup connectors located at the end point of the encoder cable. (Under this condition, remove the encoder connector and carry out the maintenance checks.)

2. After the maintenance check, confirm that all the connectors are connected, then remove the battery pack.

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2 Notes for Maintenance2.2 Encoder Connector (with CAUTION Label)

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Fig. 2-2: Battery Pack Connection

BAT10BT1a

bb

a0BTBAT

BAT10BT1a

bb

aBAT

0BT

R-, B-, T-axis motor

b

aab0BT

BAT BAT10BT1

S-, L-, U-axis motor

Connect battery to encoderto save the data beforeremoving connector.

CAUTION

CAUTION Label (Enlarged View)


CAUTION


CA

UTIO

N

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

Encoder connector

Motor

Motor power connector

Battery backup connector

Battery pack (HW9470932-A)

Internalwire

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

CAUTION label

CAUTION label

Encoder

Motor cable, etc.

Motor

Power connector

Encoder connector Battery pack (HW9470932-A)

Battery backup connector

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HP20D 3 Home Position Return3.1 Home Position Return after Motor Replacement

3 Home Position Return

3.1 Home Position Return after Motor Replacement

3.1.1 Home Position Return by Zeroing Function

The zeroing function is an optional function which automatically allows the restoration of the home position data when the manipulator’s home position data disappears.

For the details of this function, refer to “INSTRUCTIONS FOR ZEROING FUNCTION”.

3.1.2 Home Position Return by Robot Calibration (MOTOCALV EG)

The MOTOCALV EG allows the home position reset by teaching the five-point-in-five-posture.

Refer to “MOTOCALV EG for Windows Operator’s Manual” (manual No. HW0483085) for details on the operation.

NOTE

Perform calibration and set the manipulator position in one of the following cases:

• The combination of the MOTOMAN and the control unit is changed.

• The motor or absolute encoder is replaced.

• Stored memory is cleared.

• The home position is deviated by hitting the MOTOMAN against a workpiece, etc.

• The main parts of the speed reducer, etc. are replaced or disassembled and reassembled.

When performing calibration, be sure to satisfy the following conditions:

• No external force is applied to the manipulator.

• The hand and the other parts of the wrist unit are removed.

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3 Home Position Return3.1 Home Position Return after Motor Replacement

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3.1.3 Home Position Return by Setting Teaching Point for Home Position Setting before Motor Replacement

The DX100 holds the position data of the job program (hereinafter called JOB) as the pulse number from the home position of each axis. Thus, by adjusting the home position precisely, the JOB used before motor replacement can be used after the replacement without correction.

This section explains how to set the DX100.

3.1.3.1 Preparation before Motor Replacement

• Refer to the Fig. 3-1 “Preparation before Motor Replacement (Example)”.

Before motor replacement, create the standard position (hereinafter called the check-point) for home position adjustment after the replacement. The check-point must satisfy the conditions below. Furthermore, create the JOB so that the manipulator safely moves to the check-point from the standby position. (The JOB created in this manner will be hereinafter called the check-JOB.)

The position should not be deviated by turning the power ON or OFF, or lowering air pressure. Do not create the check point in the working part of the tool (end effecter) or the jigs (related unit including the rotary table). It is recommended to use a specific jig if necessary.

Use pointed jigs to create the position so that the deviation is easily found. Keep a distance as long as possible from the rotational center of the replacing axis.

Considering the moving direction of the replacing axis, create the position at the point where any deviation is easily found and the axis will not interfere with jigs even if it is deviated.

1

2

3

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Example of Check-Point Creation when Replacing U-Axis’s Motor of HP20D-A00

• The check-point cannot be created unless each axis operates. Thus, the check-point cannot be created if the axis does not move because of failure. Therefore, it is recommended to create the check-point for each axis under normal operating conditions. Next, check the home position of the axis whose motor will be replaced. Refer to the position screen, and move the axis to the 0-pulse position, the home position. Then, check the position of the home position mark. If it is deviated, adjust it.

The U-axis of YR-HP0020D-A00 is shown below as an example.

Fig. 3-1: Preparation before Motor Replacement (Example)

Home position mark

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3 Home Position Return3.1 Home Position Return after Motor Replacement

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3.1.3.2 Motor Replacement

• Refer to the Fig. 3-2 “Motor Replacement (Example)”.

The U-axis of YR-HP0020D-A00 is shown below as an example.

Fig. 3-2: Motor Replacement (Example)

Remove the motor and replace it.

CAUTION

• Since the motor is removed, the manipulator cannot keep its posture during motor replacement. When replacing the motor, hold the manipulator arm with the chain block, etc.

Failure to observe this caution may cause a hazardous condition. Replace the motor with due care.

Hanging tool

Chain block

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3.1.3.3 Home Position Adjustment

After motor replacement, move the axis to the position of the home position mark. Perform the home position calibration only to the axis whose motor was replaced. (For more information, refer to “DX100 INSTRUCTIONS” (manual No. RE-CTO-A215).)

Move the axis to the check-point by the check-JOB. (Be careful when moving the axis so that the manipulator does not interfere with jigs.) Move only the axis whose motor was replaced to correct the deviation from the check-point created before calibration.

Display the position screen (COMMAND POSITION).

The values of the U-axis is shown below as an example.

By using the above values, calculate the amount of deviation. (Subtract the CMD (command value) from the CURR (current value).)

CURR - CMD = the amount of deviation

U (-3067) - (-2989) = -78

Perform stepping back, etc. of the check JOB to move the axis whose motor was replaced to the position where the axis will not interfere with jigs when it moves to the home position. (Be careful when moving the axis so that the manipulator does not interfere with jigs.) Refer to the position screen, and move the axis to the pulse position equal to the amount of deviation.

An example is shown below.

At this position, perform the home position calibration only for the axis whose motor was replaced. (For more information, refer to “DX100 INSTRUCTIONS” (manual No. RE-CTO-A215).)

Move the axis again to the check-point by the check-JOB. Check if the axis is at the check-point created before the operation. (If it is deviated, repeat the adjustment procedures.)

Perform an operation check by using the JOB used before motor replacement. If no problem is found, write down the modified home position data (ABSO data) and the date in the label on the inside of the DX100.

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3 Home Position Return3.2 Home Position Return in Case of Exhaustion of Robot-Axis Motor Battery

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3.2 Home Position Return in Case of Exhaustion of Robot-Axis Motor Battery

3.2.1 Home Position Return at the Time of Battery Backup by Using the Function: Home Position Calibration Function for Restoration

To start the home position calibration function for restoration, move the manipulator to the posture close to the home position (within one motor rotation), then execute the software program “Backup alarm restoration” on the programming pendant.

The home position return by this function updates the multi-turn data for motor.

3.2.2 Home Position Return by Keys (for S-, L-, U-, and R-Axes)

To enable the home position return by using keys, write down the differential pulse between the key position and the default home position on the home position label on the inside of the DX100.

If the home position data disappears, move the manipulator to the key position. Then, as the home position, set the position where the above differential pulse is added to the key position.

3.2.2.1 Calibration Operation

The parts in Table 3-1 "Parts List"are required for calibration. Prepare them before calibration operation.

S-Axis Positioning

As shown in Fig. 3-3 “S-Axis Positioning”, insert the shaft SFJW6-100 in the hole ( ) on the S-head. Then, perform positioning with the programming pendant so that the shaft fits into the hole on the base.

Fig. 3-3: S-Axis Positioning

Table 3-1: Parts List

Drawing No. Name Qty. Remark

SFJW6-100 Shaft 1 For S-, L-, and U-axes

SFJW4-100 Shaft 1 For R-axis

6 dia.+0.012 0

Shaft

Base

S-head

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L-Axis Positioning

As shown in Fig. 3-4 “L-Axis Positioning”, insert the shaft SFJW6-100 in the hole ( ) on the S-head. Then, perform positioning with the programming pendant so that the shaft fits into the hole on the L-arm.

Fig. 3-4: L-Axis Positioning

U-Axis Positioning

As shown in Fig. 3-5 “U-Axis Positioning”, insert the shaft SFJW6-100 in the hole ( ) on the casing. Then, perform positioning with the programming pendant so that the shaft fits into the hole on the L-arm.

Fig. 3-5: U-Axis Positioning

6 dia.+0.012 0

Shaft

L-arm

S-head

6 dia.+0.012 0

Casing

Shaft

L-arm

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R-Axis Positioning

As shown in Fig. 3-6 “R-Axis Positioning”, insert the shaft SFJW4-100 in the hole ( ) on the U-arm. Then, perform positioning with the programming pendant so that the shaft fits into the hole on the casing.

Fig. 3-6: R-Axis Positioning

4 dia.+0.012 0

Shaft

U-arm

Casing

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HP20D 4 Grease Replenishment and Exchange4.1 Notes on Grease Replenishment and Exchange Procedures

4 Grease Replenishment and Exchange

4.1 Notes on Grease Replenishment and Exchange Procedures

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

NOTE

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

• 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.

• Make sure to fill the hose on the grease inlet with grease beforehand to prevent air from leaking into the speed reducer.

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4.2 Grease Replenishment and Exchange for S-Axis Speed Reducer

Fig. 4-1: S-Axis Speed Reducer

4.2.1 Grease Replenishment

(Refer to Fig. 4-1 “S-Axis Speed Reducer”.)

1. Remove the hexagon socket head plugs from the grease inlet and the grease exhaust port.

2. Install the grease zerk PT1/8 to the grease inlet. (The grease zerk is delivered with the manipulator.)

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

– Grease type: VIGO Grease RE No.0

– Amount of grease: 30 cc (60 cc for 1st supply)

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

– Grease injection rate: 8 g/s or less

NOTE For ceiling mounted manipulators, the exhaust port and the grease inlet are inverted.

Grease inlet(Hexagon socket head plug PT1/8)

S-axis speed reducer

Grease exhaust port(Hexagon socket head plug PT1/8)

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

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HP20D 4 Grease Replenishment and Exchange4.2 Grease Replenishment and Exchange for S-Axis Speed Reducer

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

5. Remove the grease zerk from the grease inlet and reinstall the plug. Apply ThreeBond 1206C to the thread part of the plug, and tighten the plug with a tightening torque of 5 N•m (0.51 kgf•m).

6. Wipe the discharged grease with a cloth, and reinstall the plug on the grease exhaust port. Apply ThreeBond 1206C to the thread part of the plug, and tighten the plug with a tightening torque of 5 N•m (0.51 kgf•m).

4.2.2 Grease Exchange

(Refer to Fig. 4-1 “S-Axis Speed Reducer”.)

1. Remove the hexagon socket head plugs from the grease inlet and the grease exhaust port.

2. Install the grease zerk PT1/8 to the grease inlet. (The grease zerk is delivered with the manipulator.)



– Amount of grease: approx. 1800 cc



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




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4 Grease Replenishment and Exchange4.3 Grease Replenishment and Exchange for L-Axis Speed Reducer

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4.3 Grease Replenishment and Exchange for L-Axis Speed Reducer

Fig. 4-2: L-Axis Speed Reducer


(Refer to Fig. 4-2 “L-Axis Speed Reducer”.)

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

2. Remove the hexagon socket head cap screw from the grease inlet and the hexagon socket head plug from the grease exhaust port.

3. Install the grease zerk A-MT6 x 1 to the grease inlet. (The grease zerk is delivered with the manipulator.)


– Grease type: VIGO Grease No.0




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

6. Remove the grease zerk from the grease inlet and reinstall the screw. Apply ThreeBond 1206C to the thread part of the screw, and tighten the screw with a tightening torque of 5 N•m (0.51 kgf•m).


Grease exhaust port(Hexagon socket head plug PT1/8)

Grease inlet(Hexagon socket head cap screw M6)

L-axis speed reducer

L-arm


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HP20D 4 Grease Replenishment and Exchange4.3 Grease Replenishment and Exchange for L-Axis Speed Reducer


(Refer to Fig. 4-2 “L-Axis Speed Reducer”.)

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

2. Remove the hexagon socket head cap screw from the grease inlet and the hexagon socket head plug from the grease exhaust port.








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




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4.4 Grease Replenishment and Exchange for U-Axis Speed Reducer

Fig. 4-3: U-Axis Speed Reducer


(Refer to Fig. 4-3 “U-Axis Speed Reducer”.)

1. Make the U-arm horizontal to the ground.

2. Remove the hexagon socket head plug from the grease inlet and the hexagon socket head cap screw from the grease exhaust port.







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


7. Wipe the discharged grease with a cloth, and reinstall the screw on the grease exhaust port. Apply ThreeBond 1206C to the thread part of the screw, and tighten the screw with a tightening torque of 5 N•m (0.51 kgf•m).

U-axis speed reducer

Grease inlet(Hexagon socket head plug PT1/8)

Grease exhaust port(Hexagon socket head cap screw M6)

U-arm

NOTE For ceiling mounted manipulators, the exhaust port and the grease inlet are inverted.


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HP20D 4 Grease Replenishment and Exchange4.4 Grease Replenishment and Exchange for U-Axis Speed Reducer


(Refer to Fig. 4-3 “U-Axis Speed Reducer”.)

1. Make the U-arm horizontal to the ground.

2. Remove the hexagon socket head plug from the grease inlet and the hexagon socket head cap screw from the grease exhaust port.








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


8. Wipe the discharged grease with a cloth, and reinstall the screw on the grease exhaust port. Apply ThreeBond 1206C to the thread part of the screw, and tighten the screw with a tightening torque of 5 N•m (0.51 kgf•m).


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4.5 Grease Replenishment for R-Axis Speed Reducer

Fig. 4-4: R-Axis Speed Reducer

1. Remove the hexagon socket head cap screw from the exhaust port.

2. Inject grease through the grease zerk A-MT6 x 1 on the grease inlet by using a grease gun. (See Fig. 4-4 “R-Axis Speed Reducer”.)

– Grease type: Harmonic Grease SK-1A


3. Reinstall the screw on the exhaust port. Apply ThreeBond 1206C to the thread part of the screw, and tighten the screw with a tightening torque of 5 N•m (0.51 kgf•m).

NOTE The exhaust port is used for air flow only. Do not inject excess grease through the grease inlet.

Exhaust port(Hexagon socket head cap screw M6)

Grease inlet(Grease zerk A-MT6 x 1)

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HP20D 4 Grease Replenishment and Exchange4.6 Grease Replenishment for B- and T-Axis Speed Reducers

4.6 Grease Replenishment for B- and T-Axis Speed Reducers

Fig. 4-5: B- and T-Axis Speed Reducers

1. Remove the hexagon socket head cap screw from the grease inlet and the plug LP-M5 or the hexagon socket set screw from the exhaust port.


3. Inject grease through the grease inlet using a grease gun. (See Fig. 4-5 “B- and T-Axis Speed Reducers”.)


– Amount of grease: B-axis: 10 cc (20 cc for 1st supply)T-axis: 5 cc (10 cc for 1st supply)

4. Reinstall the plug or screw on the exhaust port. Apply ThreeBond 1206C to the thread part of the plug or screw.


T-axis exhaust port

(Hexagon socket head cap screw M6)T-axis grease inlet

T-axis speed reducer

(Hexagon socket set screw M6)

B-axis exhaust port(Plug LP-M5)

B-axis speed reducer

B-axis grease inlet(Hexagon socket head cap screw M6)

NOTE For the B-axis, remove the cover.


NOTE For the B-axis, mount the cover. (Refer to chapter 2 “Notes for Maintenance”.)

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4.7 Grease Replenishment for T-Axis Gear

Fig. 4-6: T-Axis Gear

1. Remove the hexagon socket head cap screw from the grease inlet and the plug LP-M5 from the exhaust port.


3. Inject grease through the grease inlet using a grease gun. (See Fig. 4-6 “T-Axis Gear”.)


– Amount of grease: 5cc (10 cc for 1st supply)

4. Reinstall the plug on the exhaust port. Apply ThreeBond 1206C to the thread part of the plug.



Gear grease inlet

Exhaust port(Plug LP-M5)

(Hexagon socket head cap screw M6)

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HP20D 4 Grease Replenishment and Exchange4.8 Grease Replenishment for R-Axis Cross Roller Bearing

4.8 Grease Replenishment for R-Axis Cross Roller Bearing

Fig. 4-7: R-Axis Cross Roller Bearing

1. Remove the hexagon socket head cap screw from the grease inlet and the plug LP-M5 from the exhaust port.


3. Inject grease through the grease inlet using a grease gun. (See Fig. 4-7 “R-Axis Cross Roller Bearing”.)

4. Reinstall the plug on the exhaust port. Apply ThreeBond 1206C to the thread part of the plug.



Exhaust port(Plug LP-M5)

R-axis cross roller bearing

(Hexagon socket head cap screw M6 x 6)Grease inlet

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5 Disassembly and Reassembly of Motors5.1 Disassembly and Reassembly of S-Axis Motor

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5 Disassembly and Reassembly of Motors

5.1 Disassembly and Reassembly of S-Axis Motor

• Refer to Fig. 5-1 “Disassembly and Reassembly of S-Axis Motor”.

Disassembly

1. Turn OFF the DX100 power supply.

2. Connect the backup battery. (Refer to chapter 2 “Notes for Maintenance”.)

3. Disconnect the connector (signal, power) connected to the S-axis motor .

4. Disconnect the power connector of the L-axis motor. Fix the connector on the motor side by using pliers, etc. when disconnecting the power connector.

5. Remove the GT-SA bolts . Insert stud bolts M6 (length of the thread part: 30 mm or more) in the tapped holes M6 (2 holes) on the motor flange face. Screw the stud bolts in until the gap between the motor and the matching surface becomes 10 mm or more. Then, remove the S-axis motor vertically from the M-base .

6. Remove the hexagon socket head cap screw , then remove the input gear and the key .

Reassembly

1. Mount the key and the input gear on the S-axis motor . (The key is attached to the S-axis motor .)

2. Put the conical spring washer on the hexagon socket head cap screw , then apply Loctite 242 to the thread part of the screw. Then, tighten it with the tightening torque shown in Table 5-1 "S-Axis Motor Parts Checklist".

3. Apply ThreeBond 1206C on the matching surface between the flange face of the S-axis motor and the M-base . Then, mount the S-axis motor on the M-base .

4. Tighten the GT-SA bolts with the tightening torque shown in Table 5-1 "S-Axis Motor Parts Checklist".

5. Connect the connector (signal, power) of the internal wiring harness to the S-axis motor .

NOTE

• Refer to chapter 3 “Home Position Return”, chapter 4 “Grease Replenishment and Exchange”, and chapter 8 “Disassembly, Reassembly, and Adjustment of B- and T-axis Timing Belts”.

• When replacing a motor, the backup battery does not need to be connected.

• Remove old sealing bond on each part completely before reassembly.

1

2

1 5

6

3 4

4 3 1

4 1

6

1 5

1 5

2

9

1

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HP20D 5 Disassembly and Reassembly of Motors5.1 Disassembly and Reassembly of S-Axis Motor

6. Connect the power connector of the L-axis motor. Fix the connector on the motor side by using pliers, etc. when connecting the power connector.

7. Remove the backup battery.

8. Turn ON the DX100 power supply.

Table 5-1: S-Axis Motor Parts Checklist

No. Name Qty. NotesS-axis motor HW0387862-A 1 SGMRV-09ANA-YR11GT-SA bolt M8 (length: 30 mm)

3 Tightening torque:24.5 N•m

Input gear HW0313491-1 1Key 1M-base HW0305306-1 1Hexagon socket head cap screw M6 (length: 60 mm)Conical spring washer 2H-6

1 each

Tightening torque:16.5 N•m

Cover HW0305809-1 1Cross head APS bolt M5 (length: 10 mm)

4

Internal wiring harness 1

1

2

3

4

5

6

7

8

9

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Fig. 5-1: Disassembly and Reassembly of S-Axis Motor

1

1

5

3

6

9

48

7

2

2

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HP20D 5 Disassembly and Reassembly of Motors5.2 Disassembly and Reassembly of L-Axis Motor

5.2 Disassembly and Reassembly of L-Axis Motor

• Refer to Fig. 5-2 “Disassembly and Reassembly of L-Axis Motor”.

Disassembly

1. Turn OFF the DX100 power supply, then drain grease.


3. Disconnect the connector (signal, power, brake) of the internal wiring harness connected to the L-axis motor . Fix the connector on the motor side by using pliers, etc. when disconnecting the power connector.

4. Support the L-arm with a chain block, etc. so that the L-arm does not rotate before removing the L-axis motor .

5. Remove the hexagon socket head cap screws . Insert stud bolts M4 (length of the thread part: 30 mm or more) in the tapped holes M4 (2 holes) on the flange face of the L-axis motor . Screw the stud bolts in until the gap between the motor and the matching surface becomes 10 mm or more. Then, remove the L-axis motor horizontally from the M-base . At this time, be careful not to damage the oil seal inside the S-head.

6. Remove the hexagon socket head cap screw , then remove the input gear , the key , and the plate .

Reassembly

1. Apply ThreeBond 1206C on the matching surface between the L-axis motor and the plate . Then, mount the plate on the L-axis motor .

2. Apply ThreeBond 1206C on the matching surface between the input gear and the plate . Then, mount the key and the input gear on the L-axis motor . (The key is attached to the L-axis motor .)

3. Put the conical spring washer on the hexagon socket head cap screw , then apply Loctite 242 to the thread part of the screw. Then, tighten it with the tightening torque shown in Table 5-2 "L-Axis Motor Parts Checklist".

4. Apply ThreeBond 1206C on the matching surface between the flange face of the L-axis motor and the M-base . Then, mount the L-axis motor on the M-base . At this time, be careful not to damage the oil seal inside the S-head.

5. Tighten the hexagon socket head cap screws with the tightening torque shown in Table 5-2 "L-Axis Motor Parts Checklist".

6. Connect the connector (signal, power, brake) of the internal wiring harness to the L-axis motor . Fix the connector on the motor side by using pliers, etc. when connecting the power connector.

7. Replenish grease (VIGO Grease RE No.0) through the grease inlet.


9. Remove the chain block, etc. which support the L-arm.


1

1

2

1

1

3

6

4 5 7

1 7 7

1

4 7 5 4

1 5 1

6

1 3

1 3

2

1

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Fig. 5-2: Disassembly and Reassembly of L-Axis Motor

Table 5-2: L-Axis Motor Parts Checklist

No. Name Qty. NotesL-axis motor HW0387863-A 1 SGMRV-13ANA-YR21Hexagon socket head cap screw M8 (length: 25 mm)Conical spring washer 2H-8

4 each


M-base HW0304229-1 1Input gear HW0313492-1 1Key 1Hexagon socket head cap screw M6 (length: 90 mm)Conical spring washer 2H-6

1 each


Plate HW0401506-1 1

1

2

3

4

5

6

7

S-head

1

5

3

6

47

2

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HP20D 5 Disassembly and Reassembly of Motors5.3 Disassembly and Reassembly of U-Axis Motor

5.3 Disassembly and Reassembly of U-Axis Motor

• Refer to Fig. 5-3 “Disassembly and Reassembly of U-Axis Motor”.

Disassembly



3. Remove the cross head APS bolts , then remove the cover .

4. Disconnect the connector (signal, power) of the internal wiring harness.

5. Support the U-arm with a chain block, etc. so that the U-arm does not rotate before removing the U-axis motor .

6. Remove the GT-SA bolts . Insert stud bolts M6 (length of the thread part: 30 mm or more) in the tapped holes M6 (2 holes) on the flange face of the U-axis motor . Screw the stud bolts in until the gap between the motor and the matching surface becomes 10 mm or more. Then, remove the U-axis motor horizontally from the casing.

7. Remove the hexagon socket head cap screw , then remove the input gear and the key .

Reassembly

1. Mount the key and the input gear on the U-axis motor . (The key is attached to the U-axis motor .)

2. Put the conical spring washer on the hexagon socket head cap screw , then apply Loctite 242 to the thread part of the screw. Then, tighten it with the tightening torque shown in Table 5-3 "U-Axis Motor Parts Checklist".

3. Apply ThreeBond 1206C on the matching surface between the flange face of the U-axis motor and the casing. Then, mount the U-axis motor on the casing.

4. Tighten the GT-SA bolts with the tightening torque shown in Table 5-3 "U-Axis Motor Parts Checklist".

5. Connect the connector (signal, power) of the internal wiring harness to the U-axis motor .

6. Mount the cover with the cross head APS bolts .



9. Remove the chain block, etc. which support the U-arm.


9 8

1

2

1

1

5

3 4

4 3 1

4 1

5

1

1

2

1

8 9

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Fig. 5-3: Disassembly and Reassembly of U-Axis Motor

Table 5-3: U-Axis Motor Parts Checklist

No. Name Qty. NotesU-axis motor HW0387860-A 1 SGMRV-05ANA-YR11GT-SA bolt M8 (length: 30 mm)


Input Gear 1Key 1Hexagon socket head cap screw M5 (length: 65 mm)Conical spring washer 2H-5

1 each

Tightening torque:10 N•m

Cover HW0305305-1 1GT-SA bolt M6(length: 20 mm)

6 Tightening torque:10 N•m

Cover HW0313489-1 1Cross head APS bolt M4 (length: 10 mm)Flat washer 4.3 x 12.0 x 0.8

7 each

1

2

3

4

5

6

7

8

9

Casing

1

5

3

6

9

4

8

2

7

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HP20D 5 Disassembly and Reassembly of Motors5.4 Disassembly and Reassembly of R-Axis Motor

5.4 Disassembly and Reassembly of R-Axis Motor

• Refer to Fig. 5-4 “Disassembly and Reassembly of R-Axis Motor”.

Disassembly


2. Remove the GT-SA bolts , then remove the cover .

3. Remove the plastic cover on the connector (signal) of the internal wiring harness connected to the R-axis motor . Then, connect the backup battery. (Refer to chapter 2 “Notes for Maintenance”.)

4. Remove the plastic cover on the connector (power) of the R-axis motor . Then, disconnect the connector (signal, power) of the internal wiring harness connected to the R-axis motor .

5. Remove the GT-SA bolts . Insert stud bolts M6 (length of the thread part: 40 mm or more) in the tapped holes M6 (2 holes) on the M-base . Screw the stud bolts in until the gap between the motor and the matching surface becomes 10 mm or more. Then, remove the M-base from the casing.

6. Remove the hexagon socket head cap screw , then remove the shaft , the speed reducer , and the washer .

7. Remove the GT-SA bolts . Then, remove the R-axis motor from the M-base .

Reassembly

1. Mount the R-axis motor on the M-base .

2. Tighten the GT-SA bolts with the tightening torque shown in Table 5-4 "R-Axis Motor Parts Checklist".

3. Fill the hatched area of the oil seal shown in Fig. 5-4 “Disassembly and Reassembly of R-Axis Motor” with Harmonic grease SK-1A.

4. Apply ThreeBond 1206C on the matching surface between the shaft and the R-axis motor . Then, mount the shaft , the speed reducer , and the washer on the R-axis motor .

5. Apply Loctite 242 to the thread part of the hexagon socket head cap screw . Then, tighten it with the tightening torque shown in Table 5-4 "R-Axis Motor Parts Checklist".

6. Apply ThreeBond 1206C on the matching surface between the M-base and the casing. Then, mount the M-base on the casing.


8. Connect the connector (signal, power) of the internal wiring harness to the R-axis motor , and remove the backup battery. Then, put the plastic cover on the connector.

9. Apply ThreeBond 1206C on the matching surface between the cover and the casing. Then, mount the cover with the GT-SA bolts .

10 9

1

1

1

3

4

4

8

5 6 7

2 1

4

1 4

2

11

5

1 5

6 7 1

8

4 4

3

1

9 9

10

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Table 5-4: R-Axis Motor Parts Checklist

No. Name Qty. NotesR-axis motor HW0389298-A 1 SGMPH-02ANA-YR11GT-SA bolt M5(length: 20 mm)


GT-SA bolt M6(length: 30 mm)


M-base HW0304932-1 1Shaft HW0404402-1 1Speed reducerHW0381463-A

1 Wave generator

Washer HW0404196-5 1Hexagon socket head cap screw M4 (length: 45 mm)Conical spring washer 2H-4

1 each




Oil seal AE1314A0 1

10

1

2

3

4

5

6

7

8

9

10

11

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HP20D 5 Disassembly and Reassembly of Motors5.4 Disassembly and Reassembly of R-Axis Motor

Fig. 5-4: Disassembly and Reassembly of R-Axis Motor

(See the step 3 of the R-axisreassembly procedure.)

Fill with Harmonic grease SK-1A.(See the step 4 of the R-axisreassembly procedure.)

Apply ThreeBond 1206C.

Casing

1 5

310

11

6

9

4

8

2

7

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5.5 Disassembly and Reassembly of B-Axis Motor

• Refer to Fig. 5-5 “Disassembly and Reassembly of B-Axis Motor”.

Disassembly


2. Remove the GT-SA bolts , then remove the covers .

3. Remove the plastic cover on the connector (signal) of the internal wiring harness connected to the B-axis motor . Then, connect the backup battery. (Refer to chapter 2 “Notes for Maintenance”.)

4. Remove the plastic cover on the connector (power) of the internal wiring harness connected to the B-axis motor . Then, disconnect the connector (signal, power) of the internal wiring harness.

5. Remove the GT-SA bolts , then remove the B-axis motor from the U-arm.

6. Remove the hexagon socket head cap screw , then remove the pulley . (Use the holes (2 holes, diameter: 4 mm) on the surface of the pulley to fix it.)

Reassembly

1. Mount the pulley on the B-axis motor .

2. Apply Loctite 242 to the thread part of the hexagon socket head cap screw . Then, tighten it with the tightening torque shown in Table 5-5 "B-Axis Motor Parts Checklist". (Use the holes (2 holes, diameter: 4 mm) on the surface of the pulley to fix the it.)

3. Mount the B-axis motor on the U-arm, then put the belt on the pulley .

4. Then, tighten the GT-SA bolts with the tightening torque shown in Table 5-5 "B-Axis Motor Parts Checklist". (Refer to chapter 8 “Disassembly, Reassembly, and Adjustment of B- and T-axis Timing Belts” to adjust the belt tension.)

5. Connect the connector (signal, power) of the internal wiring harness to the B-axis motor , and remove the backup battery. Then, put the plastic cover on the connector.

6. Mount the covers with the GT-SA bolts . (Apply ThreeBond 1206C on the matching surface between the cover and the U-arm.)

7. Tighten the GT-SA bolts with the tightening torque shown in Table 5-5 "B-Axis Motor Parts Checklist".


6 5

1

1

2 1

4

3

3

3 1

4

3

1

3

2

1

5 6

5

6

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HP20D 5 Disassembly and Reassembly of Motors5.5 Disassembly and Reassembly of B-Axis Motor

Fig. 5-5: Disassembly and Reassembly of B-Axis Motor

Table 5-5: B-Axis Motor Parts Checklist

No. Name Qty. NotesB-axis motor HW0389298-A 1 SGMPH-02ANA-YR11GT-SA bolt M5(length: 20 mm)


Pulley HW9482727-A 1Hexagon socket head cap screw M4 (length: 16 mm)Conical spring washer 2H-4

1 each




1

2

3

4

5

6

U-arm

1

5

5

3

6

6 4

2

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5.6 Disassembly and Reassembly of T-Axis Motor

• Refer to Fig. 5-6 “Disassembly and Reassembly of T-Axis Motor”.

Disassembly


2. Remove the B-axis motor . (Perform the steps 2 to 4 of “Disassembly” in section 5.5 “Disassembly and Reassembly of B-Axis Motor”.)

3. Remove the plastic cover on the connector (signal) of the internal wiring harness connected to the T-axis motor . Then, connect the backup battery. (Refer to chapter 2 “Notes for Maintenance”.)

4. Remove the plastic cover on the connector (power) of the internal wiring harness connected to the T-axis motor . Then, disconnect the connector (signal, power) of the internal wiring harness.

5. Remove the GT-SA bolts , then remove the T-axis motor from the U-arm.

6. Remove the hexagon socket head cap screw , then remove the pulley . (Use the holes (2 holes, diameter: 4 mm) on the surface of the pulley to fix it.)

Reassembly

1. Mount the pulley on the T-axis motor .

2. Apply Loctite 242 to the thread part of the hexagon socket head cap screw . Then, tighten it with the tightening torque shown in Table 5-6 "T-Axis Motor Parts Checklist". (Use the holes (2 holes, diameter: 4 mm) on the surface of the pulley to fix the it.)

3. Mount the T-axis motor on the U-arm, then put the belt on the pulley .

4. Then, tighten the GT-SA bolts with the tightening torque shown in Table 5-6 "T-Axis Motor Parts Checklist". (Refer to chapter 8 “Disassembly, Reassembly, and Adjustment of B- and T-axis Timing Belts” to adjust the belt tension.)

5. Connect the connector (signal, power) of the internal wiring harness to the T-axis motor , and remove the backup battery. Then, put the plastic cover on the connector.

6. Remove the B-axis motor . (Perform the steps 3 to 7 of “Reassembly” in section 5.5 “Disassembly and Reassembly of B-Axis Motor”.)


5

1

1

2 1

4

3

3

3 1

4

3

1

3

2

1

5

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HP20D 5 Disassembly and Reassembly of Motors5.6 Disassembly and Reassembly of T-Axis Motor

Fig. 5-6: Disassembly and Reassembly of T-Axis Motor

Table 5-6: T-Axis Motor Parts Checklist

No. Name Qty. NotesT-axis motor HW0389298-A 1 SGMPH-02ANA-YR11GT-SA bolt M5(length: 20 mm)


Pulley HW9482727-A 1Hexagon socket head cap screw M4 (length: 16 mm)Conical spring washer 2H-4

1 each


B-axis motor HW0382152-A 1

1

2

3

4

5

U-arm

1

5 3 4

2

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6 Disassembly and Reassembly of Speed Reducer6.1 Disassembly and Reassembly of S-Axis Speed Reducer

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6 Disassembly and Reassembly of Speed Reducer

6.1 Disassembly and Reassembly of S-Axis Speed Reducer

• Refer to Fig. 6-1 “Disassembly and Reassembly of S-Axis Speed Reducer”.

Disassembly


2. Remove the S-axis motor . (Perform the steps 2 to 6 of “Disassembly” in section 5.1 “Disassembly and Reassembly of S-Axis Motor”.)

3. Remove the hexagon socket head cap screws , then remove the M-base .

4. Remove the GT-SA bolts . Then, lift up the upper part of the manipulator including the S-head by using a chain block, and put it down next to the base. Before putting it down, lay shock absorbing material (such as wooden blocks and boards) under it to avoid damages on the bottom face of the S-head. Be careful not to pinch the internal wiring harness when putting it down.

5. Remove the GT-SA bolts . Then, remove the speed reducer by using the tapped holes.

6. Drain grease which remains inside.

Reassembly

1. Apply ThreeBond 1206C on the matching surface between the base and the speed reducer . Then, mount the speed reducer on the base.

2. Tighten the GT-SA bolts with the tightening torque shown in Table 6-1 "S-Axis Speed Reducer Parts Checklist".

3. Apply ThreeBond 1206C on the matching surface between the speed reducer and the S-head. Then, mount the upper part of the manipulator including the S-head on the speed reducer .

4. Tighten the GT-SA bolts with the tightening torque shown in Table 6-1 "S-Axis Speed Reducer Parts Checklist".

5. Remove the old sealing bond on the matching surface between the M-base and the S-head, then apply ThreeBond 1206C on the matching surface. Then, mount the M-base on the S-head. Tighten the hexagon socket head cap screws with the tightening torque shown in Table 6-1 "S-Axis Speed Reducer Parts Checklist".

NOTE

• Refer to chapter 3 “Home Position Return”, chapter 4 “Grease Replenishment and Exchange”, chapter 5 “Disassembly and Reassembly of Motors”, chapter 7 “Disassembly and Reassembly of Wrist Unit”, and chapter 10 “Cable Wiring”.

• Remove old sealing bond on each part completely before reassembly.

4

6

5

3

2 1

1 1

2

1

1

3

5

5

6

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HP20D 6 Disassembly and Reassembly of Speed Reducer6.1 Disassembly and Reassembly of S-Axis Speed Reducer

6. Apply ThreeBond 1206C on the matching surface between the S-axis motor and the M-base . Then, mount the S-axis motor . (Perform the steps 3 to 6 of “Reassembly” in section 5.1 “Disassembly and Reassembly of S-Axis Motor”.)



Fig. 6-1: Disassembly and Reassembly of S-Axis Speed Reducer

Table 6-1: S-Axis Speed Reducer Parts Checklist

No. Name Qty. NotesSpeed reducer HW0387753-B 1GT-SA bolt M10(length: 40 mm)




S-axis motor HW0388932-A 1 SGMRV-09ANA-YR11M-base HW0305306-2 1Hexagon socket head cap screw M8 (length: 60 mm)Conical spring washer 2H-8

3 each


4 5 4

1

2

3

4

5

6

Internal wiring harness

Base

S-head

1

5

36

4

2

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6.2 Disassembly and Reassembly of L-Axis Speed Reducer

• Refer to Fig. 6-2 “Disassembly and Reassembly of L-Axis Speed Reducer”.

Disassembly


2. Before removing the L-arm , support the L-arm with a chain block, etc. to prevent it from falling.

3. Remove the hexagon socket head cap screws and . Then, remove the L-arm from the speed reducer .

4. Remove the GT-SA bolts . Then, remove the speed reducer from the S-head. (When removing the speed reducer , make sure to pull it out straight to avoid load on the input gear. If the input gear is subjected to a load, damage to the motor may result.)

5. Remove the old sealing bond on the L-arm and the S-head.

Reassembly

1. Apply ThreeBond 1206C on the matching surface between the speed reducer and the S-head. Then, mount the speed reducer on the S-head. (When mounting, make sure not to apply a load on the input gear.)

2. Tighten the GT-SA bolts with the tightening torque shown in Table 6-2 "L-Axis Speed Reducer Parts Checklist".

3. Apply ThreeBond 1206C on the matching surface between the speed reducer and the L-arm . Then, mount the L-arm on the speed reducer .

4. Tighten the hexagon socket head cap screws and with the tightening torque shown in Table 6-2 "L-Axis Speed Reducer Parts Checklist".



3 3

4 5

3 1

2 1

1

3

Table 6-2: L-Axis Speed Reducer Parts Checklist

No. Name Qty. NotesSpeed reducer HW0387753-C 1GT-SA bolt M10(length: 40 mm)


L-arm HW0100546-2 1Hexagon socket head cap screw M12 (length: 40 mm)Conical spring washer 2H-12

12 each


Hexagon socket head cap screw M10 (length: 35 mm)Conical spring washer 2H-10

6 each


1 1

2

1 3 3

1

4 5

1

2

3

4

5

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HP20D 6 Disassembly and Reassembly of Speed Reducer6.2 Disassembly and Reassembly of L-Axis Speed Reducer

Fig. 6-2: Disassembly and Reassembly of L-Axis Speed Reducer

Input gear


L-axis motor

S-head

1

53

4

2

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6.3 Disassembly and Reassembly of U-Axis Speed Reducer

• Refer to Fig. 6-3 “Disassembly and Reassembly of U-Axis Speed Reducer”.

Disassembly


2. Before removing the U-arm unit, support the U-arm unit with a chain block, etc. to prevent it from falling.

3. Remove the hexagon socket head cap screws . Then, remove the U-arm unit from the L-arm.

4. Remove the U-axis motor from the U-arm unit. (Perform “Disassembly” in section 5.3 “Disassembly and Reassembly of U-Axis Motor”.)

5. Remove the GT-SA bolts , then remove the speed reducer .

6. Remove the hexagon socket head cap screw , then remove the input gear .

7. Remove the old sealing bond on the L-arm and the U-arm unit.

Reassembly

1. Mount the input gear on the U-axis motor. (The input gear is attached to the speed reducer . Thus, when replacing the speed reducer , replace the input gear too.)

2. Apply Loctite 242 to the thread part of the hexagon socket head cap screw . Then, tighten it with the tightening torque shown in Table 6-3 "U-Axis Speed Reducer Parts Checklist".

3. Apply ThreeBond 1206C on the matching surface between the speed reducer and the U-arm unit. Then, mount the speed reducer on the U-arm unit.

4. Tighten the GT-SA bolts with the tightening torque shown in Table 6-3 "U-Axis Speed Reducer Parts Checklist".

5. Mount the U-axis motor on the U-arm unit. (Perform “Reassembly” in section 5.3 “Disassembly and Reassembly of U-Axis Motor”.)

6. Apply ThreeBond 1206C on the matching surface between the speed reducer and the L-arm. Then, mount the U-arm unit with the speed reducer on the L-arm.

7. Tighten the hexagon socket head cap screws with the tightening torque shown in Table 6-3 "U-Axis Speed Reducer Parts Checklist". For the screws marked with , apply ThreeBond 1206C on the thread parts of them before tightening them.



3

2 1

4

5

5 5

1

1 5

4

1 1

2

1

1

3

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HP20D 6 Disassembly and Reassembly of Speed Reducer6.3 Disassembly and Reassembly of U-Axis Speed Reducer

Fig. 6-3: Disassembly and Reassembly of U-Axis Speed Reducer

Table 6-3: U-Axis Speed Reducer Parts Checklist

No. Name Qty. NotesSpeed reducer HW9280880-G 1GT-SA bolt M8(length: 45 mm)


Hexagon socket head cap screw M14 (length: 35 mm)Conical spring washer GT-SH-14

6 each



1 each


Input gear 1

1

2

3

4

5

L-armU-axis motor

U-arm unit

1

5

3

4

2

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6.4 Disassembly and Reassembly of R-Axis Speed Reducer

• Refer to Fig. 6-4 “Disassembly and Reassembly of R-Axis Speed Reducer”.

Disassembly


2. Remove the R-axis motor. (Perform the steps 2 to 5 of “Disassembly” in section 5.4 “Disassembly and Reassembly of R-Axis Motor”.)

3. Remove the GT-SA bolts , then remove the shaft and the flex spline .

4. Remove the hexagon socket head cap screws , then remove the circular spline .

Reassembly

1. Mount the circular spline on the casing.

2. Tighten the hexagon socket head cap screws with the tightening torque shown in Table 6-4 "R-Axis Speed Reducer Parts Checklist".

3. Apply Harmonic Grease SK-1A on the surface between the teeth of the circular spline and the flex spline . Then, mount the flex spline and the shaft on the casing.

4. Tighten the GT-SA bolts with the tightening torque shown in Table 6-4 "R-Axis Speed Reducer Parts Checklist".

5. Apply Harmonic Grease SK-1A on the bearing of the wave generator . Then, mount the wave generator on the R-axis motor. (Perform the steps 3 to 10 of “Reassembly” in section 5.4 “Disassembly and Reassembly of R-Axis Motor”.)


5 4

2

6

1

1

6

1 2

2 4

5

3 3

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HP20D 6 Disassembly and Reassembly of Speed Reducer6.4 Disassembly and Reassembly of R-Axis Speed Reducer

Fig. 6-4: Disassembly and Reassembly of R-Axis Speed Reducer

Table 6-4: R-Axis Speed Reducer Parts Checklist

No. Name Qty. NotesSpeed reducer HW0381463-A

1 Circular spline

Speed reducer HW0381463-A

1 Flex spline


1 Wave generator

Shaft HW0404403-1 1GT-SA bolt M6(length: 20 mm)



12 each


1

2

3

4

5

6

CasingR-axis motor

1

53

6 4

2

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6.5 Disassembly and Reassembly of B-Axis Speed Reducer

• Refer to Fig. 6-5 “Disassembly and Reassembly of B-Axis Speed Reducer”.

Disassembly


2. Remove the GT-SA bolts , then remove the covers .

3. Loosen the GT-SA bolts which fix the B-axis motor. Then, remove the timing belt .

4. Remove the GT-SA bolts . Then, remove the pulley , the housing , the wave generator , and the bearings and .

5. Remove the hexagon socket head cap screw , then remove the pulley .

6. Remove the GT-SA bolts , then remove the circular spline .

7. Remove the GT-SA bolts , then remove the flex spline .

Reassembly

1. Mount the flex spline on the wrist base.

2. Tighten the GT-SA bolts with the tightening torque shown in Table 6-5 "B-Axis Speed Reducer Parts Checklist".

3. Apply Harmonic Grease SK-1A on the surface between the teeth of the circular spline and the flex spline . Apply ThreeBond 1206C on the matching surface between the circular spline and the U-arm. Then, mount the circular spline on the U-arm.


5. Apply Harmonic Grease SK-1A on the bearing part of the wave generator . Press-fit the bearings and . Then, mount the housing and the pulley . (When replacing the speed reducer, replace the bearings and too.)

6. Apply Loctite 242 to the thread part of the hexagon socket head cap screw . Then, tighten it with the tightening torque shown in Table 6-5 "B-Axis Speed Reducer Parts Checklist".

7. Insert the wave generator assembled at the step 5 above in the wrist base.


9. Put the timing belt on the pulley .

10. Adjust the initial tension of the timing belt to the designated tension. Then, tighten the GT-SA bolts with the tightening torque shown in Table 6-5 "B-Axis Speed Reducer Parts Checklist". (Refer to chapter 8 “Disassembly, Reassembly, and Adjustment of B- and T-axis Timing Belts”.)

11. Remove the old sealing bond on the covers and the U-arm. Apply ThreeBond 1206C on the matching surface between the covers and the U-arm. Then, mount the covers on the U-arm.


11 10

14

5

9 6

15 3 8 12

7

6

4 2

13 1

1

13

2 1

2

2

4

3 8 12

15 6

8 12

7

3

9

5 6

5

14

10

10

10

11

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HP20D 6 Disassembly and Reassembly of Speed Reducer6.5 Disassembly and Reassembly of B-Axis Speed Reducer


Table 6-5: B-Axis Speed Reducer Parts Checklist


1 Flex spline


1 Circular spline


1 Wave generator



Timing belt 80S4.5M653 1Pulley HW9482725-A 1Hexagon socket head cap screw M5 (length: 16 mm)Conical spring washer 2H-5

1 each


Bearing 6002ZZ 1GT-SA bolt M4(length: 12 mm)




Bearing 6901ZZ 1GT-SA bolt M5(length: 16 mm)




Housing HW9405792-1 1

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

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Fig. 6-5: Disassembly and Reassembly of B-Axis Speed Reducer

Wrist base U-armB-axis motor

1 121314

10

79 8

15

11

5

3

64

2

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HP20D 6 Disassembly and Reassembly of Speed Reducer6.6 Disassembly and Reassembly of T-Axis Speed Reducer

6.6 Disassembly and Reassembly of T-Axis Speed Reducer

• Refer to Fig. 6-6 “Disassembly and Reassembly of T-Axis Speed Reducer”.

Disassembly


2. Remove the GT-SA bolts , then remove the right side part from the point “A” in chapter 6-6 “Disassembly and Reassembly of T-Axis Speed Reducer”.

3. Remove the circular spline from the flange.

4. Remove the GT-SA bolts , then, remove the flex spline .

5. Remove the GT-SA bolts . Then, remove the housing from the wrist base.

6. Remove the hexagon socket head cap screw , and remove the gear and the shim . Then, pull out the wave generator .

Reassembly

1. Apply Harmonic Grease SK-1A to the bearing of the wave generator . Then, insert the wave generator in the housing .

2. Mount the shim and the gear .

3. Apply Loctite 242 to the thread part of the hexagon socket head cap screw . Then, tighten it with the tightening torque shown in Table 6-6 "T-Axis Speed Reducer Parts Checklist".

4. Mount the housing (the assembly prepared in the steps 1 to 3 above) on the wrist base.

5. Temporarily tighten the GT-SA bolts .

6. Check if the backlash is proper, and adjust the shim as follows when necessary: Remove the GT-SA bolt , then remove the housing . Adjust the backlash by inserting the shim(s) on the list below between the gear and the wave generator . Set the backlash to 0.05 to 0.1 mm on the gear’s pitch circle diameter of 52.5 mm.

7. Confirm the backlash is correct. Then, remove the GT-SA bolts again, and remove the housing . Apply Harmonic Grease SK-1A on the teeth of the gear .

8. Apply ThreeBond 1206C on the matching surface between the housing and the wrist base. Then, mount the housing on the wrist base. Tighten the GT-SA bolts with the tightening torque shown in Table 6-6 "T-Axis Speed Reducer Parts Checklist".

9. Mount the flex spline on the flange.

10. Tighten the GT-SA bolts with the tightening torque shown in Table 6-6 "T-Axis Speed Reducer Parts Checklist".

10

2

4 1

5 6

8

7 9 3

Shim Type Thickness (mm)SP012010 0.1SP012015 0.15SP012020 0.2SP012050 0.5

3 3 6

9 7

8

6

5

5 6

7 3

5

6

7

6 6

5

1

4

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11. Apply Harmonic Grease SK-1A on the surface between the teeth of the circular spline and the flex spline . Apply ThreeBond 1206C on the matching surface between the housing and the circular spline . Then, insert the circular spline in the flange, and mount it on the housing .

12. Tighten the GT-SA bolts with the tightening torque shown in Table 6-6 "T-Axis Speed Reducer Parts Checklist".

13. Replenish grease (Harmonic Grease SK-1A) through the grease inlet.


Table 6-6: T-Axis Speed Reducer Parts Checklist


1 Flex spline


1 Circular spline


1 Wave generator





Housing HW0304086-1 1Gear HW9381659-A 1Hexagon socket head cap screw M5 (length: 16 mm)Conical spring washer 2H-5

1 each


Shim (Refer to the table in the previous page.)GT-SA bolt M5(length: 16 mm)


2 1

6 2

2

6

10

1

2

3

4

5

6

7

8

9

10

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Fig. 6-6: Disassembly and Reassembly of T-Axis Speed Reducer

A

Flange

Wrist base

1

10

7

985

3

6

4

2

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7 Disassembly and Reassembly of Wrist Unit

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7 Disassembly and Reassembly of Wrist Unit

• Refer to Fig. 7-1 “Disassembly and Reassembly of Wrist Unit”.

Disassembly



3. Connect backup batteries to the B- and T-axis motors.

4. Disconnect the connectors of the B- and T-axis internal wiring harness.

5. Remove the GT-SA bolts , and remove the support . Then, cut off the cable tie which fixes the B- and T-axis internal wiring harness.

6. Remove the hexagon socket head cap screws , then remove the wrist unit .

Reassembly

1. Run the B- and T-axis internal wiring harness through the wrist unit , then fix the wrist unit with the hexagon socket head cap screws .

2. Tighten the hexagon socket head cap screws with the tightening torque shown in Table 7-1 "Wrist Unit Parts Checklist".

3. Fix the white-marked part of the B- and T-axis internal wiring harness to the support with a cable tie.

4. Mount the support on the wrist unit with the GT-SA bolts .

5. Tighten the GT-SA bolts with the tightening torque shown in Table 7-1 "Wrist Unit Parts Checklist".

6. Connect the B- and T-axis internal wiring harness to the B- and T-axis motor connectors, then remove the backup batteries. (Refer to chapter 10 “Cable Wiring”.)

7. Apply ThreeBond 1206C on the matching surface between the cover and the wrist unit . Then, mount the cover on the wrist unit with the GT-SA bolts .

8. Tighten the GT-SA bolts with the tightening torque shown in Table 7-1 "Wrist Unit Parts Checklist".


NOTE Refer to chapter 2 “Notes for Maintenance”, chapter 3 “Home Position Return”, and chapter 10 “Cable Wiring”.

6 5

4 3

2

1

1

1 2

2

3

3 1 4

4

5 1 5

1 6

6

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HP20D 7 Disassembly and Reassembly of Wrist Unit

Fig. 7-1: Disassembly and Reassembly of Wrist Unit

Table 7-1: Wrist Unit Parts Checklist

No. Name Qty. NotesWrist unit 1 Mass: 14.5 kgHexagon socket head cap screw M6 (length: 65 mm)Conical spring washer 2H-6

8 each


Support HW9406556-1 1GT-SA bolt M4(length: 12 mm)




1

2

3

4

5

6

B- and T-axis internal wiring harness

1536 42

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8 Disassembly, Reassembly, and Adjustment of B- and T-axis Timing Belts

8.1 Disassembly and Reassembly of B- and T-axis Timing Belts

• Refer to Table 8-1 "B- and T-Axis Timing Belt Parts Checklist" and Fig. 8-1 “Disassembly and Reassembly of B- and T-Axis Timing Belts”.

Disassembly(Refer to section 5.5 “Disassembly and Reassembly of B-Axis Motor” and section 5.6 “Disassembly and Reassembly of T-Axis Motor”.)

1. Remove the B-axis motor , then remove the B-axis timing belt .

2. Remove the T-axis motor , then remove the T-axis timing belt .

Reassembly(Refer to section 5.5 “Disassembly and Reassembly of B-Axis Motor” and section 5.6 “Disassembly and Reassembly of T-Axis Motor”.)

1. Install the T-axis timing belt , then install the T-axis motor .

2. Install the B-axis timing belt , then install the B-axis motor .

5 1

3 2

2 3

1 5

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HP20D 8 Disassembly, Reassembly, and Adjustment of B- and T-axis Timing Belts8.1 Disassembly and Reassembly of B- and T-axis Timing Belts

Fig. 8-1: Disassembly and Reassembly of B- and T-Axis Timing Belts

Table 8-1: B- and T-Axis Timing Belt Parts Checklist

No. Name Qty. NotesB-axis timing belt 80S4.5M653 1T-axis timing belt 80S4.5M518 1T-axis motor HW0389298-A 1 SGMPH-02ANA-YR11GT-SA bolt M5(length: 20 mm)


B-axis motor HW0389298-A 1 SGMPH-02ANA-YR11GT-SA bolt M5(length: 20 mm)




Pulley HW9482727-A 1 For B-axisPulley HW9482727-A 1 For T-axis

1

2

3

4

5

6

7

8

9

10

1

10

7

7

9

8

8

5

3

6

4

2

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8.2 Adjustment of Timing Belts

8.2.1 B-Axis

1. Loosen the GT-SA bolts shown in Fig. 8-1 “Disassembly and Reassembly of B- and T-Axis Timing Belts”.

2. Adjust the initial tension of the timing belt by pushing the pulley in the direction in which the timing belt stretches.

3. Temporarily tighten the GT-SA bolts , then adjust the initial tension to the tension specified in Table 8-2 "Initial Tension of Timing Belt" by using a tension meter.

4. Tighten the GT-SA bolts with the specified tightening torque. Then, operate the B-axis at low speed to equalize the tension, and confirm that the initial tension of the timing belt is the initial tension shown in Table 8-2 "Initial Tension of Timing Belt". As the set value of the tension meter, start with the following:

Belt mass: 34 gram per meter (width: 10 mm)Belt width: 8 mmDistance between axes: 276 mm

8.2.2 T-Axis

1. Loosen the GT-SA bolts shown in Fig. 8-1 “Disassembly and Reassembly of B- and T-Axis Timing Belts”.

2. Adjust the initial tension of the timing belt by pushing the pulley in the direction in which the timing belt stretches.

3. Temporarily tighten the GT-SA bolts , then adjust the initial tension to the tension specified in Table 8-2 "Initial Tension of Timing Belt" by using a tension meter.

4. Tighten the GT-SA bolts with the specified tightening torque. Then, operate the B-axis at low speed to equalize the tension, and confirm that the initial tension of the timing belt is the initial tension shown in Table 8-2 "Initial Tension of Timing Belt". As the set value of the tension meter, start with the following:

Belt mass: 34 gram per meter (width: 10 mm)Belt width: 8 mmDistance between axes: 184 mm

6

1 9

1

6

6

Table 8-2: Initial Tension of Timing Belt

Initial tensionB-axis 15 to 36 N (1.5 to 3.6 kgf)T-axis 15 to 36 N (1.5 to 3.6 kgf)

4

2 10

2

4

4

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HP20D 9 Battery Pack Replacement

9 Battery Pack Replacement

The battery packs are installed in the position shown in Fig. 9-1 “Battery Pack Location”. If the battery alarm occurs in the DX100, replace the battery in accordance with the following procedure:

Fig. 9-1: Battery Pack Location

Connector baseSupport

Battery pack

Connector base fixing screw

Connector base

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Fig. 9-2: Battery Pack Connection

1. Turn OFF the DX100 main power supply.

2. Remove the plate on the connector base, then pull the battery pack out to replace it with the new one.

3. Remove the battery pack from the battery holder.

4. Connect the new battery pack to an unconnected connector on the board.

5. Remove the old battery pack from the board.

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

7. Reinstall the plate.

Connector

Battery pack before replacementSee the step 5

New battery pack(HW0470360-A)

Circuit board

See the step 4

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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10 Cable Wiring

10.1 Disconnecting Cables

10.1.1 Cables in Wrist Unit

• Refer to Table 10-1 "B- and T-Axis Cable Wiring Parts Checklist" and Fig. 10-1 “B- and T- Axis Cable Wiring”.


2. Remove the plastic covers on the connector parts of the B- and T-axis motors. Then, connect the backup batteries to the B- and T-axis motors.

3. Disconnect the connectors of the B- and T-axis motors.

4. Remove the GT-SA bolts , then remove the support .

5. Cut off the cable tie which fixes the B- and T-axis internal wiring harness to the support .

NOTETo prevent loss of the encoder absolute data, make sure to connect the new battery pack before disconnecting the encoder cable connectors. (Refer to chapter 2 “Notes for Maintenance”.)

Table 10-1: B- and T-Axis Cable Wiring Parts Checklist

No. Name Qty. NotesCover HW9200798-1 1GT-SA bolt M5(length: 12 mm)




Support HW9406556-1 1

2 1

3 4

4

1

2

3

4

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Fig. 10-1: B- and T- Axis Cable Wiring

B- and T-axis internal wiring harness

B-axis internal wiring harness,connector

T-axis internal wiring harness,connector

Wrist unit

B-axis motor T-axis motor 13 4 2

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10.1.2 Cables in U-Arm

• Refer to Table 10-2 "U-Arm Cable Wiring Parts Checklist" and Fig. 10-2 “U-Arm Cable Wiring”.


2. Connect the backup batteries to the U- and R-axis motors.

3. Remove the cross head APS bolts , then pull out the N-base .

4. Remove the pan-head sems screws , then remove the connectors of the internal wiring harness from the N-base . Remove the tube (for air) on the back of the N-base , then remove the N-base .

5. Remove the plastic covers on the connectors of the internal wiring harness and the B- and T-axis internal wiring harness. Then, disconnect all the connectors.

6. Remove the cross head APS bolt which fixes the ground wire.

7. Remove the GT-SA bolts and hexagon socket head cap screws , then remove the S-cover .

8. Pull out the internal wiring harness to the L-arm side. Then, cut off the cable tie which fixes the internal wiring harness to the S-cover and the cable tie which fixes the internal wiring harness to the support .

9. Remove the GT-SA bolts , then remove the stoppers from the S-cover . Then, remove the internal wiring harness from the S-cover .

10. Remove the GT-SA bolts , then remove the support .

11. Remove the GT-SA bolts and , then pull out the B- and T-axis internal wiring harness to the casing side.

12. Remove the hexagon socket head cap screws , then cut off the cable tie. Then, remove the saddles and the B- and T-axis internal wiring harness from the supports and .

2 1

3 5

4

5

5 5

9

6

7

7

8

10 11

7 7

12 13

14 15

17

16

18 19

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Table 10-2: U-Arm Cable Wiring Parts Checklist

No. Name Qty. NotesCover HW0305305-1 1GT-SA bolt M6(length: 20 mm)


Cross head APS bolt M4(length: 10 mm)

4

Pan-head sems screw M3(length: 16 mm)Nut M3

2 each

N-base HW0404900-1 1GT-SA bolt M5 (length: 16 mm)Hexagon socket head cap screw M5 (length: 35 mm)Conical spring washer 2H-5

42 each

For part For part

S-cover HW0200530-1 1Support HW0404919-1 1Cross head APS bolt M5(length: 8 mm)

1



Stopper HW0404179-1 2GT-SA bolt M4(length: 12 mm)


Support HW0304930-1 1GT-SA bolt M4(length: 12 mm)




Saddle HW0404503-1 2Hexagon socket head cap screw M4 (length: 20 mm)Conical spring washer 2H-4

4 each


Support HW0304914-1 1Support HW0304918-1 1

1

2

3

4

5

6 AB

7

8

9

10

11

12

13

14

15

16

17

18

19

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Fig. 10-2: U-Arm Cable Wiring

AA A

B

AB

Gro

und

wire

Air

hose

Inte

rnal

use

r I/O

wirin

g ha

rnes

sB-

and T

-axis e

ncod

er ca

ble

R-ax

is en

code

r cab

leB-

and T

-axis

powe

r cab

leR-

axis

powe

r cab

le

U-ax

is po

wer c

able

U-ax

is en

code

r cab

le

R-a

xis

mot

or

B- a

nd T

-axis

inte

rnal

wirin

g ha

rnes

s

Conn

ecto

r of i

nter

nal u

ser

I/O w

iring

har

ness

Mai

n ke

y po

sitio

n

U-a

xis

mot

or

Cas

ing

Vie

w W

ithou

t Cov

er

(E

nlar

ged)

Vie

w W

ithou

t Cov

er

1

1

1219

13

1417

16

10

7

9

8

1518

1716

11

53

66

4

2

U-, R

-, B-

, and

T-a

xispo

wer c

able

U-, R

-, B-

, and

T-a

xisen

code

r cab

le

3BC

enco

der c

able

3BC

powe

r cab

le

Air

hose

17

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10.1.3 Cables in S-Head

• Refer to Table 10-3 "S-Head Cable Wiring Parts Checklist" and Fig. 10-3 “S-Head Cable Wiring”.

1. Remove the cross head APS bolts , then remove the cover . Then, cut off the cable tie which fixes the internal wiring harness.

2. Connect the backup batteries to the S-axis motor and the L-axis motor.

3. Disconnect the connectors (signal, power, brake) connected to the S-axis motor and the L-axis motor.

4. Remove the cross head APS bolts , then remove the tube for grease exhaust on the back of the cover. Then, remove the cover .

5. Disconnect the connector of the S-axis motor from the internal wiring harness.

6. Remove the GT-SA bolts . Then, pull out the holder which fixes the internal wiring harness.

7. Remove the hexagon socket head cap screws , then remove the saddle .

8. Cut off the cable tie which fixes the internal wiring harness, then remove the holder .


10. Remove the GT-SA bolts , then remove the holder .

11. Pull out the internal wiring harness from the S-head, then remove the GT-SA bolts . Then, remove the saddle , cut off the cable tie, and remove the holder .

12. Remove the cross head APS bolts , then pull out the C-base .

13. Remove the tube for grease replenishment installed on the back of the C-base .

14. Pull out the C-base further, and remove the internal wiring harness.

2 1

4

3

2 6

7

8

6

11 12

13 14

15 16

14

9 10

10

10

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Table 10-3: S-Head Cable Wiring Parts Checklist

No. Name Qty. NotesCover HW0304227-1 1Cross head APS bolt M6(length: 8 mm)

4

Cover HW0305809-1 1Cross head APS bolt M5(length: 10 mm)

4



Holder HW0305812-1 1Hexagon socket head cap screw M6 (length: 10 mm)Conical spring washer 2H-6

2 each


Saddle CD-31 1Cross head APS bolt M5(length: 10 mm)

6

C-base HW0303378-2 1GT-SA bolt M5(length: 12 mm)




Holder HW0305813-1 1GT-SA bolt M5(length: 12 mm)


Saddle FCD-31 1Support HW0304226-1 1

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

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Fig. 10-3: S-Head Cable Wiring

S-axis connector

S-head

Apply sealingbond to thehatched area.

L-axis motor

S-axis motor


Cable ties (2 pieces)T18S

1

12

13

14

16

10

7

9

8

15

11

5

3

6

4

2

17

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10.2 Connecting Cables

10.2.1 Cables in S-Head

• Refer to Table 10-3 "S-Head Cable Wiring Parts Checklist" and Fig. 10-3 “S-Head Cable Wiring”.

1. Run the internal wiring harness to which the C-base is attached through the S-head from the back of the manipulator.

2. Before installing the C-base , insert the tube for grease replenishment to the back of the C-base , and push the internal wiring harness to the left.

3. Apply ThreeBond 1206C on the upper part of the matching surface of the C-base (the hatched area in Fig. 10-3 “S-Head Cable Wiring”). Then, mount the C-base with the cross head APS bolts .

4. Mount the holder to the internal wiring harness. Hold the spring part (the second or third coil from the end of the spring) by using the saddle . Fix it to the holder with the hexagon socket head cap screws . Then, fix the white marked part of the internal wiring harness by using cable ties. Tighten the hexagon socket head cap screws with the tightening torque shown in Table 10-3 "S-Head Cable Wiring Parts Checklist".

5. Mount the holder on the S-head with the GT-SA bolts . Then, tighten them with the tightening torque shown in Table 10-3 "S-Head Cable Wiring Parts Checklist".

6. Mount the holder to the internal wiring harness. Fix the holder to the white marked part of the internal wiring harness by using cable ties. Hold the spring part (the second or third coil from the end of the spring) by using the saddle . Fix it to the holder with the GT-SA bolts . Tighten the GT-SA bolts with the tightening torque shown in Table 10-3 "S-Head Cable Wiring Parts Checklist".

7. Mount the holder on the S-head with the GT-SA bolts . Then, tighten them with the tightening torque shown in Table 10-3 "S-Head Cable Wiring Parts Checklist".

8. Connect the connectors of the S-axis motor and the L-axis motor to the internal wiring harness.

9. Remove the backup batteries connected to the S-axis motor and the L-axis motor.

10. Connect the tube for grease exhaust to the back of the cover , and mount the cover with the cross head APS bolts .

11. Mount the cover with the GT-SA bolts .

12. Tighten the GT-SA bolts with the tightening torque shown in Table 10-3 "S-Head Cable Wiring Parts Checklist".

13. Fix the white marked part of the internal wiring harness to the support by using cable ties.

14. Run the internal wiring harness through the L-arm, then mount the cover with the cross head APS bolts .

10

10

10

10

10 9

6

8 6

7

7

6 5

14 14

16 14

15 15

14 13

3

3 4

12 11

11

17

1 2

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10.2.2 Cables in U-Arm

• Refer to Table 10-2 "U-Arm Cable Wiring Parts Checklist" and Fig. 10-2 “U-Arm Cable Wiring”.

1. Hold the spring part (the second or third coil from the end of the spring) of the B- and T-axis internal wiring harness by using the saddles . Then, fix it to the support and with the hexagon socket head cap screws .

2. Tighten the hexagon socket head cap screws with the tightening torque shown in Table 10-2 "U-Arm Cable Wiring Parts Checklist".

3. Fix the white marked part of the B- and T-axis internal wiring harness by using a cable tie.

4. Apply the Multemp PS2A grease to the spring of the B- and T-axis internal wiring harness. Pass the B- and T-axis motor connectors through the wrist unit, then set the spring in the casing. Mount the support and to the casing respectively with the GT-SA bolts and .

5. Tighten the GT-SA bolts and with the tightening torque shown in Table 10-2 "U-Arm Cable Wiring Parts Checklist".

6. Pass the connectors of the B- and T-axis internal wiring harness to the R-axis motor side. Mount the support to the casing with the GT-SA bolts .

7. Tighten the GT-SA bolts with the tightening torque shown in Table 10-2 "U-Arm Cable Wiring Parts Checklist".

8. Run the internal wiring harness through the S-cover . Hold the spring by using the stoppers , then fix it to the S-cover with the GT-SA bolts .

9. Tighten the GT-SA bolts with the tightening torque shown in Table 10-2 "U-Arm Cable Wiring Parts Checklist".

10. Fix the white marked part of the internal wiring harness to the support (which is mounted on the S-cover ) by using a cable tie.

11. Fix the internal wiring harness to the S-cover by using cable ties. (For the positions of the air line tube, 3BC cable, and U-, R-, B-, and T-axis cables, see Fig. 10-2 “U-Arm Cable Wiring”.)

12. Push the internal wiring harness into the casing, then apply ThreeBond 1206C to the matching surface between the S-cover and the casing. Mount the S-cover to the casing with the GT-SA bolts and hexagon socket head cap screws .

13. Tighten the GT-SA bolts and hexagon socket head cap screws with the tightening torque shown in Table 10-2 "U-Arm Cable Wiring Parts Checklist".

14. Mount the internal wiring harness connector to the N-base with the pan-head sems screws . At this time, make sure that the main key of the connector is set upward. Then, insert the air line tube.

15. Mount the N-base to the casing with the cross head APS bolts .

16. Mount the ground wire of the internal wiring harness to the casing with the cross head APS bolt .

17. Connect the B- and T-axis internal wiring harness to the internal wiring harness.

18. Mount the cover with the GT-SA bolts .

16

18 19

17

17

18 19 15

14

15 14

13

12

12

7

11 7

10

10

8 7

7

7

7

6

6

5

4

5 3

9

1 2

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19. Apply ThreeBond 1206C to the matching surface between the cover and the casing. Tighten the GT-SA bolts with the tightening torque shown in Table 10-2 "U-Arm Cable Wiring Parts Checklist".

10.2.3 Cables in Wrist Unit

• Refer to Table 10-1 "B- and T-Axis Cable Wiring Parts Checklist" and Fig. 10-1 “B- and T- Axis Cable Wiring”.

1. Fix the white marked part of the B- and T-axis internal wiring harness to the support by using a cable tie.

2. Mount the support to the wrist unit with the GT-SA bolts .

3. Tighten the GT-SA bolts with the tightening torque shown in Table 10-1 "B- and T-Axis Cable Wiring Parts Checklist".

4. Connect the connectors of the B- and T-axis motors to the internal wiring harness.

5. Remove the backup batteries connected to the B- and T-axis motors. Protect the connecting parts of the connectors of the B- and T-axis motors and the internal wiring harness by using plastic covers, then put them back. Tie up both ends of each plastic cover by using cable ties.

6. Apply ThreeBond 1206C to the matching surface between the cover and the wrist unit. Then, mount the cover with the GT-SA bolts .

7. Tighten the GT-SA bolts with the tightening torque shown in Table 10-1 "B- and T-Axis Cable Wiring Parts Checklist".

1

2

4

4 3

3

1

1 2

2

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11 Parts List

11.1 S-Axis Unit

Fig. 11-1: S-Axis Unit

1002

1004

1003

1007

1005

1020

1025

1014

1006

1016

1017

1018

1015

1028

1029

1030

1009

1030

10311032

1033

1035

1036

1034

1001

1008

1027

1024

10241023

1026

1020

1023

1022

1012

1013

1010

1014

1011

1021

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HP20D 11 Parts List11.1 S-Axis Unit

Table 11-1: S-Axis Unit

No. DWG No. Name Pcs.1001 SGMRV-09ANA-YR1* Motor 11002 HW0100545-2 S-head 11003 M16X20 Socket screw 11004 2H-16 Conical spring washer 11005 HW0387753-B Speed reducer 11006 M10X40 GT-SA bolt 161007 HW0100544-2 Base 11008 M8X30 GT-SA bolt 31009 HW0305306-2 M-base 11010 M5X10 APS bolt 11011 PT1/8 Plug 11012 UKM6-01 Union 11013 HW0305809-1 Cover 11014 NB-0640-0.3 Tube 21015 HW0304221-1 Cover 11016 M6X15 GT-SA bolt 21017 MSB8-15 Shoulder 11018 HW0400645-1 Lever 11019 M5X10 APS bolt 61020 TSH6-01M Union 21021 CD-31 Saddle 11022 M6X10 Socket screw 21023 TA1-S10 Clamp 21024 M5X10 Screw with spring washer 21025 EZ5036A0 Cap 11026 M6X15 GT-SA bolt 21027 HW0305812-1 Holder 11028 HW9406775-1 Cover 11029 M6X8 APS bolt 11030 M12 Eye bolt 21031 M8X60 Socket screw 31032 2H-8 Conical spring washer 31033 M12X35 GT-SA bolt 121034 HW0313491-1 Gear 11035 M6X60 Socket screw 11036 2H-6 Conical spring washer 1

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11.2 L-Axis Unit

Fig. 11-2: L-Axis Unit

1002

20122011

2018 2006

2032

20022003

2004

2005

2001

2023

20252024

200720192008

2010

2017

2009

2027

2013

2013

2014

2014

20262028

20152016

2020

2031

2030

2029

2031

20362035

20332034

20212022

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HP20D 11 Parts List11.2 L-Axis Unit

Table 11-2: L-Axis Unit

No. DWG No. Name Pcs.2001 SGMRV-13ANA-YR2* Motor 12002 M6X90 Socket screw 12003 2H-6 Conical spring washer 12004 HW0313492-1 Gear 12005 HW0304229-1 M-base 12006 Y426012.5 Oil seal 12007 HW0401506-1 Plate 12008 HW0304226-1 Support 12009 M6X10 Socket screw 22010 2H-6 Conical spring washer 22011 HW0304227-1 Cover 12012 M6X8 APS bolt 42013 M12X40 Socket screw 122014 2H-12 Conical spring washer 122015 M10X35 Socket screw 62016 2H-10 Conical spring washer 62017 HW0100546-2 L-arm 12018 HW0387753-C Speed reducer 12019 M10X40 Socket screw 162020 M12X40 Socket screw 22021 2H-12 Conical spring washer 22022 HW0404196-4 Washer 12023 M8X30 GT-SA bolt 42024 M8X25

*DACROTIZED coating*Socket screw 4

2025 2H-8*DACROTIZED coating*

Conical spring washer 4

2026 TA1-S10 Clamp 42027 M5X10 Screw with spring washer 42028 M6X10 Socket screw 12029 HW0305813-1 Holder 12030 HW0305698-1 Cover 12031 M5X12 GT-SA bolt 62032 PT1/8

*DACROTIZED coating*Plug 1

2033 CD-31 Saddle 12034 M5X12 GT-SA bolt 22035 TA1-S10 Clamp 22036 M5X10 Screw with spring washer 21002 HW0100545-2 S-head 1

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11.3 U-Axis Unit

Fig. 11-3: U-Axis Unit

2017

3011

3006

3019

3007

3016

3016

30053020

3001

3012

3002

3002

30043003

30043003

3018

3018

3017

301730083009

3010

3015 30143013

3019

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HP20D 11 Parts List11.3 U-Axis Unit

Table 11-3: U-Axis Unit

No. DWG No. Name Pcs.3001 SGMRV-05A3A-YR1* Motor 13002 HW0313489-1 Cover 13003 M4X10 APS bolt 73004 M4 Washer 73005 HW0102379-1 Casing 13006 HW9280880-G Speed reducer 13007 M8X45 GT-SA bolt 163008 M5X65 Socket screw 13009 2H-5 Conical spring washer 13010 M14X35 Socket screw 63011 GT-SH-14 GT-SH washer 63012 M8X30 GT-SA bolt 43013 M10X20 Socket screw 13014 H-10 Conical spring washer 13015 M6X10 Socket screw 13016 HW0404196-2 Washer 23017 M10X35 Socket screw 23018 2H-10 Conical spring washer 23019 PT1/8 Plug 23020 EZ2940A0 Cap 12017 HW0100546-2 L-arm 1

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11.4 R-Axis Unit

Fig. 11-4: R-Axis Unit

4022

4025

4026

406040234034

4073

40574035

4036

40424058

4027

4040

4011

4043

4044

4039

30054005

4037

40454046

4030

40324012

4029

4033

4008

4071

4056

4003

4009

4074

40064007

40294010

4031

4001

5046

4002

406540674017

4018

4070

4019

4020

40214015

4062

4013

4014

4024

4055

4051

40694068

40164004

3014

3012

40764075

40664072

4028

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HP20D 11 Parts List11.4 R-Axis Unit

Table 11-4: R-Axis Unit (Sheet 1 of 2)

No. DWG No. Name Pcs.4001 M6X65 Socket screw 84002 2H-6 Conical spring washer 84003 M5X20 GT-SA bolt 44004 M4X12 GT-SA bolt 44005 HW0305305-1 M-cover 14006 M4X20 Socket screw 124007 2H-4 Conical spring washer 124008 HW0404196-5 Washer 14009 M6X20 GT-SA bolt 84010 M4X45 Socket screw 14011 M6X6 Socket screw 14012 A-MT6X1 G Nipple 14013 HW0381872-A Cross roller bearing 14014 M6X35 GT-SA bolt 84015 HW0403879-1 Saddle 14016 TC941045*A727* Oil seal 14017 HW0403857-1 Shaft 14018 HW0405201-2 Block 14019 HW0304318-1 Housing 14020 HW0304085-1 Shaft 14021 HW0304914-1 Support 14022 HW0403879-1 Saddle 14023 M4X20 Socket screw 24024 M4X12 GT-SA bolt 24025 HW0200530-1 S-cover 14026 HW0404919-1 Support 14027 M5X16 Socket screw 24028 2H-5 Conical spring washer 24029 HW0381463-A Speed reducer 14030 HW0404403-1 Shaft 14031 AE1314A0 Oil seal 14032 HW0304932-1 M-base 14033 HW0404402-1 Shaft 14034 2H-4 Conical spring washer 24035 HW0404900-1 N-base 14036 M4X10 Screw with spring washer 44037 M5X16 GT-SA bolt 44039 TA1-S8 Clamp 44040 M4X8 Screw with spring washer 44042 M5X8 APS bolt 14043 M6X6 Socket screw 14044 LP-M5 Plug 14045 M5X35 Socket screw 24046 2H-5 Conical spring washer 2

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HP20D

4051 M4X12 GT-SA bolt 24055 HW0404918-1 Support 14056 SGMPH-02A2A-YR1* Motor 14057 EZ5036A0 Cap 14058 M6X20 GT-SA bolt 64060 HW0304930-1 Support 14062 6811LLU Bearing 14065 M4X20 Socket screw 24066 KQE12-03 Union 14067 2H-4 Conical spring washer 24068 M4X20 Socket screw 24069 2H-4 Conical spring washer 24070 MS4-10 Pin 24071 2H-4 Conical spring washer 14072 PT 3/8 Plug 14073 M4X12 GT-SA bolt 24074 M6X30 GT-SA bolt 34075 TA1-S8 Clamp 34076 M4X8 Screw with spring washer 33005 HW0102378-1 Casing 13012 M4X16 GT-SA bolt 43014 HW0404179-1 Support 25046 HW0100623-1 U-arm 1

Table 11-4: R-Axis Unit (Sheet 2 of 2)

No. DWG No. Name Pcs.

92 of 96

11-10

159281-1CD

HW1480357

HP20D 11 Parts List11.5 Wrist Unit

11.5 Wrist Unit

Fig. 11-5: Wrist Unit

5001 5002

5005

5039

5040

5041

5046

5064

50085008

5012

5016

5005

5003

5003

5006

50065007

5007

5048

5049

50475017

5036

5011

5043

5044

5045

5045

5037

5038

5033

5034

5042

50635062

50145019

5020

5021

5022

5013

50535050

5035

5018

5023

5026

5032

5031

5065

5025

5027

5028

5029

5030

5024

5052

5060

5066

5071

5071

5026

3005

93 of 96

11 Parts List11.5 Wrist Unit

11-11

159281-1CD

HW1480357

HP20D

Table 11-5: Wrist Unit (Sheet 1 of 2)

No. DWG No. Name Pcs.5001 HW9406556-1 Support 15002 M4X12 GT-SA bolt 25003 M5X20 GT-SA bolt 45005 HW9200798-1 Cover 25006 SGMPH-02A2A-YR12 Motor 25007 M4X16 Socket screw 25008 HW9482727-A Pulley 25011 80S4.5M518 Belt 15012 HW9381658-A Gear 15013 M4X12 GT-SA bolt 45014 HW9405452-1 B-cover 15016 HW9482725-A Pulley 15017 M5X16 GT-SA bolt 15018 M4X16 GT-SA bolt 45019 HW9482218-A Bearing 15020 HW9405199-1 B nut 15021 SP-0120** Shim 15022 HW9481180-A Bearing 15023 M5X16 GT-SA bolt 15024 M5X12 GT-SA bolt 85025 HW0304232-1 Shaft 15026 TC60747 Oil seal 25027 HW9481187-A Bearing 15028 HW0304233-1 Shaft 15029 S75 O ring 15030 HW0304087-1 Housing 15031 HW0382140-A Speed reducer 15032 HW0304086-1 Housing 15033 HW9381659-A Gear 15034 HW9482726-A Pulley 15035 M5X16 Socket screw 15036 6002ZZ Bearing 15037 6901ZZ Bearing 15038 6814ZZ Bearing 15039 HW9482668-A Oil seal 15040 HW9381633-A Speed reducer 15041 HW9405792-1 Housing 15042 HW0200451-1 Wrist base 15043 M5X16 GT-SA bolt 115044 80S4.5M653 Belt 15045 M5X12 GT-SA bolt 245046 HW0100623-1 U-arm 15047 M6X6 Socket screw 15048 M4X16 GT-SA bolt 13

94 of 96

11-12

159281-1CD

HW1480357

HP20D 11 Parts List11.5 Wrist Unit

5049 M4X12 GT-SA bolt 45050 M6X6 Socket screw 15052 M5X16 GT-SA bolt 55053 M6X6 Socket screw 15062 LP-M5 Plug 15063 HW9405791-3 Housing 15064 6811LLU Bearing 15065 HW0404606-1 Cover 15066 HW040605-1 Plug 13005 HW0102378-1 Casing 1

Table 11-5: Wrist Unit (Sheet 2 of 2)

No. DWG No. Name Pcs.

95 of 96

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

MANUAL NO.

3HW1480357

HEAD OFFICE2-1 Kurosakishiroishi, Yahatanishi-ku, Kitakyushu 806-0004, JapanPhone +81-93-645-7703 Fax +81-93-645-7802

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YASKAWA America Inc. (Motoman Robotics Division)

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No7 Yongchang North Road, Beijing E&T Development Area China 100176Phone +86-10-6788-2858 Fax +86-10-6788-2878

YASKAWA SHOUGANG ROBOT Co. Ltd.

#426, Udyog Vihar, Phase- IV, Gurgaon, Haryana, IndiaFax +91-124-475-8542Phone +91-124-475-8500

YASKAWA India Private Ltd. (Robotics Division)

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YASKAWA Electric (Thailand) Co., Ltd.59,1st-5th Floor, Flourish Building, Soi Ratchadapisek 18,Ratchadapisek Road, Huaykwang, Bangkok 10310, THAILANDPhone +66-2-017-0099 Fax +66-2-017-0199

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

PT. YASKAWA Electric Indonesia

Phone +46-480-417-800 Fax +46-486-414-10

YASKAWA Nordic ABVerkstadsgatan 2, Box 504 ,SE-385 25 Torsas, Sweden

35F, Three IFC, 10 Gukjegeumyung-ro, Yeongdeungpo-gu, Seoul, Korea　07326YASKAWA Electric Korea Corporation

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