YASKAWA MOTOMAN-HP20D Maintenance Manual

MOTOMAN-HP20D

MAINTENANCE 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 INSTRUCTIONS

DX100 INSTRUCTIONS

DX100 OPERATOR’S MANUAL

DX100 MAINTENACE MANUAL

The DX100 operator’s manual above corresponds to specific usage.

Be sure to use the appropriate manual.

Part Number: 159281-1CD

Revision: 1

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Copyright © 2018, 2011 Yaskawa America, Inc.

Terms of Use and Copyright Notice

All 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 Division

100 Automation Way

Miamisburg, OH 45342

Phone: 937-847-6200 www.motoman.com ii

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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 ......................................... 3-2

3.1.3.1 Preparation before Motor Replacement .................................................. 3-2

3.1.3.2 Motor Replacement................................................................................. 3-4

3.1.3.3 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)................................. 3-6

3.2.2.1 Calibration Operation .............................................................................. 3-6

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HP20D Table of Contents

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

4.3.1 Grease Replenishment.........................................................................................4-4

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

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

4.4.1 Grease Replenishment.........................................................................................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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HP20D

1 Introduction

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 Introduction

1.1 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 Association

900 Victors Way

P.O. Box 3724

Ann Arbor, Michigan 48106

TEL: (734) 994-6088

FAX: (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 Introduction

1.2 Notes for Safe Operation

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”.

DANGER

WARNING

CAUTION

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

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

Indicates a potentially hazardous situation which, if not avoided, could result in minor or moderate injury to personnel and damage to equipment.

It may also be used to alert against unsafe practices.

MANDATORY

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

Must never be performed.

PROHIBITED

Even items described as “CAUTION” may result in a serious accident in some situations.

At any rate, be sure to follow these important items

NOTE

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

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 Introduction

1.2 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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1.3 Definition of Terms Used Often in This Manual

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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:

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:

Equipment

DX100 controller

DX100 programming pendant

Cable between the manipulator and the controller

Manual Designation

DX100

Programming pendant

Manipulator cable

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.

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HP20D 1 Introduction

1.5 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

Nameplate

Warning label A

Warning label B

Nameplate

MODEL

MOTOMAN-

TYPE

PAYLOAD

ORDER NO.

SERIAL NO.

kg

MASS

DATE kg

YASKAWA ELECTRIC CORPORATION

2-1 Kurosakishiroishi, Yahatanishi-ku,

Kitakyushu 806-0004 Japan

MADE IN JAPAN NJ3247

Warning Label A:

WARNING

Moving parts may cause injury

Warning Label B:

WARNING

Do not enter robot work area.

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1.6 Safeguarding Tips

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 Introduction

1.8 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 Introduction

1.9 Maintenance Safety

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 Yaskawatrained, 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 Introduction

1.11 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:

(937) 847-3200

For routine technical inquiries, you can also contact YASKAWA Customer

Support at the following e-mail address: [email protected]

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.

NOTE

Please 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.

Please have the following information ready before you call Customer

Support:

• System

• Robots

HP20D

___________________________

• Primary Application

• Controller

• Software Version

___________________________

DX100

Access this information on the

Programming Pendant’s LCD display screen by selecting {MAIN

MENU} - {SYSTEM INFO} -

{VERSION}

• Robot Serial Number

• Robot Sales Order Number

Located on the robot data plate

Located on the DX100 controller data plate

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HP20D 2 Notes for Maintenance

2.1 Wrist Unit

2 Notes for Maintenance

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.

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

Cover

Cover matching surface

Cover

Cover matching surface

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HP20D 2 Notes for Maintenance

2.2 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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Encoder connector

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2 Notes for Maintenance

2.2 Encoder Connector (with CAUTION Label)

Fig. 2 2: Battery Pack Connection

Motor

S-, L-, U-axis motor

0BT

BAT

CAUTION

Connect battery to encoder to save the data before removing connector.

CAUTION label b a

Motor power connector a 0BT1 b BAT1

Battery pack (HW9470932-A)

Battery backup connector a: Crimped contact-pin (pin) b: Crimped contact-pin (socket)

Encoder

Motor

R-, B-, T-axis motor

Motor cable, etc.

Internal wire

Power connector

CAUTION label

CAUTION Label (Enlarged View)

CAUTION

Connect battery to encoder to save the data before removing connector.

0BT

BAT b a

Encoder connector a b

0BT1

BAT1

Battery pack (HW9470932-A)

Battery backup connector

0BT

BAT b a a b

0BT1

BAT1 a: Crimped contact-pin (pin) b: Crimped contact-pin (socket)

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HP20D

3 Home Position Return

3.1 Home Position Return after Motor Replacement

3 Home Position Return

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.

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 fivepoint-in-five-posture.

Refer to “MOTOCALV EG for Windows Operator’s Manual” (manual No.

HW0483085) for details on the operation.

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3 Home Position Return

3.1 Home Position Return after Motor Replacement

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.)

1

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.

2

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.

3

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.

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3 Home Position Return

3.1 Home Position Return after Motor Replacement

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 0pulse 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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HP20D 3 Home Position Return

3.1 Home Position Return after Motor Replacement

3.1.3.2 Motor Replacement

• Refer to the

Fig. 3 2 “Motor Replacement (Example)” .

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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.

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

Fig. 3 2: Motor Replacement (Example)

Chain block

Hanging tool

Remove the motor and replace it.

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HP20D

3 Home Position Return

3.1 Home Position Return after Motor Replacement

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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HP20D 3 Home Position Return

3.2 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.

Table 3 1: Parts List

Drawing No.

Name Qty.

Remark

SFJW6-100

SFJW4-100

Shaft

Shaft

1

1

For S-, L-, and Uaxes

For R-axis

 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

S-head

Shaft

3-6

Base

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3 Home Position Return

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

Battery

 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

L-arm

Shaft

S-head

 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

Casing

Shaft

L-arm

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

Battery

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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

Casing

U-arm

Shaft

3-8

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HP20D

4 Grease Replenishment and Exchange

4.1 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

4.2 Grease Replenishment and Exchange for S-Axis Speed Reducer

Fig. 4 1: S-Axis Speed Reducer

Grease exhaust port

(Hexagon socket head plug PT1/8)

Grease inlet

(Hexagon socket head plug PT1/8)

S-axis speed reducer

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

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.

NOTE

If 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.

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

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4.2 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.

NOTE

If 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.

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: approx. 1800 cc

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

– Grease injection rate: 8 g/s or less

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

6. 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).

7. 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).

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4.3 Grease Replenishment and Exchange for L-Axis Speed Reducer

4.3 Grease Replenishment and Exchange for L-Axis Speed Reducer

Fig. 4 2: L-Axis Speed Reducer

Grease exhaust port

(Hexagon socket head plug PT1/8)

L-arm

L-axis speed reducer

Grease inlet

(Hexagon socket head cap screw M6)

4.3.1 Grease Replenishment

(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.

NOTE

If 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.

3. Install the grease zerk A-MT6 x 1 to the grease inlet.

(The grease zerk is delivered with the manipulator.)

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

– Grease type: VIGO Grease 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

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).

7. 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).

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4.3 Grease Replenishment and Exchange for L-Axis Speed Reducer

4.3.2 Grease Exchange

(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.

NOTE

If 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.

3. Install the grease zerk A-MT6 x 1 to the grease inlet.

(The grease zerk is delivered with the manipulator.)

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

– Grease type: VIGO Grease No.0

– Amount of grease: approx. 500 cc

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

– Grease injection rate: 8 g/s or less

5. The grease exchange is completed when new grease appears in the exhaust port. (The new grease can be distinguished from the old grease by color.)

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

7. 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).

8. 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).

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4.4 Grease Replenishment and Exchange for U-Axis Speed Reducer

4.4 Grease Replenishment and Exchange for U-Axis Speed Reducer

Fig. 4 3: U-Axis Speed Reducer

U-arm

Grease exhaust port

(Hexagon socket head cap screw M6)

U-axis speed reducer

Grease inlet

(Hexagon socket head plug PT1/8)

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

4.4.1 Grease Replenishment

(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.

NOTE

If 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.

3. Install the grease zerk A-MT6 x 1 to the grease inlet.

(The grease zerk is delivered with the manipulator.)

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

– Grease type: VIGO Grease 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

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

6. 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).

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).

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4 Grease Replenishment and Exchange

4.4 Grease Replenishment and Exchange for U-Axis Speed Reducer

4.4.2 Grease Exchange

(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.

NOTE

If 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.

3. Install the grease zerk A-MT6 x 1 to the grease inlet.

(The grease zerk is delivered with the manipulator.)

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

– Grease type: VIGO Grease RE No.0

– Amount of grease: approx. 300 cc

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

– Grease injection rate: 8 g/s or less

5. The grease exchange is completed when new grease appears in the exhaust port. (The new grease can be distinguished from the old grease by color.)

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

7. 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).

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

4.5 Grease Replenishment for R-Axis Speed Reducer

Fig. 4 4: R-Axis Speed Reducer

Grease inlet

(Grease zerk A-MT6 x 1)

Exhaust port

(Hexagon socket head cap screw M6)

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:

– Amount of grease:

Harmonic Grease SK-1A

8 cc

(16 cc for 1st supply)

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

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).

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4 Grease Replenishment and Exchange

4.6 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

B-axis exhaust port

(Plug LP-M5)

B-axis speed reducer

T-axis speed reducer

T-axis exhaust port

(Hexagon socket set screw M6)

T-axis grease inlet

(Hexagon socket head cap screw M6)

B-axis grease inlet

(Hexagon socket head cap screw M6)

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.

NOTE

For the B-axis, remove the cover.

2. Install the grease zerk A-MT6 x 1 to the grease inlet.

(The grease zerk is delivered with the manipulator.)

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

(See Fig. 4 5 “B- and T-Axis Speed Reducers”

.)

– Grease type: Harmonic Grease SK-1A

– Amount of grease: B-axis: 10 cc

(20 cc for 1st supply)

T-axis: 5 cc

(10 cc for 1st supply)

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

4. Reinstall the plug or screw on the exhaust port. Apply ThreeBond

1206C to the thread part of the plug or screw.

5. 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).

NOTE For the B-axis, mount the cover. (Refer to

for Maintenance”

.)

chapter 2 “Notes

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HP20D 4 Grease Replenishment and Exchange

4.7 Grease Replenishment for T-Axis Gear

4.7 Grease Replenishment for T-Axis Gear

Fig. 4 6: T-Axis Gear

Exhaust port

(Plug LP-M5)

159281-1CD

Gear grease inlet

(Hexagon socket head cap screw M6)

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

2. Install the grease zerk A-MT6 x 1 to the grease inlet.

(The grease zerk is delivered with the manipulator.)

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

(See

Fig. 4 6 “T-Axis Gear”

.)

– Grease type: Harmonic Grease SK-1A

– Amount of grease: 5cc

(10 cc for 1st supply)

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

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

5. 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).

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4 Grease Replenishment and Exchange

4.8 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

Exhaust port

(Plug LP-M5)

R-axis cross roller bearing

Grease inlet

(Hexagon socket head cap screw M6 x 6)

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

2. Install the grease zerk A-MT6 x 1 to the grease inlet.

(The grease zerk is delivered with the manipulator.)

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

(See Fig. 4 7 “R-Axis Cross Roller Bearing” .)

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

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

5. 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).

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HP20D 5 Disassembly and Reassembly of Motors

5.1 Disassembly and Reassembly of S-Axis Motor

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”

.

NOTE

• Refer to chapter 3 “Home Position Return” ,

chapter 4

“Grease Replenishment and Exchange”

, and chapter 8

“Disassembly, Reassembly, and Adjustment of B- and Taxis 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.

 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

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

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

6

 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

5 1 "S-Axis Motor Parts Checklist" .

Table

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5.1 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

1 S-axis motor HW0387862-A

2

3

GT-SA bolt M8

(length: 30 mm)

Input gear HW0313491-1

4

5

6

7

8

9

Key

M-base HW0305306-1

Hexagon socket head cap screw M6

(length: 60 mm)

Conical spring washer 2H-6

Cover HW0305809-1

Cross head APS bolt M5

(length: 10 mm)

Internal wiring harness

1

4

1

Qty. Notes

1 SGMRV-09ANA-YR11

3 Tightening torque:

24.5 N•m

1

1

1

1 each

Tightening torque:

16.5 N•m

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HP20D 5 Disassembly and Reassembly of Motors

5.1 Disassembly and Reassembly of S-Axis Motor

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

2

1

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9

7

8

4

1

2

6

3

5

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5 Disassembly and Reassembly of Motors

5.2 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.

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

Maintenance”

.)

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.

1

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

M-base . At this time, be careful not to damage the oil seal inside the

S-head.

3

 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

2. Apply ThreeBond 1206C on the matching surface between the input gear and the plate . Then, mount the key and the input gear

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

1 3 oil seal inside the S-head.

3 motor on the M-base . At this time, be careful not to damage the

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.

8. Remove the backup battery.

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

10. Turn ON the DX100 power supply.

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5 Disassembly and Reassembly of Motors

5.2 Disassembly and Reassembly of L-Axis Motor

Table 5 2: L-Axis Motor Parts Checklist

No. Name

1 L-axis motor HW0387863-A

2

Hexagon socket head cap screw M8

(length: 25 mm)

Conical spring washer 2H-8

3

4

5

6

7

M-base HW0304229-1

Input gear HW0313492-1

Key

Hexagon socket head cap screw M6

(length: 90 mm)

Conical spring washer 2H-6

Plate HW0401506-1

Qty. Notes

1 SGMRV-13ANA-YR21

4 each

Tightening torque:

24.5 N•m

1

1

1

1 each

Tightening torque:

16.5 N•m

1

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

S-head

1

2

3

7

5

4

6

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5 Disassembly and Reassembly of Motors

5.3 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

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

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

Maintenance”

.)

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

 Reassembly

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

4. Tighten the GT-SA bolts with the tightening torque shown in

5 3 "U-Axis Motor Parts Checklist"

.

Table

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

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

8. Remove the backup battery.

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

10. Turn ON the DX100 power supply.

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5.3 Disassembly and Reassembly of U-Axis Motor

Table 5 3: U-Axis Motor Parts Checklist

No. Name

1 U-axis motor HW0387860-A

2

3

GT-SA bolt M8

(length: 30 mm)

Input Gear

4

5

Key

Hexagon socket head cap screw M5

(length: 65 mm)

Conical spring washer 2H-5

6

7

8

9

Cover HW0305305-1

GT-SA bolt M6

(length: 20 mm)

Cover HW0313489-1

Cross head APS bolt M4

(length: 10 mm)

Flat washer 4.3 x 12.0 x 0.8

Qty. Notes

1 SGMRV-05ANA-YR11

4 Tightening torque:

24.5 N•m

1

1

1 each

Tightening torque:

10 N•m

1

6

1

7 each

Tightening torque:

10 N•m

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

6

7

8

9

4

5

3

1

2

Casing

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5 Disassembly and Reassembly of Motors

5.4 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

1. Turn OFF the DX100 power supply.

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

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 Mbase . Screw the stud bolts in until the gap between the motor and the matching surface becomes 10 mm or more. Then, remove the M-

 Reassembly

2. Tighten the GT-SA bolts with the tightening torque shown in

5 4 "R-Axis Motor Parts Checklist"

.

Table

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

5

5. Apply Loctite 242 to the thread part of the hexagon socket head cap screw . Then, tighten it with the tightening torque shown in

"R-Axis Motor Parts Checklist" .

Table 5 4

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

7. Tighten the GT-SA bolts with the tightening torque shown in

5 4 "R-Axis Motor Parts Checklist"

.

Table

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

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5.4 Disassembly and Reassembly of R-Axis Motor

10. Tighten the GT-SA bolts with the tightening torque shown in

5 4 "R-Axis Motor Parts Checklist" .

Table

11. Turn ON the DX100 power supply.

Table 5 4: R-Axis Motor Parts Checklist

No. Name

1 R-axis motor HW0389298-A

2

3

4

GT-SA bolt M5

(length: 20 mm)

GT-SA bolt M6

(length: 30 mm)

M-base HW0304932-1

5

6

7

8

9

10

11

Shaft HW0404402-1

Speed reducer

HW0381463-A

Washer HW0404196-5

Hexagon socket head cap screw M4

(length: 45 mm)

Conical spring washer 2H-4

Cover HW0305305-1

GT-SA bolt M6

(length: 20 mm)

Oil seal AE1314A0

1

6

1

1

1

Qty. Notes

1 SGMPH-02ANA-YR11

4

3

Tightening torque:

6 N•m

Tightening torque:

10 N•m

1

Wave generator

1

1 each

Tightening torque:

4.8 N•m

Tightening torque:

10 N•m

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5.4 Disassembly and Reassembly of R-Axis Motor

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

2

1

5 6 7

8

9

10

3

11

4

Apply ThreeBond 1206C.

(See the step 4 of the R-axis reassembly procedure.)

Casing

Fill with Harmonic grease SK-1A.

(See the step 3 of the R-axis reassembly procedure.)

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5 Disassembly and Reassembly of Motors

5.5 Disassembly and Reassembly of B-Axis Motor

5.5 Disassembly and Reassembly of B-Axis Motor

• Refer to

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

.

 Disassembly

1. Turn OFF the DX100 power supply.

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.

2 1

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

 Reassembly

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 .

1

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

5 5 "B-Axis Motor Parts Checklist"

.

Table

8. Turn ON the DX100 power supply.

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5.5 Disassembly and Reassembly of B-Axis Motor

Table 5 5: B-Axis Motor Parts Checklist

No. Name

1 B-axis motor HW0389298-A

2 GT-SA bolt M5

(length: 20 mm)

3

4

5

6

Pulley HW9482727-A

Hexagon socket head cap screw M4

(length: 16 mm)

Conical spring washer 2H-4

Cover HW9200798-1

GT-SA bolt M5

(length: 12 mm)

Qty. Notes

1 SGMPH-02ANA-YR11

2 Tightening torque:

6 N•m

1

1 each

Tightening torque:

4.8 N•m

2

24 Tightening torque:

6 N•m

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

2 1

5

6

6 5 4 3

U-arm

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5.6 Disassembly and Reassembly of T-Axis Motor

5.6 Disassembly and Reassembly of T-Axis Motor

• Refer to

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

 Disassembly

1. Turn OFF the DX100 power supply.

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”

.)

5

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.

2 1

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

 Reassembly

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 .

1

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

7. Turn ON the DX100 power supply.

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5.6 Disassembly and Reassembly of T-Axis Motor

Table 5 6: T-Axis Motor Parts Checklist

No. Name

1 T-axis motor HW0389298-A

2 GT-SA bolt M5

(length: 20 mm)

3

4

5

Pulley HW9482727-A

Hexagon socket head cap screw M4

(length: 16 mm)

Conical spring washer 2H-4

B-axis motor HW0382152-A

Qty. Notes

1 SGMPH-02ANA-YR11

2 Tightening torque:

6 N•m

1

1 each

Tightening torque:

4.8 N•m

1

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

5 3 4

2

1

U-arm

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HP20D 6 Disassembly and Reassembly of Speed Reducer

6.1 Disassembly and Reassembly of S-Axis Speed Reducer

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” .

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.

 Disassembly

1. Turn OFF the DX100 power supply.

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”

.)

4

3. Remove the hexagon socket head cap screws , then remove the Mbase .

6

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.

2 1

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.

1 1

2. Tighten the GT-SA bolts with the tightening torque shown in

6 1 "S-Axis Speed Reducer Parts Checklist" .

Table

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

4. Tighten the GT-SA bolts with the tightening torque shown in

6 1 "S-Axis Speed Reducer Parts Checklist" .

Table

5. Remove the old sealing bond on the matching surface between the Mbase 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" .

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6.1 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” .)

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

8. Turn ON the DX100 power supply.

Table 6 1: S-Axis Speed Reducer Parts Checklist

No. Name

1 Speed reducer HW0387753-B

2

3

4

GT-SA bolt M10

(length: 40 mm)

GT-SA bolt M12

(length: 35 mm)

S-axis motor HW0388932-A

5

6

M-base HW0305306-2

Hexagon socket head cap screw M8

(length: 60 mm)

Conical spring washer 2H-8

Qty. Notes

1

16

9

1

Tightening torque:

82 N•m

Tightening torque:

142 N•m

SGMRV-09ANA-YR11

1

3 each

Tightening torque:

24.5 N•m

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

4

3

6

5

S-head

Internal wiring harness

Base

2

1

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6.2 Disassembly and Reassembly of L-Axis Speed Reducer

6.2 Disassembly and Reassembly of L-Axis Speed Reducer

• Refer to

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

Reducer” .

 Disassembly

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

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

3

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.)

 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.)

1 1

2. Tighten the GT-SA bolts with the tightening torque shown in

6 2 "L-Axis Speed Reducer Parts Checklist"

.

Table

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

4. Tighten the hexagon socket head cap screws and with the

tightening torque shown in Table 6 2 "L-Axis Speed Reducer Parts

Checklist" .

4 5

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

6. Turn ON the DX100 power supply.

Table 6 2: L-Axis Speed Reducer Parts Checklist

No. Name

1 Speed reducer HW0387753-C

2 GT-SA bolt M10

(length: 40 mm)

3

4

5

L-arm HW0100546-2

Hexagon socket head cap screw M12

(length: 40 mm)

Conical spring washer 2H-12

Hexagon socket head cap screw M10

(length: 35 mm)

Conical spring washer 2H-10

Qty. Notes

1

14 Tightening torque:

82 N•m

1

12 each

Tightening torque:

142 N•m

6 each

Tightening torque:

82 N•m

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6.2 Disassembly and Reassembly of L-Axis Speed Reducer

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

2

S-head

1

L-axis motor

Internal wiring harness

Input gear

3

5

4

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6.3 Disassembly and Reassembly of U-Axis Speed Reducer

6.3 Disassembly and Reassembly of U-Axis Speed Reducer

• Refer to

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

Reducer” .

 Disassembly

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

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.

3

4. Remove the U-axis motor from the U-arm unit.

(Perform “Disassembly”

in section 5.3 “Disassembly and Reassembly of U-Axis Motor” .)

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

4

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

 Reassembly 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

"U-Axis Speed Reducer Parts Checklist" .

Table 6 3

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.

1

4. Tighten the GT-SA bolts with the tightening torque shown in

6 3 "U-Axis Speed Reducer Parts Checklist" .

Table

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

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.

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

9. Turn ON the DX100 power supply.

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6.3 Disassembly and Reassembly of U-Axis Speed Reducer

Table 6 3: U-Axis Speed Reducer Parts Checklist

No. Name

1 Speed reducer HW9280880-G

2

3

GT-SA bolt M8

(length: 45 mm)

Hexagon socket head cap screw M14

(length: 35 mm)

Conical spring washer GT-SH-14

4

5

Hexagon socket head cap screw M4

(length: 65 mm)

Conical spring washer 2H-4

Input gear

Qty. Notes

1

12

6 each

Tightening torque:

26.5 N•m

Tightening torque:

226 N•m

1 each

1

Tightening torque:

4.8 N•m

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

U-arm unit

U-axis motor

1 2

4

3

5

L-arm

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6.4 Disassembly and Reassembly of R-Axis Speed Reducer

6.4 Disassembly and Reassembly of R-Axis Speed Reducer

• Refer to

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

Reducer” .

 Disassembly

1. Turn OFF the DX100 power supply.

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 .

5 4

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

6

 Reassembly

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

4. Tighten the GT-SA bolts with the tightening torque shown in

6 4 "R-Axis Speed Reducer Parts Checklist" .

Table

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” .)

6. Turn ON the DX100 power supply.

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6.4 Disassembly and Reassembly of R-Axis Speed Reducer

Table 6 4: R-Axis Speed Reducer Parts Checklist

No. Name

1 Speed reducer

HW0381463-A

2

3

4

5

6

Speed reducer

HW0381463-A

Speed reducer

HW0381463-A

Shaft HW0404403-1

GT-SA bolt M6

(length: 20 mm)

Hexagon socket head cap screw M4

(length: 20 mm)

Conical spring washer 2H-4

1

1

1

8

Qty. Notes

1 Circular spline

12 each

Flex spline

Wave generator

Tightening torque:

16.5 N•m

Tightening torque:

2.8 N•m

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

1 3

2

5

Casing

R-axis motor

6 4

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6.5 Disassembly and Reassembly of B-Axis Speed Reducer

6.5 Disassembly and Reassembly of B-Axis Speed Reducer

• Refer to

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

Reducer” .

 Disassembly

1. Turn OFF the DX100 power supply.

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

14

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 .

7

 Reassembly

2. Tighten the GT-SA bolts with the tightening torque shown in

6 5 "B-Axis Speed Reducer Parts Checklist" .

Table

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.

2

4. Tighten the GT-SA bolts with the tightening torque shown in

6 5 "B-Axis Speed Reducer Parts Checklist" .

Table

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

"B-Axis Speed Reducer Parts Checklist"

.

Table 6 5

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

3

8. Tighten the GT-SA bolts with the tightening torque shown in

6 5 "B-Axis Speed Reducer Parts Checklist" .

Table

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

12. Tighten the GT-SA bolts with the tightening torque shown in

6 5 "B-Axis Speed Reducer Parts Checklist" .

Table

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6.5 Disassembly and Reassembly of B-Axis Speed Reducer

13. Turn ON the DX100 power supply.

Table 6 5: B-Axis Speed Reducer Parts Checklist

No. Name

1 Speed reducer

HW9381633-A

2

3

Speed reducer

HW9381633-A

Speed reducer

HW9381633-A

4

5

6

7

8

GT-SA bolt M4

(length: 16 mm)

Timing belt 80S4.5M653

Pulley HW9482725-A

Hexagon socket head cap screw M5

(length: 16 mm)

Conical spring washer 2H-5

Bearing 6002ZZ

9

10

11

12

13

14

15

GT-SA bolt M4

(length: 12 mm)

Cover HW9200798-1

GT-SA bolt M5

(length: 12 mm)

Bearing 6901ZZ

GT-SA bolt M5

(length: 16 mm)

GT-SA bolt M5

(length: 20 mm)

Housing HW9405792-1

1

4

Qty. Notes

1 Flex spline

1

1

12

1

1

1 each

2

24

1

11

2

1

Circular spline

Wave generator

Tightening torque:

2.8 N•m

Tightening torque:

10 N•m

Tightening torque:

2.8 N•m

Tightening torque:

6 N•m

Tightening torque:

6 N•m

Tightening torque:

6 N•m

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HP20D 6 Disassembly and Reassembly of Speed Reducer

6.5 Disassembly and Reassembly of B-Axis Speed Reducer

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

B-axis motor Wrist base U-arm

14 13 1 12

2

5

10

4 9 8

7

6

15

3

11

6-11

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6 Disassembly and Reassembly of Speed Reducer

6.6 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

1. Turn OFF the DX100 power supply.

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”

.

10

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

5 6

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

3. Apply Loctite 242 to the thread part of the hexagon socket head cap screw . Then, tighten it with the tightening torque shown in

"T-Axis Speed Reducer Parts Checklist" .

Table 6 6

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

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.

Shim Type

SP012010

SP012015

SP012020

SP012050

Thickness (mm)

0.1

0.15

0.2

0.5

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

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"

.

10. Tighten the GT-SA bolts with the tightening torque shown in

6 6 "T-Axis Speed Reducer Parts Checklist"

.

Table

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6 Disassembly and Reassembly of Speed Reducer

6.6 Disassembly and Reassembly of T-Axis Speed Reducer

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

2

12. Tighten the GT-SA bolts with the tightening torque shown in

6 6 "T-Axis Speed Reducer Parts Checklist" .

Table

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

14. Turn ON the DX100 power supply.

Table 6 6: T-Axis Speed Reducer Parts Checklist

No. Name

1 Speed reducer

HW0382140-A

2

3

Speed reducer

HW0382140-A

Speed reducer

HW0382140-A

4

5

6

7

8

9

10

GT-SA bolt M5

(length: 12 mm)

GT-SA bolt M4

(length: 12 mm)

Housing HW0304086-1

Gear HW9381659-A

Hexagon socket head cap screw M5

(length: 16 mm)

Conical spring washer 2H-5

Shim

(Refer to the table in the previous page.)

GT-SA bolt M5

(length: 16 mm)

Qty. Notes

1 Flex spline

1

1

8

8

1

1

1 each

4

Circular spline

Wave generator

Tightening torque:

10 N•m

Tightening torque:

2.8 N•m

Tightening torque:

10 N•m

Tightening torque:

10 N•m

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6 Disassembly and Reassembly of Speed Reducer

6.6 Disassembly and Reassembly of T-Axis Speed Reducer

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

8 9

5

3

1

4

Wrist base

7

A

6

2

10

Flange

6-14

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7 Disassembly and Reassembly of Wrist Unit

7 Disassembly and Reassembly of Wrist Unit

• Refer to

Fig. 7 1 “Disassembly and Reassembly of Wrist Unit”

.

NOTE

Refer to chapter 2 “Notes for Maintenance”

,

chapter 3

“Home Position Return” , and

chapter 10 “Cable Wiring”

.

 Disassembly

1. Turn OFF the DX100 power supply.

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 .

2

 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.

5. Tighten the GT-SA bolts with the tightening torque shown in

7 1 "Wrist Unit Parts Checklist" .

Table

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

8. Tighten the GT-SA bolts with the tightening torque shown in

7 1 "Wrist Unit Parts Checklist" .

Table

9. Turn ON the DX100 power supply.

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7 Disassembly and Reassembly of Wrist Unit

Table 7 1: Wrist Unit Parts Checklist

No. Name

1 Wrist unit

2

Hexagon socket head cap screw M6

(length: 65 mm)

Conical spring washer 2H-6

3

4

5

6

Support HW9406556-1

GT-SA bolt M4

(length: 12 mm)

Cover HW9200798-1

GT-SA bolt M5

(length: 12 mm)

1

2

Qty. Notes

1 Mass: 14.5 kg

8 each

Tightening torque:

10 N•m

Tightening torque:

2.8 N•m

1

12 Tightening torque:

6 N•m

Fig. 7 1: Disassembly and Reassembly of Wrist Unit

2

6 4

3

5

1

B- and T-axis internal wiring harness

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HP20D 8 Disassembly, Reassembly, and Adjustment of B- and T-axis Timing

Belts

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

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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”

.)

 Reassembly

(Refer to

section 5.5 “Disassembly and Reassembly of B-Axis Motor”

and

section 5.6 “Disassembly and Reassembly of T-Axis Motor”

.)

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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

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

No. Name

1 B-axis timing belt 80S4.5M653

2

T-axis timing belt 80S4.5M518

3

4

5

6

T-axis motor HW0389298-A

GT-SA bolt M5

(length: 20 mm)

B-axis motor HW0389298-A

GT-SA bolt M5

(length: 20 mm)

7

8

9

10

Cover HW9200798-1

GT-SA bolt M5

(length: 12 mm)

Pulley HW9482727-A

Pulley HW9482727-A

1

1

1

2

1

2

Qty. Notes

1

1

SGMPH-02ANA-YR11

Tightening torque:

6 N•m

SGMPH-02ANA-YR11

Tightening torque:

6 N•m

2

24 Tightening torque:

6 N•m

For B-axis

For T-axis

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

8 7 6 5 10 2

8 7 9 4 3 1

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HP20D 8 Disassembly, Reassembly, and Adjustment of B- and T-axis Timing

Belts

8.2 Adjustment of Timing Belts

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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.

9

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.

6

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:

Belt width:

34 gram per meter (width: 10 mm)

8 mm

Distance 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.

10

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

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:

Belt width:

34 gram per meter (width: 10 mm)

8 mm

Distance between axes: 184 mm

Table 8 2: Initial Tension of Timing Belt

B-axis

T-axis

Initial tension

15 to 36 N (1.5 to 3.6 kgf)

15 to 36 N (1.5 to 3.6 kgf)

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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

Battery pack

Connector base

Support

Connector base fixing screw

Connector base

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HP20D 9 Battery Pack Replacement

Fig. 9 2: Battery Pack Connection

See the step 5

Connector

Circuit board

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Battery pack before replacement

See the step 4

New battery pack

(HW0470360-A)

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.

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

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

7. Reinstall the plate.

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

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10 Cable Wiring

10 Cable Wiring

10.1 Disconnecting Cables

NOTE

To 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” .)

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.

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

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

No. Name

1 Cover HW9200798-1

2

3

4

GT-SA bolt M5

(length: 12 mm)

GT-SA bolt M4

(length: 12 mm)

Support HW9406556-1

Qty. Notes

1

12

2

Tightening torque:

6 N•m

Tightening torque:

2.8 N•m

1

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10.1 Disconnecting Cables

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

B-axis internal wiring harness, connector

B- and T-axis internal wiring harness

3 4

B-axis motor

T-axis internal wiring harness, connector

T-axis motor

1

Wrist unit

2

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10 Cable Wiring

10.1 Disconnecting Cables

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.

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.

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

6

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

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

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

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10 Cable Wiring

10.1 Disconnecting Cables

Table 10 2: U-Arm Cable Wiring Parts Checklist

No. Name

1 Cover HW0305305-1

2

3

4

GT-SA bolt M6

(length: 20 mm)

Cross head APS bolt M4

(length: 10 mm)

Pan-head sems screw M3

(length: 16 mm)

Nut M3

5

6

7

8

N-base HW0404900-1

GT-SA bolt M5

(length: 16 mm)

Hexagon socket head cap screw M5

(length: 35 mm)

Conical spring washer 2H-5

S-cover HW0200530-1

Support HW0404919-1

9

10

11

12

13

Cross head APS bolt M5

(length: 8 mm)

GT-SA bolt M4

(length: 16 mm)

Stopper HW0404179-1

GT-SA bolt M4

(length: 12 mm)

Support HW0304930-1

14

15

16

17

18

19

GT-SA bolt M4

(length: 12 mm)

GT-SA bolt M4

(length: 12 mm)

Saddle HW0404503-1

Hexagon socket head cap screw M4

(length: 20 mm)

Conical spring washer 2H-4

Support HW0304914-1

Support HW0304918-1

1

1

1

4

1

2

2

1

1

2

2

Qty. Notes

1

6 Tightening torque:

10 N•m

4

2 each

1

4

2 each

2

4 each

For part

For part

A

B

Tightening torque:

2.8 N•m

Tightening torque:

2.8 N•m

Tightening torque:

2.8 N•m

Tightening torque:

2.8 N•m

Tightening torque:

2.8 N•m

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10 Cable Wiring

10.1 Disconnecting Cables

Fig. 10 2: U-Arm Cable Wiring

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10 Cable Wiring

10.1 Disconnecting Cables

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.

1

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.

6

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

7

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

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

C-base .

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10 Cable Wiring

10.1 Disconnecting Cables

Table 10 3: S-Head Cable Wiring Parts Checklist

No. Name

1 Cover HW0304227-1

2

3

Cross head APS bolt M6

(length: 8 mm)

Cover HW0305809-1

4

5

6

7

Cross head APS bolt M5

(length: 10 mm)

GT-SA bolt M6

(length: 15 mm)

Holder HW0305812-1

Hexagon socket head cap screw M6

(length: 10 mm)

Conical spring washer 2H-6

8

9

10

11

Saddle CD-31

Cross head APS bolt M5

(length: 10 mm)

C-base HW0303378-2

GT-SA bolt M5

(length: 12 mm)

12

13

14

15

16

17

Cover HW0305698-1

GT-SA bolt M5

(length: 12 mm)

Holder HW0305813-1

GT-SA bolt M5

(length: 12 mm)

Saddle FCD-31

Support HW0304226-1

1

2

1

4

1

4

2

1

1

1

2

1

6

Qty. Notes

1

4

1

2 each

Tightening torque:

10 N•m

Tightening torque:

10 N•m

Tightening torque:

6 N•m

Tightening torque:

6 N•m

Tightening torque:

6 N•m

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HP20D 10 Cable Wiring

10.1 Disconnecting Cables

Fig. 10 3: S-Head Cable Wiring

8

7

5

6

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L-axis motor

S-axis motor

Cable ties (2 pieces)

T18S

Apply sealing bond to the hatched area.

10

S-axis connector

9

17

Internal wiring harness

2

1

S-head

4

3

12

11

16

15

14

13

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10 Cable Wiring

10.2 Connecting Cables

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.

10

10

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”

).

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

Cable Wiring Parts Checklist"

.

Table 10 3 "S-Head

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"

.

5

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"

.

13

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 Laxis motor.

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

3

12. Tighten the GT-SA bolts with the tightening torque shown in

10 3 "S-Head Cable Wiring Parts Checklist" .

Table

13. Fix the white marked part of the internal wiring harness to the support

17

by using cable ties.

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

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10 Cable Wiring

10.2 Connecting Cables

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 .

18 19

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

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

7. Tighten the GT-SA bolts with the tightening torque shown in

10 2 "U-Arm Cable Wiring Parts Checklist" .

Table

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-

9. Tighten the GT-SA bolts with the tightening torque shown in

10 2 "U-Arm Cable Wiring Parts Checklist" .

Table

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" .

6

14. Mount the internal wiring harness connector to the N-base with the

4 the connector is set upward. Then, insert the air line tube.

5 pan-head sems screws . At this time, make sure that the main key of

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.

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10 Cable Wiring

10.2 Connecting Cables

19. Apply ThreeBond 1206C to the matching surface between the cover

2 shown in

Table 10 2 "U-Arm Cable Wiring Parts Checklist" .

1 and the casing. Tighten the GT-SA bolts with the tightening torque

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.

3. Tighten the GT-SA bolts with the tightening torque shown in

10 1 "B- and T-Axis Cable Wiring Parts Checklist" .

Table

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 .

1

7. Tighten the GT-SA bolts with the tightening torque shown in

10 1 "B- and T-Axis Cable Wiring Parts Checklist" .

Table

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HP20D 11 Parts List

11.1 S-Axis Unit

11 Parts List

11.1 S-Axis Unit

Fig. 11 1: S-Axis Unit

1011

1012

1010

1013

1022

1021

1024

1023

1027

1014

1024

1023

1026

1009

1020

1030

1008

1001

1034

1036

1035

1031

1032

1030

1033

159281-1CD

1016

1015 1017

1018

1025

1014

1020

1006

1004

1003

1005

1002

11-1

1028

1029

1007

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11 Parts List

11.1 S-Axis Unit

Table 11 1: S-Axis Unit

1023

1024

1025

1026

1027

1028

1029

1030

1015

1016

1017

1018

1019

1020

1021

1022

1031

1032

1033

1034

1035

1036

1007

1008

1009

1010

1011

1012

1013

1014

No.

1001

1002

1003

1004

1005

1006

HW0304221-1

M6X15

MSB8-15

HW0400645-1

M5X10

TSH6-01M

CD-31

M6X10

TA1-S10

M5X10

EZ5036A0

M6X15

HW0305812-1

HW9406775-1

M6X8

M12

DWG No.

SGMRV-09ANA-YR1*

HW0100545-2

M16X20

2H-16

HW0387753-B

M10X40

HW0100544-2

M8X30

HW0305306-2

M5X10

PT1/8

UKM6-01

HW0305809-1

NB-0640-0.3

M8X60

2H-8

M12X35

HW0313491-1

M6X60

2H-6

Name

Motor

S-head

Socket screw

Conical spring washer

Speed reducer

GT-SA bolt

Base

GT-SA bolt

M-base

APS bolt

Plug

Union

Cover

Tube

Cover

GT-SA bolt

Shoulder

Lever

APS bolt

Union

Saddle

Socket screw

Clamp

Screw with spring washer

Cap

GT-SA bolt

Holder

Cover

APS bolt

Eye bolt

Socket screw

Conical spring washer

GT-SA bolt

Gear

Socket screw

Conical spring washer

1

2

1

1

1

2

2

2

1

2

6

2

1

1

1

2

1

1

3

3

12

1

1

2

1

1

1

1

1

3

1

1

1

16

Pcs.

1

1

11-2

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HP20D 11 Parts List

11.2 L-Axis Unit

11.2 L-Axis Unit

Fig. 11 2: L-Axis Unit

2012

2011

2010

2009

2017

2008

2005

2023

2024

2025 2001

2019 2018

2006

2003

2002

2004

2007

2026

2027

2028

2014

2013

2014

2013

2016

2015

2022

2021

2020

2030

2033

2034

2031

2029

2035

2036

2031

2032

1002

11-3

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11 Parts List

11.2 L-Axis Unit

2025

2026

2027

2028

2029

2030

2031

2032

Table 11 2: L-Axis Unit

2007

2008

2009

2010

2011

2012

2013

2014

No.

2001

2002

2003

2004

2005

2006

2015

2016

2017

2018

2019

2020

2021

2022

2023

2024

2033

2034

2035

2036

1002

DWG No.

SGMRV-13ANA-YR2*

M6X90

2H-6

HW0313492-1

HW0304229-1

Y426012.5

HW0401506-1

HW0304226-1

M6X10

2H-6

HW0304227-1

M6X8

M12X40

2H-12

M10X35

2H-10

HW0100546-2

HW0387753-C

M10X40

M12X40

2H-12

HW0404196-4

M8X30

M8X25

*DACROTIZED coating*

2H-8

*DACROTIZED coating*

TA1-S10

M5X10

M6X10

HW0305813-1

HW0305698-1

M5X12

PT1/8

*DACROTIZED coating*

CD-31

M5X12

TA1-S10

M5X10

HW0100545-2

Name

Motor

Socket screw

Conical spring washer

Gear

M-base

Oil seal

Plate

Support

Socket screw

Conical spring washer

Cover

APS bolt

Socket screw

Conical spring washer

Socket screw

Conical spring washer

L-arm

Speed reducer

Socket screw

Socket screw

Conical spring washer

Washer

GT-SA bolt

Socket screw

Conical spring washer

Clamp

Screw with spring washer

Socket screw

Holder

Cover

GT-SA bolt

Plug

Saddle

GT-SA bolt

Clamp

Screw with spring washer

S-head

4

6

1

1

1

4

4

1

1

2

2

2

1

1

4

12

12

2

2

1

1

1

1

1

1

Pcs.

1

1

4

4

2

1

16

2

1

1

6

6

11-4

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HP20D 11 Parts List

11.3 U-Axis Unit

Fig. 11 3: U-Axis Unit

11.3 U-Axis Unit

3019

3019

3006

3016

3018

3017

3020

3005

3011

3010

3015

2017

3009

3008

3013

3014

3007

3016

3018

3017

3001

3003

3004

3002 3003

3004

3002

3012

11-5

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HP20D

11 Parts List

11.3 U-Axis Unit

Table 11 3: U-Axis Unit

3007

3008

3009

3010

3011

3012

3013

3014

No.

3001

3002

3003

3004

3005

3006

3015

3016

3017

3018

3019

3020

2017

DWG No.

SGMRV-05A3A-YR1*

HW0313489-1

M4X10

M4

HW0102379-1

HW9280880-G

M8X45

M5X65

2H-5

M14X35

GT-SH-14

M8X30

M10X20

H-10

M6X10

HW0404196-2

M10X35

2H-10

PT1/8

EZ2940A0

HW0100546-2

Name

Motor

Cover

APS bolt

Washer

Casing

Speed reducer

GT-SA bolt

Socket screw

Conical spring washer

Socket screw

GT-SH washer

GT-SA bolt

Socket screw

Conical spring washer

Socket screw

Washer

Socket screw

Conical spring washer

Plug

Cap

L-arm

1

1

6

4

1

6

16

1

1

1

7

7

Pcs.

1

1

2

1

1

2

2

1

2

11-6

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HP20D 11 Parts List

11.4 R-Axis Unit

Fig. 11 4: R-Axis Unit

11.4 R-Axis Unit

4033 4012

4031

4032

4058

4074

4005

4056

159281-1CD

4029

4008

4071

4010

4030 4029

4009

4006

4007

4042

3005

4057

4036

4072

4066

4043

4035

4044

4011

4003

4037

4025

3014

4076

4075

4026

4028

4027

4034

4023

4022

4073

4060

4039

4055

4040

4051

4062

3012

4045

4046

4020

4013

4024

4019

4017 4067

4065

4015

4021

4014

4002

4001

4016

4004

4069

4068

4070

4018

5046

11-7

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HP20D

11 Parts List

11.4 R-Axis Unit

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

4023

4024

4025

4026

4027

4028

4029

4030

4015

4016

4017

4018

4019

4020

4021

4022

4007

4008

4009

4010

4011

4012

4013

4014

No.

4001

4002

4003

4004

4005

4006

4040

4042

4043

4044

4045

4046

4031

4032

4033

4034

4035

4036

4037

4039

AE1314A0

HW0304932-1

HW0404402-1

2H-4

HW0404900-1

M4X10

M5X16

TA1-S8

M4X8

M5X8

M6X6

LP-M5

M5X35

2H-5

DWG No.

M6X65

2H-6

M5X20

M4X12

HW0305305-1

M4X20

2H-4

HW0404196-5

M6X20

M4X45

M6X6

A-MT6X1

HW0381872-A

M6X35

HW0403879-1

TC941045*A727*

HW0403857-1

HW0405201-2

HW0304318-1

HW0304085-1

HW0304914-1

HW0403879-1

M4X20

M4X12

HW0200530-1

HW0404919-1

M5X16

2H-5

HW0381463-A

HW0404403-1

Name

Socket screw

Conical spring washer

GT-SA bolt

GT-SA bolt

M-cover

Socket screw

Conical spring washer

Washer

GT-SA bolt

Socket screw

Socket screw

G Nipple

Cross roller bearing

GT-SA bolt

Saddle

Oil seal

Shaft

Block

Housing

Shaft

Support

Saddle

Socket screw

GT-SA bolt

S-cover

Support

Socket screw

Conical spring washer

Speed reducer

Shaft

Oil seal

M-base

Shaft

Conical spring washer

N-base

Screw with spring washer

GT-SA bolt

Clamp

Screw with spring washer

APS bolt

Socket screw

Plug

Socket screw

Conical spring washer

11-8

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1

1

2

2

1

1

2

2

1

1

1

1

1

1

1

1

1

8

1

1

8

1

12

1

4

4

1

12

Pcs.

8

8

1

1

4

1

2

2

4

4

1

4

1

2

1

1

HP20D 11 Parts List

11.4 R-Axis Unit

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

4062

4065

4066

4067

4068

4069

4070

4071

No.

4051

4055

4056

4057

4058

4060

4072

4073

4074

4075

4076

3005

3012

3014

5046

DWG No.

M4X12

HW0404918-1

SGMPH-02A2A-YR1*

EZ5036A0

M6X20

HW0304930-1

6811LLU

M4X20

KQE12-03

2H-4

M4X20

2H-4

MS4-10

2H-4

PT 3/8

M4X12

M6X30

TA1-S8

M4X8

HW0102378-1

M4X16

HW0404179-1

HW0100623-1

Name

GT-SA bolt

Support

Motor

Cap

GT-SA bolt

Support

Bearing

Socket screw

Union

Conical spring washer

Socket screw

Conical spring washer

Pin

Conical spring washer

Plug

GT-SA bolt

GT-SA bolt

Clamp

Screw with spring washer

Casing

GT-SA bolt

Support

U-arm

159281-1CD

2

1

2

2

1

2

1

2

6

1

1

1

Pcs.

2

1

4

2

3

1

1

3

3

1

2

11-9

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HP20D

11 Parts List

11.5 Wrist Unit

Fig. 11 5: Wrist Unit

11.5 Wrist Unit

3005

5045

5047

5032

5050

5045

5046

5005

5001

5002

5003

5006

5007

5011

5008

5007

5008

5005

5031

5029

5044

5006

5037

5003

5048

5043

5017

5049

5016

5040

5036

5041

5062

5039

5038

5012

5028

5042

5053

5023

5071

5020

5022

5064

5026

5071

5035

5019

5014

5013

5034

5063

5018

5027

5033

5021

5024

5025

5052

5026

5030

5065

5066

5060

11-10

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11 Parts List

11.5 Wrist Unit

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

5027

5028

5029

5030

5031

5032

5033

5034

5019

5020

5021

5022

5023

5024

5025

5026

5008

5011

5012

5013

5014

5016

5017

5018

No.

5001

5002

5003

5005

5006

5007

5043

5044

5045

5046

5047

5048

5035

5036

5037

5038

5039

5040

5041

5042

M5X16

6002ZZ

6901ZZ

6814ZZ

HW9482668-A

HW9381633-A

HW9405792-1

HW0200451-1

M5X16

80S4.5M653

M5X12

HW0100623-1

M6X6

M4X16

HW9482218-A

HW9405199-1

SP-0120**

HW9481180-A

M5X16

M5X12

HW0304232-1

TC60747

HW9481187-A

HW0304233-1

S75

HW0304087-1

HW0382140-A

HW0304086-1

HW9381659-A

HW9482726-A

DWG No.

HW9406556-1

M4X12

M5X20

HW9200798-1

SGMPH-02A2A-YR12

M4X16

HW9482727-A

80S4.5M518

HW9381658-A

M4X12

HW9405452-1

HW9482725-A

M5X16

M4X16

Bearing

B nut

Shim

Bearing

GT-SA bolt

GT-SA bolt

Shaft

Oil seal

Bearing

Shaft

O ring

Housing

Speed reducer

Housing

Gear

Pulley

Name

Support

GT-SA bolt

GT-SA bolt

Cover

Motor

Socket screw

Pulley

Belt

Gear

GT-SA bolt

B-cover

Pulley

GT-SA bolt

GT-SA bolt

Socket screw

Bearing

Bearing

Bearing

Oil seal

Speed reducer

Housing

Wrist base

GT-SA bolt

Belt

GT-SA bolt

U-arm

Socket screw

GT-SA bolt

11-11

HW1480357

1

1

1

1

1

1

1

1

1

2

1

8

1

1

1

1

1

4

1

1

1

4

2

1

2

2

4

2

Pcs.

1

2

11

1

24

1

1

13

1

1

1

1

1

1

1

1

94 of 96

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HP20D

11 Parts List

11.5 Wrist Unit

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

No.

5049

5050

5052

5053

5062

5063

5064

5065

5066

3005

DWG No.

M4X12

M6X6

M5X16

M6X6

LP-M5

HW9405791-3

6811LLU

HW0404606-1

HW040605-1

HW0102378-1

Name

GT-SA bolt

Socket screw

GT-SA bolt

Socket screw

Plug

Housing

Bearing

Cover

Plug

Casing

1

1

1

1

1

1

5

1

Pcs.

4

1

11-12

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MOTOMAN-HP20D

MAINTENANCE MANUAL

HEAD OFFICE

2-1 Kurosakishiroishi, Yahatanishi-ku, Kitakyushu 806-0004, Japan

Phone +81-93-645-7703 Fax +81-93-645-7802

YASKAWA America Inc. (Motoman Robotics Division)

100 Automation Way, Miamisburg, OH 45342, U.S.A.

Phone +1-937-847-6200 Fax +1-937-847-6277

YASKAWA Europe GmbH Robotics Divsion )

Yaskawastrasse 1, 85391 Allershausen, Germany

Phone +49-8166-90-100 Fax +49-8166-90-103

YASKAWA Nordic AB

Verkstadsgatan 2, Box 504 ,SE-385 25 Torsas, Sweden

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

YASKAWA Electric (China) Co., Ltd.

22F, One Corporate Avenue, No.222, Hubin Road, Huangpu District, Shanghai 200021, China

Phone +86-21-5385-2200 Fax 㸩 86-21-5385-3299

YASKAWA SHOUGANG ROBOT Co. Ltd.

No7 Yongchang North Road, Beijing E&T Development Area China 100176

Phone +86-10-6788-2858 Fax +86-10-6788-2878

YASKAWA India Private Ltd. (Robotics Division)

#426, Udyog Vihar, Phase- IV, Gurgaon, Haryana, India

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

YASKAWA Electric Korea Corporation

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

Phone +82-2-784-7844 Fax +82-2-784-8495

YASKAWA Electric Taiwan Corporation

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

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

YASKAWA Electric (Singapore) PTE Ltd.

151 Lorong Chuan, #04-02A, New Tech Park, Singapore 556741

Phone +65-6282-3003 Fax +65-6289-3003

YASKAWA Electric (Thailand) Co., Ltd.

59,1st-5th Floor, Flourish Building, Soi Ratchadapisek 18,Ratchadapisek Road,

Huaykwang, Bangkok 10310, THAILAND

Phone +66-2-017-0099 Fax +66-2-017-0199

PT. YASKAWA Electric Indonesia

Secure Building-Gedung B Lantai Dasar & Lantai 1 JI. Raya Protokol Halim Perdanakusuma,

Jakarta 13610, Indonesia

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

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

MANUAL NO.

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