Yaskawa Motoman HP20D Owner's 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.
159281-1CD
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Contents
1 Introduction ..................................................................................................................................... 1-1
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
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 (Refer to fig. 4-1 “S-Axis Speed Reducer” .) .................. 4-2
4.2.2 Grease Exchange (Refer to fig. 4-1 “S-Axis Speed Reducer” .) .......................... 4-3
4.3 Grease Replenishment and Exchange for L-Axis Speed Reducer .................................... 4-4
4.3.1 Grease Replenishment (Refer to fig. 4-2 “L-Axis Speed Reducer” .) .................. 4-4
4.3.2 Grease Exchange (Refer to fig. 4-2 “L-Axis Speed Reducer” .) .......................... 4-5
4.4 Grease Replenishment and Exchange for U-Axis Speed Reducer ................................... 4-6
4.4.1 Grease Replenishment (Refer to fig. 4-3 “U-Axis Speed Reducer” .).................. 4-6
4.4.2 Grease Exchange (Refer to fig. 4-3 “U-Axis Speed Reducer” .).......................... 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
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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
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
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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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Introduction
HP20D
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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Introduction
HP20D
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”.
Indicates an imminent hazardous
situation which, if not avoided, could
result in death or serious injury to
personnel.
DANGER
Indicates a potentially hazardous
situation which, if not avoided, could
result in death or serious injury to
personnel.
WARNING
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.
CAUTION
Always be sure to follow explicitly the
MANDATORY items listed under this heading.
PROHIBITED
Must never be performed.
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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Introduction
HP20D
WARNING
•
Before operating the manipulator, check that servo power is turned
OFF pressing the emergency stop buttons on the front door of the
DX100 and the programming pendant.
When the servo power is turned OFF, the SERVO ON LED on the
programming pendant is turned OFF.
Injury or damage to machinery may result if the emergency stop circuit
cannot stop the manipulator during an emergency. The manipulator
should not be used if the emergency stop buttons do not function.
Fig. : 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.
Fig. : 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.
The emergency stop buttons are located on the right of front door of the
DX100 and the programming pendant.
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Introduction
HP20D
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:
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Introduction
HP20D
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
Manual Designation
DX100 controller
DX100
DX100 programming pendant
Programming pendant
Cable between the manipulator and the
controller
Manipulator cable
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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Introduction
HP20D
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.
Fig. : Warning Label Locations
Warning label B
Warning label A
Warning label B
Nameplate
Nameplate
Warning Label A:
WARNING
MODEL
MOTOMANTYPE
kg
ORDER NO.
Moving parts
may cause
injury
MASS
PAYLOAD
kg
DATE
SERIAL NO.
YASKAWA ELECTRIC CORPORATION
2-1 Kurosakishiroishi, Yahatanishi-ku,
Kitakyushu 806-0004 Japan
MADE IN JAPAN
NJ3247
Warning Label B:
WARNING
Do not enter
robot
work area.
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2.1
HP20D
2
Notes for Maintenance
Wrist Unit
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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2.2
HP20D
2.2
Notes for Maintenance
Encoder Connector (with CAUTION Label)
Encoder Connector (with CAUTION Label)
Before disconnecting the encoder connector (with CAUTION label),
connect the battery pack to the motor referring to fig. 2-2 “Battery Pack
Connection” .
2.2.1
Battery Pack Connection for S-, L-, and U-axis Motors
The connectors (crimped contact-pin) for the battery backup are installed
at the end point of the motor (BAT and OBT are marked). Connect the
battery pack according to the following procedure.
1. Remove the caps attached to the battery backup connectors of the
motor.
2. Connect the battery pack (HW9470932-A) with the battery backup
connectors located at the end point of the encoder cable. (Under this
condition, remove the encoder connector and carry out the
maintenance checks.)
3. After the maintenance check, confirm that all the connectors are
connected, then remove the battery pack. Install the caps attached to
the battery backup connectors of the motor.
2.2.2
Battery Pack Connection for R-, B-, and T-axis Motors
The connectors (crimped contact-pin) for the battery backup are installed
at the end point of the encoder cables for the motor (BAT and OBT are
marked). Connect the battery pack according to the following procedure.
1. Connect the battery pack (HW9470932-A) with the battery backup
connectors located at the end point of the encoder cable. (Under this
condition, remove the encoder connector and carry out the
maintenance checks.)
2. After the maintenance check, confirm that all the connectors are
connected, then remove the battery pack.
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2.2
HP20D
Notes for Maintenance
Encoder Connector (with CAUTION Label)
Fig. 2-2: Battery Pack Connection
Motor
S-, L-, U-axis motor
Encoder connector
CAUTION
Motor power connector
Connect battery to encoder
to save the data before
removing connector.
CAUTION label
0BT
b
a 0BT1
BAT
a
b BAT1
Battery pack (HW9470932-A)
Battery backup connector
a: Crimped contact-pin (pin)
b: Crimped contact-pin (socket)
Encoder
R-, B-, T-axis motor
Motor
Motor cable, etc.
Internal
wire
Power connector
a 0BT1
0BT
b
BAT
a
b BAT1
CAUTION
Connect battery to encoder
to save the data before
removing connector.
Encoder connector
Battery pack (HW9470932-A)
Battery backup connector
CAUTION label
CAUTION Label (Enlarged View)
CAUTION
0BT
b
a
0BT1
BAT
a
b
BAT1
a: Crimped contact-pin (pin)
b: Crimped contact-pin (socket)
Connect battery to encoder
to save the data before
removing connector.
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3.1
HP20D
3
Home Position Return
Home Position Return after Motor Replacement
Home Position Return
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.
NOTE
• 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
3.1.1
Home Position Return after Motor Replacement
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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3.1
Home Position Return
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.
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.
2
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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3.1
Home Position Return
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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3.1.3.2
3
3.1
Home Position Return
Home Position Return after Motor Replacement
Motor Replacement
• Refer to the fig. 3-2 “Motor Replacement (Example)” .
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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3.1.3.3
3
3.1
Home Position Return
Home Position Return after Motor Replacement
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. RECTO-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. RECTO-A215).)
Move the axis again to the check-point by the check-JOB. Check if the
axis is at the check-point created before the operation. (If it is deviated,
repeat the adjustment procedures.)
Perform an operation check by using the JOB used before motor
replacement. If no problem is found, write down the modified home
position data (ABSO data) and the date in the label on the inside of the
DX100.
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3.2
HP20D
3.2
3.2.1
Home Position Return
Home Position Return in Case of Exhaustion of Robot-Axis Motor
Battery
Home Position Return in Case of Exhaustion of Robot-Axis Motor Battery
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
HW1408504-1
Shaft
1
For S-, L-, and Uaxes
HW2402221-1
Shaft
1
For R-axis
S-Axis Positioning
As shown in fig. 3-3 “S-Axis Positioning” , insert the shaft HW1408504-1
in the hole ( 6 +0.012
dia. ) on the S-head. Then, perform positioning with
0
the programming pendant so that the shaft fits into the hole on the base.
Fig. 3-3: S-Axis Positioning
S-head
Shaft
Base
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3.2
HP20D

Home Position Return
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 HW1408504-1
in the hole ( 6 +0.012
dia. ) on the S-head. Then, perform positioning with
0
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 HW1408504-1
in the hole ( 6 +0.012
dia. ) on the casing. Then, perform positioning with
0
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
HP20D

Home Position Return
Home Position Return in Case of Exhaustion of Robot-Axis Motor
Battery
R-Axis Positioning
As shown in fig. 3-6 “R-Axis Positioning” , insert the shaft HW2402221-1
in the hole ( 4 +0.012
dia. ) on the U-arm. Then, perform positioning with
0
the programming pendant so that the shaft fits into the hole on the casing.
Fig. 3-6: R-Axis Positioning
U-arm
Shaft
Casing
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4.1
HP20D
4
Grease Replenishment and Exchange
Notes on Grease Replenishment and Exchange Procedures
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.
• 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.
NOTE
• Do not install a joint, a hose, etc. to the grease exhaust
port. Failure to observe this instruction may result in damage to the motor due to coming off of an oil seal.
• Make sure to use a 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
HP20D
4.2
Grease Replenishment and Exchange
Grease Replenishment and Exchange for S-Axis Speed Reducer
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)
NOTE
4.2.1
S-axis speed reducer
For ceiling mounted manipulators, the exhaust port and the
grease inlet are inverted.
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
4. Move the S-axis for a few minutes to discharge excess grease.
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4.2
Grease Replenishment and Exchange
Grease Replenishment and Exchange for S-Axis Speed Reducer
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
HP20D
4.3
Grease Replenishment and Exchange
Grease Replenishment and Exchange for L-Axis Speed Reducer
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
4.3
Grease Replenishment and Exchange
Grease Replenishment and Exchange for L-Axis Speed Reducer
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
HP20D
4.4
Grease Replenishment and Exchange
Grease Replenishment and Exchange for U-Axis Speed Reducer
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
4.4.1
For ceiling mounted manipulators, the exhaust port and the
grease inlet are inverted.
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
4.4
Grease Replenishment and Exchange
Grease Replenishment and Exchange for U-Axis Speed Reducer
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
HP20D
4.5
Grease Replenishment and Exchange
Grease Replenishment for R-Axis Speed Reducer
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:
Harmonic Grease SK-1A
– Amount of grease:
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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4.6
HP20D
4.6
Grease Replenishment and Exchange
Grease Replenishment for B- and T-Axis Speed Reducers
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)
T-axis speed reducer
T-axis exhaust port
(Hexagon socket set screw M6)
B-axis speed reducer
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 chapter 2 “Notes
for Maintenance” .)
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4.7
HP20D
4.7
Grease Replenishment and Exchange
Grease Replenishment for T-Axis Gear
Grease Replenishment for T-Axis Gear
Fig. 4-6: T-Axis Gear
Exhaust port
(Plug LP-M5)
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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4.8
HP20D
4.8
Grease Replenishment and Exchange
Grease Replenishment for R-Axis Cross Roller Bearing
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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5.1
HP20D
5
Disassembly and Reassembly of Motors
Disassembly and Reassembly of S-Axis Motor
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
motor 1 .
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 2 . Insert stud bolts M6 (length of the thread
part: 30 mm or more) in the tapped holes M6 (2 holes) on the motor
flange face. Screw the stud bolts in until the gap between the motor
and the matching surface becomes 10 mm or more. Then, remove the
S-axis motor 1 vertically from the M-base 5 .
6. Remove the hexagon socket head cap screw 6 , then remove the input
gear 3 and the key 4 .

Reassembly
1. Mount the key 4 and the input gear 3 on the S-axis motor 1 .
(The key 4 is attached to the S-axis motor 1 .)
2. Put the conical spring washer on the hexagon socket head cap
screw 6 , 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 1 and the M-base 5 . Then, mount the S-axis
motor 1 on the M-base 5 .
4. Tighten the GT-SA bolts 2 with the tightening torque shown in
table 5-1 “S-Axis Motor Parts Checklist” .
5. Connect the connector (signal, power) of the internal wiring harness 9
to the S-axis motor 1 .
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5.1
Disassembly and Reassembly of Motors
Disassembly and Reassembly of S-Axis Motor
6. Connect the power connector of the L-axis motor. Fix the connector
on the motor side by using pliers, etc. when connecting the power
connector.
7. Remove the backup battery.
8. Turn ON the DX100 power supply.
Table 5-1: S-Axis Motor Parts Checklist
No.
Name
Qty.
Notes
1
S-axis motor HW0387862-A
1
SGMRV-09ANA-YR11
2
GT-SA bolt M8
(length: 30 mm)
3
Tightening torque:
24.5 N•m
3
Input gear HW0313491-1
1
4
Key
1
5
M-base HW0305306-1
1
6
Hexagon socket head cap screw M6
(length: 60 mm)
Conical spring washer 2H-6
1
Tightening torque:
each 16.5 N•m
7
Cover HW0305809-1
1
8
Cross head APS bolt M5
(length: 10 mm)
4
9
Internal wiring harness
1
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5.1
Disassembly and Reassembly of Motors
Disassembly and Reassembly of S-Axis Motor
Fig. 5-1: Disassembly and Reassembly of S-Axis Motor
2
1
9
1
4
2
8
7
5
3
6
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5.2
HP20D
5.2
Disassembly and Reassembly of Motors
Disassembly and Reassembly of L-Axis Motor
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 1 . Fix the connector on the
motor side by using pliers, etc. when disconnecting the power
connector.
4. Support the L-arm with a chain block, etc. so that the L-arm does not
rotate before removing the L-axis motor 1 .
5. Remove the hexagon socket head cap screws 2 . 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 1 . Screw the stud bolts in
until the gap between the motor and the matching surface becomes 10
mm or more. Then, remove the L-axis motor 1 horizontally from the
M-base 3 . At this time, be careful not to damage the oil seal inside the
S-head.
6. Remove the hexagon socket head cap screw 6 , then remove the input
gear 4 , the key 5 , and the plate 7 .

Reassembly
1. Apply ThreeBond 1206C on the matching surface between the L-axis
motor 1 and the plate 7 . Then, mount the plate 7 on the L-axis
motor 1 .
2. Apply ThreeBond 1206C on the matching surface between the input
gear 4 and the plate 7 . Then, mount the key 5 and the input gear 4
on the L-axis motor 1 . (The key 5 is attached to the L-axis motor 1 .)
3. Put the conical spring washer on the hexagon socket head cap
screw 6 , 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 1 and the M-base 3 . Then, mount the L-axis
motor 1 on the M-base 3 . At this time, be careful not to damage the
oil seal inside the S-head.
5. Tighten the hexagon socket head cap screws 2 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 1 . 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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5.2
Disassembly and Reassembly of Motors
Disassembly and Reassembly of L-Axis Motor
Table 5-2: L-Axis Motor Parts Checklist
No.
Name
Qty.
Notes
1
L-axis motor HW0387863-A
1
SGMRV-13ANA-YR21
2
Hexagon socket head cap screw M8
(length: 25 mm)
Conical spring washer 2H-8
4
Tightening torque:
each 24.5 N•m
3
M-base HW0304229-1
1
4
Input gear HW0313492-1
1
5
Key
1
6
Hexagon socket head cap screw M6
(length: 90 mm)
Conical spring washer 2H-6
1
Tightening torque:
each 16.5 N•m
7
Plate HW0401506-1
1
Fig. 5-2: Disassembly and Reassembly of L-Axis Motor
S-head
3
1
2
6
7
4
5
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5.3
HP20D
5.3
Disassembly and Reassembly of Motors
Disassembly and Reassembly of U-Axis Motor
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” .)
3. Remove the cross head APS bolts 9 , then remove the cover 8 .
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 1 .
6. Remove the GT-SA bolts 2 . 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 1 . Screw the stud bolts in until the gap
between the motor and the matching surface becomes 10 mm or
more. Then, remove the U-axis motor 1 horizontally from the casing.
7. Remove the hexagon socket head cap screw 5 , then remove the input
gear 3 and the key 4 .

Reassembly
1. Mount the key 4 and the input gear 3 on the U-axis motor 1 .
(The key 4 is attached to the U-axis motor 1 .)
2. Put the conical spring washer on the hexagon socket head cap
screw 5 , 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 1 and the casing. Then, mount the U-axis
motor 1 on the casing.
4. Tighten the GT-SA bolts 2 with the tightening torque shown in
table 5-3 “U-Axis Motor Parts Checklist” .
5. Connect the connector (signal, power) of the internal wiring harness to
the U-axis motor 1 .
6. Mount the cover 8 with the cross head APS bolts 9 .
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 Motors
Disassembly and Reassembly of U-Axis Motor
Table 5-3: U-Axis Motor Parts Checklist
No.
Name
Qty.
Notes
1
U-axis motor HW0387860-A
1
SGMRV-05ANA-YR11
2
GT-SA bolt M8
(length: 30 mm)
4
Tightening torque:
24.5 N•m
3
Input Gear
1
4
Key
1
5
Hexagon socket head cap screw M5
(length: 65 mm)
Conical spring washer 2H-5
1
Tightening torque:
each 10 N•m
6
Cover HW0305305-1
1
7
GT-SA bolt M6
(length: 20 mm)
6
8
Cover HW0313489-1
1
9
Cross head APS bolt M4
(length: 10 mm)
Flat washer 4.3 x 12.0 x 0.8
7
each
Tightening torque:
10 N•m
Fig. 5-3: Disassembly and Reassembly of U-Axis Motor
6
4
7
8
9
5
3
1
2
Casing
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5.4
HP20D
5.4
Disassembly and Reassembly of Motors
Disassembly and Reassembly of R-Axis Motor
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.
2. Remove the GT-SA bolts 10 , then remove the cover 9 .
3. Remove the plastic cover on the connector (signal) of the internal
wiring harness connected to the R-axis motor 1 . 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 1 . Then, disconnect the connector (signal, power) of the
internal wiring harness connected to the R-axis motor 1 .
5. Remove the GT-SA bolts 3 . Insert stud bolts M6 (length of the thread
part: 40 mm or more) in the tapped holes M6 (2 holes) on the Mbase 4 . Screw the stud bolts in until the gap between the motor and
the matching surface becomes 10 mm or more. Then, remove the Mbase 4 from the casing.
6. Remove the hexagon socket head cap screw 8 , then remove the
shaft 5 , the speed reducer 6 , and the washer 7 .
7. Remove the GT-SA bolts 2 . Then, remove the R-axis motor 1 from
the M-base 4 .

Reassembly
1. Mount the R-axis motor 1 on the M-base 4 .
2. Tighten the GT-SA bolts 2 with the tightening torque shown in
table 5-4 “R-Axis Motor Parts Checklist” .
3. Fill the hatched area of the oil seal 11 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 5
and the R-axis motor 1 . Then, mount the shaft 5 , the speed
reducer 6 , and the washer 7 on the R-axis motor 1 .
5. Apply Loctite 242 to the thread part of the hexagon socket head cap
screw 8 . Then, tighten it with the tightening torque shown in table 5-4
“R-Axis Motor Parts Checklist” .
6. Apply ThreeBond 1206C on the matching surface between the Mbase 4 and the casing. Then, mount the M-base 4 on the casing.
7. Tighten the GT-SA bolts 3 with the tightening torque shown in
table 5-4 “R-Axis Motor Parts Checklist” .
8. Connect the connector (signal, power) of the internal wiring harness to
the R-axis motor 1 , and remove the backup battery. Then, put the
plastic cover on the connector.
9. Apply ThreeBond 1206C on the matching surface between the
cover 9 and the casing. Then, mount the cover 9 with the GT-SA
bolts 10 .
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5.4
Disassembly and Reassembly of Motors
Disassembly and Reassembly of R-Axis Motor
10. Tighten the GT-SA bolts 10 with the tightening torque shown in
table 5-4 “R-Axis Motor Parts Checklist” .
11. Turn ON the DX100 power supply.
Table 5-4: R-Axis Motor Parts Checklist
No.
Name
Qty.
Notes
1
R-axis motor HW0389298-A
1
SGMPH-02ANA-YR11
2
GT-SA bolt M5
(length: 20 mm)
4
Tightening torque:
6 N•m
3
GT-SA bolt M6
(length: 30 mm)
3
Tightening torque:
10 N•m
4
M-base HW0304932-1
1
5
Shaft HW0404402-1
1
6
Speed reducer
HW0381463-A
1
Wave generator
7
Washer HW0404196-5
1
8
Hexagon socket head cap screw M4
(length: 45 mm)
Conical spring washer 2H-4
1
Tightening torque:
each 4.8 N•m
9
Cover HW0305305-1
1
10
GT-SA bolt M6
(length: 20 mm)
6
11
Oil seal AE1314A0
1
Tightening torque:
10 N•m
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5.4
HP20D
Disassembly and Reassembly of Motors
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
4
11
Apply ThreeBond 1206C.
Fill with Harmonic grease SK-1A.
(See the step 4 of the R-axis
reassembly procedure.)
(See the step 3 of the R-axis
reassembly procedure.)
Casing
5-10
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5.5
HP20D
5.5
Disassembly and Reassembly of Motors
Disassembly and Reassembly of B-Axis Motor
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.
2. Remove the GT-SA bolts 6 , then remove the covers 5 .
3. Remove the plastic cover on the connector (signal) of the internal
wiring harness connected to the B-axis motor 1 . 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 1 . Then, disconnect the
connector (signal, power) of the internal wiring harness.
5. Remove the GT-SA bolts 2 , then remove the B-axis motor 1 from the
U-arm.
6. Remove the hexagon socket head cap screw 4 , then remove the
pulley 3 . (Use the holes (2 holes, diameter: 4 mm) on the surface of
the pulley 3 to fix it.)

Reassembly
1. Mount the pulley 3 on the B-axis motor 1 .
2. Apply Loctite 242 to the thread part of the hexagon socket head cap
screw 4 . 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 3 to fix the it.)
3. Mount the B-axis motor 1 on the U-arm, then put the belt on the
pulley 3 .
4. Then, tighten the GT-SA bolts 2 with the tightening torque shown in
table 5-5 “B-Axis Motor Parts Checklist” .
(Refer to chapter 8 “Disassembly, Reassembly, and Adjustment of Band 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 1 , and remove the backup battery. Then, put the
plastic cover on the connector.
6. Mount the covers 5 with the GT-SA bolts 6 . (Apply ThreeBond 1206C
on the matching surface between the cover 5 and the U-arm.)
7. Tighten the GT-SA bolts 6 with the tightening torque shown in
table 5-5 “B-Axis Motor Parts Checklist” .
8. Turn ON the DX100 power supply.
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5.5
Disassembly and Reassembly of Motors
Disassembly and Reassembly of B-Axis Motor
Table 5-5: B-Axis Motor Parts Checklist
No.
Name
Qty.
Notes
1
B-axis motor HW0389298-A
1
SGMPH-02ANA-YR11
2
GT-SA bolt M5
(length: 20 mm)
2
Tightening torque:
6 N•m
3
Pulley HW9482727-A
1
4
Hexagon socket head cap screw M4
(length: 16 mm)
Conical spring washer 2H-4
1
Tightening torque:
each 4.8 N•m
5
Cover HW9200798-1
2
6
GT-SA bolt M5
(length: 12 mm)
24
Tightening torque:
6 N•m
Fig. 5-5: Disassembly and Reassembly of B-Axis Motor
5
1
2
6
6
5
4
3
U-arm
5-12
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5.6
HP20D
5.6
Disassembly and Reassembly of Motors
Disassembly and Reassembly of T-Axis Motor
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 5 . (Perform the steps 2 to 4 of
“Disassembly” in chapter 5.5 “Disassembly and Reassembly of B-Axis
Motor” .)
3. Remove the plastic cover on the connector (signal) of the internal
wiring harness connected to the T-axis motor 1 . 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 1 . Then, disconnect the
connector (signal, power) of the internal wiring harness.
5. Remove the GT-SA bolts 2 , then remove the T-axis motor 1 from the
U-arm.
6. Remove the hexagon socket head cap screw 4 , then remove the
pulley 3 . (Use the holes (2 holes, diameter: 4 mm) on the surface of
the pulley 3 to fix it.)

Reassembly
1. Mount the pulley 3 on the T-axis motor 1 .
2. Apply Loctite 242 to the thread part of the hexagon socket head cap
screw 4 . 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 3 to fix the it.)
3. Mount the T-axis motor 1 on the U-arm, then put the belt on the
pulley 3 .
4. Then, tighten the GT-SA bolts 2 with the tightening torque shown in
table 5-6 “T-Axis Motor Parts Checklist” .
(Refer to chapter 8 “Disassembly, Reassembly, and Adjustment of Band 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 1 , and remove the backup battery. Then, put the
plastic cover on the connector.
6. Remove the B-axis motor 5 . (Perform the steps 3 to 7 of
“Reassembly” in chapter 5.5 “Disassembly and Reassembly of B-Axis
Motor” .)
7. Turn ON the DX100 power supply.
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5.6
Disassembly and Reassembly of Motors
Disassembly and Reassembly of T-Axis Motor
Table 5-6: T-Axis Motor Parts Checklist
No.
Name
Qty.
Notes
1
T-axis motor HW0389298-A
1
SGMPH-02ANA-YR11
2
GT-SA bolt M5
(length: 20 mm)
2
Tightening torque:
6 N•m
3
Pulley HW9482727-A
1
4
Hexagon socket head cap screw M4
(length: 16 mm)
Conical spring washer 2H-4
1
Tightening torque:
each 4.8 N•m
5
B-axis motor HW0382152-A
1
Fig. 5-6: Disassembly and Reassembly of T-Axis Motor
3
5
4
2
1
U-arm
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6.1
HP20D
6
Disassembly and Reassembly of Speed Reducer
Disassembly and Reassembly of S-Axis Speed Reducer
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 4 . (Perform the steps 2 to 6 of
“Disassembly” in chapter 5.1 “Disassembly and Reassembly of S-Axis
Motor” .)
3. Remove the hexagon socket head cap screws 6 , then remove the Mbase 5 .
4. Remove the GT-SA bolts 3 . 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 2 . Then, remove the speed reducer 1 by
using the tapped holes.
6. Drain grease which remains inside.

Reassembly
1. Apply ThreeBond 1206C on the matching surface between the base
and the speed reducer 1 . Then, mount the speed reducer 1 on the
base.
2. Tighten the GT-SA bolts 2 with the tightening torque shown in
table 6-1 “S-Axis Speed Reducer Parts Checklist” .
3. Apply ThreeBond 1206C on the matching surface between the speed
reducer 1 and the S-head. Then, mount the upper part of the
manipulator including the S-head on the speed reducer 1 .
4. Tighten the GT-SA bolts 3 with the tightening torque shown in
table 6-1 “S-Axis Speed Reducer Parts Checklist” .
5. Remove the old sealing bond on the matching surface between the Mbase 5 and the S-head, then apply ThreeBond 1206C on the matching
surface. Then, mount the M-base 5 on the S-head. Tighten the
hexagon socket head cap screws 6 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 Speed Reducer
Disassembly and Reassembly of S-Axis Speed Reducer
6. Apply ThreeBond 1206C on the matching surface between the S-axis
motor 4 and the M-base 5 . Then, mount the S-axis motor 4 .
(Perform the steps 3 to 6 of “Reassembly” in chapter 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
Qty.
Notes
1
Speed reducer HW0387753-B
1
2
GT-SA bolt M10
(length: 40 mm)
16
Tightening torque:
82 N•m
3
GT-SA bolt M12
(length: 35 mm)
9
Tightening torque:
142 N•m
4
S-axis motor HW0388932-A
1
SGMRV-09ANA-YR11
5
M-base HW0305306-2
1
6
Hexagon socket head cap screw M8
(length: 60 mm)
Conical spring washer 2H-8
3
Tightening torque:
each 24.5 N•m
Fig. 6-1: Disassembly and Reassembly of S-Axis Speed Reducer
4
3
6
5
S-head
Internal wiring harness
2
Base
1
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6.2
HP20D
6.2
Disassembly and Reassembly of Speed Reducer
Disassembly and Reassembly of L-Axis Speed Reducer
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 3 , support the L-arm 3 with a chain block,
etc. to prevent it from falling.
3. Remove the hexagon socket head cap screws 4 and 5 . Then,
remove the L-arm 3 from the speed reducer 1 .
4. Remove the GT-SA bolts 2 . Then, remove the speed reducer 1 from
the S-head. (When removing the speed reducer 1 , make sure to pull it
out straight to avoid load on the input gear. If the input gear is
subjected to a load, damage to the motor may result.)
5. Remove the old sealing bond on the L-arm 3 and the S-head.

Reassembly
1. Apply ThreeBond 1206C on the matching surface between the speed
reducer 1 and the S-head. Then, mount the speed reducer 1 on the
S-head. (When mounting, make sure not to apply a load on the input
gear.)
2. Tighten the GT-SA bolts 2 with the tightening torque shown in
table 6-2 “L-Axis Speed Reducer Parts Checklist” .
3. Apply ThreeBond 1206C on the matching surface between the speed
reducer 1 and the L-arm 3 . Then, mount the L-arm 3 on the speed
reducer 1 .
4. Tighten the hexagon socket head cap screws 4 and 5 with the
tightening torque shown in table 6-2 “L-Axis Speed Reducer Parts
Checklist” .
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
Qty.
1
Speed reducer HW0387753-C
1
2
GT-SA bolt M10
(length: 40 mm)
14
Notes
Tightening torque:
82 N•m
3
L-arm HW0100546-2
1
4
Hexagon socket head cap screw M12
(length: 40 mm)
Conical spring washer 2H-12
12
Tightening torque:
each 142 N•m
5
Hexagon socket head cap screw M10
(length: 35 mm)
Conical spring washer 2H-10
6
Tightening torque:
each 82 N•m
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6.2
Disassembly and Reassembly of Speed Reducer
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
4
3
5
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6.3
HP20D
6.3
Disassembly and Reassembly of Speed Reducer
Disassembly and Reassembly of U-Axis Speed Reducer
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 3 . Then, remove the
U-arm unit from the L-arm.
4. Remove the U-axis motor from the U-arm unit.
(Perform “Disassembly” in chapter 5.3 “Disassembly and Reassembly
of U-Axis Motor” .)
5. Remove the GT-SA bolts 2 , then remove the speed reducer 1 .
6. Remove the hexagon socket head cap screw 4 , then remove the input
gear 5 .
7. Remove the old sealing bond on the L-arm and the U-arm unit.

Reassembly
1. Mount the input gear 5 on the U-axis motor. (The input gear 5 is
attached to the speed reducer 1 . Thus, when replacing the speed
reducer 1 , replace the input gear 5 too.)
2. Apply Loctite 242 to the thread part of the hexagon socket head cap
screw 4 . Then, tighten it with the tightening torque shown in table 6-3
“U-Axis Speed Reducer Parts Checklist” .
3. Apply ThreeBond 1206C on the matching surface between the speed
reducer 1 and the U-arm unit. Then, mount the speed reducer 1 on
the U-arm unit.
4. Tighten the GT-SA bolts 2 with the tightening torque shown in
table 6-3 “U-Axis Speed Reducer Parts Checklist” .
5. Mount the U-axis motor on the U-arm unit. (Perform “Reassembly” in
chapter 5.3 “Disassembly and Reassembly of U-Axis Motor” .)
6. Apply ThreeBond 1206C on the matching surface between the speed
reducer 1 and the L-arm. Then, mount the U-arm unit with the speed
reducer 1 on the L-arm.
7. Tighten the hexagon socket head cap screws 3 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 Speed Reducer
Disassembly and Reassembly of U-Axis Speed Reducer
Table 6-3: U-Axis Speed Reducer Parts Checklist
No.
Name
Qty.
Notes
1
Speed reducer HW9280880-G
1
2
GT-SA bolt M8
(length: 45 mm)
16
3
Hexagon socket head cap screw M14
(length: 35 mm)
Conical spring washer GT-SH-14
6
Tightening torque:
each 226 N•m
4
Hexagon socket head cap screw M4
(length: 65 mm)
Conical spring washer 2H-4
1
Tightening torque:
each 4.8 N•m
5
Input gear
1
Tightening torque:
26.5 N•m
Fig. 6-3: Disassembly and Reassembly of U-Axis Speed Reducer
U-arm unit
3
4
5
U-axis motor
L-arm
1
2
6-6
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6.4
HP20D
6.4
Disassembly and Reassembly of Speed Reducer
Disassembly and Reassembly of R-Axis Speed Reducer
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 chapter 5.4 “Disassembly and Reassembly of R-Axis Motor” .)
3. Remove the GT-SA bolts 5 , then remove the shaft 4 and the flex
spline 2 .
4. Remove the hexagon socket head cap screws 6 , then remove the
circular spline 1 .

Reassembly
1. Mount the circular spline 1 on the casing.
2. Tighten the hexagon socket head cap screws 6 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 1 and the flex spline 2 . Then, mount the flex
spline 2 and the shaft 4 on the casing.
4. Tighten the GT-SA bolts 5 with the tightening torque shown in
table 6-4 “R-Axis Speed Reducer Parts Checklist” .
5. Apply Harmonic Grease SK-1A on the bearing of the wave
generator 3 . Then, mount the wave generator 3 on the R-axis motor.
(Perform the steps 3 to 10 of “Reassembly” in chapter 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 Speed Reducer
Disassembly and Reassembly of R-Axis Speed Reducer
Table 6-4: R-Axis Speed Reducer Parts Checklist
No.
Name
Qty.
Notes
1
Speed reducer
HW0381463-A
1
Circular spline
2
Speed reducer
HW0381463-A
1
Flex spline
3
Speed reducer
HW0381463-A
1
Wave generator
4
Shaft HW0404403-1
1
5
GT-SA bolt M6
(length: 20 mm)
8
6
Hexagon socket head cap screw M4
(length: 20 mm)
Conical spring washer 2H-4
12
Tightening torque:
each 2.8 N•m
Tightening torque:
16.5 N•m
Fig. 6-4: Disassembly and Reassembly of R-Axis Speed Reducer
1
3
2
5
Casing
R-axis motor
4
6
6-8
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6.5
HP20D
6.5
Disassembly and Reassembly of Speed Reducer
Disassembly and Reassembly of B-Axis Speed Reducer
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.
2. Remove the GT-SA bolts 11 , then remove the covers 10 .
3. Loosen the GT-SA bolts 14 which fix the B-axis motor. Then, remove
the timing belt 5 .
4. Remove the GT-SA bolts 9 . Then, remove the pulley 6 , the
housing 15 , the wave generator 3 , and the bearings 8 and 12 .
5. Remove the hexagon socket head cap screw 7 , then remove the
pulley 6 .
6. Remove the GT-SA bolts 4 , then remove the circular spline 2 .
7. Remove the GT-SA bolts 13 , then remove the flex spline 1 .

Reassembly
1. Mount the flex spline 1 on the wrist base.
2. Tighten the GT-SA bolts 13 with the tightening torque shown in
table 6-5 “B-Axis Speed Reducer Parts Checklist” .
3. Apply Harmonic Grease SK-1A on the surface between the teeth of
the circular spline 2 and the flex spline 1 . Apply ThreeBond 1206C on
the matching surface between the circular spline 2 and the U-arm.
Then, mount the circular spline 2 on the U-arm.
4. Tighten the GT-SA bolts 4 with the tightening torque shown in
table 6-5 “B-Axis Speed Reducer Parts Checklist” .
5. Apply Harmonic Grease SK-1A on the bearing part of the wave
generator 3 . Press-fit the bearings 8 and 12 . Then, mount the
housing 15 and the pulley 6 . (When replacing the speed reducer,
replace the bearings 8 and 12 too.)
6. Apply Loctite 242 to the thread part of the hexagon socket head cap
screw 7 . Then, tighten it with the tightening torque shown in table 6-5
“B-Axis Speed Reducer Parts Checklist” .
7. Insert the wave generator 3 assembled at the step 5 above in the wrist
base.
8. Tighten the GT-SA bolts 9 with the tightening torque shown in
table 6-5 “B-Axis Speed Reducer Parts Checklist” .
9. Put the timing belt 5 on the pulley 6 .
10. Adjust the initial tension of the timing belt 5 to the designated tension.
Then, tighten the GT-SA bolts 14 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 Taxis Timing Belts” .)
11. Remove the old sealing bond on the covers 10 and the U-arm. Apply
ThreeBond 1206C on the matching surface between the covers 10 and
the U-arm. Then, mount the covers 10 on the U-arm.
12. Tighten the GT-SA bolts 11 with the tightening torque shown in
table 6-5 “B-Axis Speed Reducer Parts Checklist” .
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6.5
Disassembly and Reassembly of Speed Reducer
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
Qty.
Notes
1
Speed reducer
HW9381633-A
1
Flex spline
2
Speed reducer
HW9381633-A
1
Circular spline
3
Speed reducer
HW9381633-A
1
Wave generator
4
GT-SA bolt M4
(length: 16 mm)
12
Tightening torque:
2.8 N•m
5
Timing belt 80S4.5M653
1
6
Pulley HW9482725-A
1
7
Hexagon socket head cap screw M5
(length: 16 mm)
Conical spring washer 2H-5
1
Tightening torque:
each 10 N•m
8
Bearing 6002ZZ
1
9
GT-SA bolt M4
(length: 12 mm)
4
10
Cover HW9200798-1
2
11
GT-SA bolt M5
(length: 12 mm)
24
12
Bearing 6901ZZ
1
13
GT-SA bolt M5
(length: 16 mm)
11
Tightening torque:
6 N•m
14
GT-SA bolt M5
(length: 20 mm)
2
Tightening torque:
6 N•m
15
Housing HW9405792-1
1
Tightening torque:
2.8 N•m
Tightening torque:
6 N•m
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6.5
HP20D
Disassembly and Reassembly of Speed Reducer
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
1
13
14
12
2
11
3
5
15
10
6
4
9
8
7
6-11
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6.6
HP20D
6.6
Disassembly and Reassembly of Speed Reducer
Disassembly and Reassembly of T-Axis Speed Reducer
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 10 , then remove the right side part from the
point “A” in chapter 6 “Disassembly and Reassembly of Speed
Reducer” .
3. Remove the circular spline 2 from the flange.
4. Remove the GT-SA bolts 4 , then, remove the flex spline 1 .
5. Remove the GT-SA bolts 5 . Then, remove the housing 6 from the
wrist base.
6. Remove the hexagon socket head cap screw 8 , and remove the
gear 7 and the shim 9 . Then, pull out the wave generator 3 .

Reassembly
1. Apply Harmonic Grease SK-1A to the bearing of the wave
generator 3 . Then, insert the wave generator 3 in the housing 6 .
2. Mount the shim 9 and the gear 7 .
3. Apply Loctite 242 to the thread part of the hexagon socket head cap
screw 8 . Then, tighten it with the tightening torque shown in table 6-6
“T-Axis Speed Reducer Parts Checklist” .
4. Mount the housing 6 (the assembly prepared in the steps 1 to 3
above) on the wrist base.
5. Temporarily tighten the GT-SA bolts 5 .
6. Check if the backlash is proper, and adjust the shim as follows when
necessary: Remove the GT-SA bolt 5 , then remove the housing 6 .
Adjust the backlash by inserting the shim(s) on the list below between
the gear 7 and the wave generator 3 . Set the backlash to 0.05 to 0.1
mm on the gear’s pitch circle diameter of 52.5 mm.
Shim Type
Thickness (mm)
SP012010
0.1
SP012015
0.15
SP012020
0.2
SP012050
0.5
7. Confirm the backlash is correct. Then, remove the GT-SA bolts 5
again, and remove the housing 6 . Apply Harmonic Grease SK-1A on
the teeth of the gear 7 .
8. Apply ThreeBond 1206C on the matching surface between the
housing 6 and the wrist base. Then, mount the housing 6 on the wrist
base. Tighten the GT-SA bolts 5 with the tightening torque shown in
table 6-6 “T-Axis Speed Reducer Parts Checklist” .
9. Mount the flex spline 1 on the flange.
10. Tighten the GT-SA bolts 4 with the tightening torque shown in
table 6-6 “T-Axis Speed Reducer Parts Checklist” .
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6.6
Disassembly and Reassembly of Speed Reducer
Disassembly and Reassembly of T-Axis Speed Reducer
11. Apply Harmonic Grease SK-1A on the surface between the teeth of
the circular spline 2 and the flex spline 1 . Apply ThreeBond 1206C on
the matching surface between the housing 6 and the circular spline 2 .
Then, insert the circular spline 2 in the flange, and mount it on the
housing 6 .
12. Tighten the GT-SA bolts 10 with the tightening torque shown in
table 6-6 “T-Axis Speed Reducer Parts Checklist” .
13. Replenish grease (Harmonic Grease SK-1A) through the grease inlet.
14. Turn ON the DX100 power supply.
Table 6-6: T-Axis Speed Reducer Parts Checklist
No.
Name
Qty.
Notes
1
Speed reducer
HW0382140-A
1
Flex spline
2
Speed reducer
HW0382140-A
1
Circular spline
3
Speed reducer
HW0382140-A
1
Wave generator
4
GT-SA bolt M5
(length: 12 mm)
8
Tightening torque:
10 N•m
5
GT-SA bolt M4
(length: 12 mm)
8
Tightening torque:
2.8 N•m
6
Housing HW0304086-1
1
7
Gear HW9381659-A
1
8
Hexagon socket head cap screw M5
(length: 16 mm)
Conical spring washer 2H-5
1
Tightening torque:
each 10 N•m
9
Shim
(Refer to the table in the previous page.)
10
GT-SA bolt M5
(length: 16 mm)
4
Tightening torque:
10 N•m
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6.6
Disassembly and Reassembly of Speed Reducer
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
2
6
7
Wrist base
A
10
Flange
6-14
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Disassembly and Reassembly of Wrist Unit
HP20D
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.
2. Remove the GT-SA bolts 6 , then remove the cover 5 .
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 4 , and remove the support 3 . Then, cut off
the cable tie which fixes the B- and T-axis internal wiring harness.
6. Remove the hexagon socket head cap screws 2 , then remove the
wrist unit 1 .

Reassembly
1. Run the B- and T-axis internal wiring harness through the wrist unit 1 ,
then fix the wrist unit 1 with the hexagon socket head cap screws 2 .
2. Tighten the hexagon socket head cap screws 2 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 3 with a cable tie.
4. Mount the support 3 on the wrist unit 1 with the GT-SA bolts 4 .
5. Tighten the GT-SA bolts 4 with the tightening torque shown in
table 7-1 “Wrist Unit Parts Checklist” .
6. Connect the B- and T-axis internal wiring harness to the B- and T-axis
motor connectors, then remove the backup batteries. (Refer to
chapter 10 “Cable Wiring” .)
7. Apply ThreeBond 1206C on the matching surface between the
cover 5 and the wrist unit 1 . Then, mount the cover 5 on the wrist
unit 1 with the GT-SA bolts 6 .
8. Tighten the GT-SA bolts 6 with the tightening torque shown in
table 7-1 “Wrist Unit Parts Checklist” .
9. Turn ON the DX100 power supply.
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Disassembly and Reassembly of Wrist Unit
HP20D
Table 7-1: Wrist Unit Parts Checklist
No.
Name
Qty.
Notes
1
Wrist unit
1
Mass: 14.5 kg
2
Hexagon socket head cap screw M6
(length: 65 mm)
Conical spring washer 2H-6
8
Tightening torque:
each 10 N•m
3
Support HW9406556-1
1
4
GT-SA bolt M4
(length: 12 mm)
2
5
Cover HW9200798-1
1
6
GT-SA bolt M5
(length: 12 mm)
12
Tightening torque:
2.8 N•m
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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8.1
HP20D
8
Disassembly, Reassembly, and Adjustment of B- and T-axis Timing Belts
Disassembly and Reassembly of B- and T-axis Timing Belts
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 chapter 5.5 “Disassembly and Reassembly of B-Axis Motor”
and chapter 5.6 “Disassembly and Reassembly of T-Axis Motor” .)
1. Remove the B-axis motor 5 , then remove the B-axis timing belt 1 .
2. Remove the T-axis motor 3 , then remove the T-axis timing belt 2 .

Reassembly
(Refer to chapter 5.5 “Disassembly and Reassembly of B-Axis Motor”
and chapter 5.6 “Disassembly and Reassembly of T-Axis Motor” .)
1. Install the T-axis timing belt 2 , then install the T-axis motor 3 .
2. Install the B-axis timing belt 1 , then install the B-axis motor 5 .
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8.1
Disassembly, Reassembly, and Adjustment of B- and T-axis Timing Belts
Disassembly and Reassembly of B- and T-axis Timing Belts
Table 8-1: B- and T-Axis Timing Belt Parts Checklist
No.
Name
Qty.
1
B-axis timing belt 80S4.5M653
1
2
T-axis timing belt 80S4.5M518
1
Notes
3
T-axis motor HW0389298-A
1
SGMPH-02ANA-YR11
4
GT-SA bolt M5
(length: 20 mm)
2
Tightening torque:
6 N•m
5
B-axis motor HW0389298-A
1
SGMPH-02ANA-YR11
6
GT-SA bolt M5
(length: 20 mm)
2
Tightening torque:
6 N•m
7
Cover HW9200798-1
2
8
GT-SA bolt M5
(length: 12 mm)
24
Tightening torque:
6 N•m
9
Pulley HW9482727-A
1
For B-axis
10
Pulley HW9482727-A
1
For T-axis
Fig. 8-1: Disassembly and Reassembly of B- and T-Axis Timing Belts
8
7
8
7
6
5
9
10
4
2
3
1
8-2
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8.2
HP20D
8.2
8.2.1
Disassembly, Reassembly, and Adjustment of B- and T-axis Timing Belts
Adjustment of Timing Belts
Adjustment of Timing Belts
B-Axis
1. Loosen the GT-SA bolts 6 shown in fig. 8-1 “Disassembly and
Reassembly of B- and T-Axis Timing Belts” .
2. Adjust the initial tension of the timing belt 1 by pushing the pulley 9 in
the direction in which the timing belt 1 stretches.
3. Temporarily tighten the GT-SA bolts 6 , then adjust the initial tension to
the tension specified in table 8-2 “Initial Tension of Timing Belt” by
using a tension meter.
4. Tighten the GT-SA bolts 6 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:
26 gram per meter (width: 10 mm)
Belt width:
8 mm
Distance between axes: 276 mm
8.2.2
T-Axis
1. Loosen the GT-SA bolts 4 shown in fig. 8-1 “Disassembly and
Reassembly of B- and T-Axis Timing Belts” .
2. Adjust the initial tension of the timing belt 2 by pushing the pulley 10 in
the direction in which the timing belt 2 stretches.
3. Temporarily tighten the GT-SA bolts 4 , then adjust the initial tension to
the tension specified in table 8-2 “Initial Tension of Timing Belt” by
using a tension meter.
4. Tighten the GT-SA bolts 4 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:
26 gram per meter (width: 10 mm)
Belt width:
8 mm
Distance between axes: 184 mm
Table 8-2: Initial Tension of Timing Belt
Initial tension
B-axis
15 to 36 N (1.5 to 3.6 kgf)
T-axis
15 to 36 N (1.5 to 3.6 kgf)
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Battery Pack Replacement
HP20D
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
Connector base fixing screw
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Battery Pack Replacement
HP20D
Fig. 9-2: Battery Pack Connection
Battery pack before replacement
See the step 5
Connector
Circuit board
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.
9-2
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Cable Wiring
10.1 Disconnecting Cables
HP20D
10 Cable Wiring
NOTE
10.1
10.1.1
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” .)
Disconnecting Cables
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. Remove the GT-SA bolts 2 , then remove the cover 1 .
2. Remove the plastic covers on the connector parts of the B- and T-axis
motors. Then, connect the backup batteries to the B- and T-axis
motors.
3. Disconnect the connectors of the B- and T-axis motors.
4. Remove the GT-SA bolts 3 , then remove the support 4 .
5. Cut off the cable tie which fixes the B- and T-axis internal wiring
harness to the support 4 .
Table 10-1: B- and T-Axis Cable Wiring Parts Checklist
No.
Name
Qty.
Notes
1
Cover HW9200798-1
1
2
GT-SA bolt M5
(length: 12 mm)
12
Tightening torque:
6 N•m
3
GT-SA bolt M4
(length: 12 mm)
2
Tightening torque:
2.8 N•m
4
Support HW9406556-1
1
10-1
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Cable Wiring
10.1 Disconnecting Cables
Fig. 10-1: B- and T- Axis Cable Wiring
B-axis internal wiring harness,
connector
T-axis internal wiring harness,
connector
Wrist unit
B- and T-axis internal wiring harness
3
4
B-axis motor
T-axis motor
1
2
10-2
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Cable Wiring
10.1 Disconnecting Cables
HP20D
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” .
1. Remove the GT-SA bolts 2 , then remove the cover 1 .
2. Connect the backup batteries to the U- and R-axis motors.
3. Remove the cross head APS bolts 3 , then pull out the N-base 5 .
4. Remove the pan-head sems screws 4 , then remove the connectors of
the internal wiring harness from the N-base 5 . Remove the tube (for
air) on the back of the N-base 5 , then remove the N-base 5 .
5. Remove the plastic covers on the connectors of the internal wiring
harness and the B- and T-axis internal wiring harness. Then,
disconnect all the connectors.
6. Remove the cross head APS bolt 9 which fixes the ground wire.
7. Remove the GT-SA bolts and hexagon socket head cap screws 6 ,
then remove the S-cover 7 .
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 7 and
the cable tie which fixes the internal wiring harness to the support 8 .
9. Remove the GT-SA bolts 10 , then remove the stoppers 11 from the Scover 7 . Then, remove the internal wiring harness from the S-cover 7 .
10. Remove the GT-SA bolts 12 , then remove the support 13 .
11. Remove the GT-SA bolts 14 and 15 , then pull out the B- and T-axis
internal wiring harness to the casing side.
12. Remove the hexagon socket head cap screws 17 , then cut off the cable
tie. Then, remove the saddles 16 and the B- and T-axis internal wiring
harness from the supports 18 and 19 .
10-3
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Cable Wiring
10.1 Disconnecting Cables
Table 10-2: U-Arm Cable Wiring Parts Checklist
No.
Name
Qty.
Notes
1
Cover HW0305305-1
1
2
GT-SA bolt M6
(length: 20 mm)
6
3
Cross head APS bolt M4
(length: 10 mm)
4
4
Pan-head sems screw M3
(length: 16 mm)
Nut M3
2
each
5
N-base HW0404900-1
1
6
GT-SA bolt M5
(length: 16 mm)
Hexagon socket head cap screw M5
(length: 35 mm)
Conical spring washer 2H-5
4
For part A
2
For part B
each
7
S-cover HW0200530-1
1
8
Support HW0404919-1
1
9
Cross head APS bolt M5
(length: 8 mm)
1
10
GT-SA bolt M4
(length: 16 mm)
4
11
Stopper HW0404179-1
2
12
GT-SA bolt M4
(length: 12 mm)
2
13
Support HW0304930-1
1
14
GT-SA bolt M4
(length: 12 mm)
2
Tightening torque:
2.8 N•m
15
GT-SA bolt M4
(length: 12 mm)
2
Tightening torque:
2.8 N•m
16
Saddle HW0404503-1
2
17
Hexagon socket head cap screw M4
(length: 20 mm)
Conical spring washer 2H-4
4
Tightening torque:
each 2.8 N•m
18
Support HW0304914-1
1
19
Support HW0304918-1
1
Tightening torque:
10 N•m
Tightening torque:
2.8 N•m
Tightening torque:
2.8 N•m
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8
11
10
Casing
3
5
Main key position
U-axis motor
Internal user I/O
wiring harness
1
U-, R-, B-, and T-axis
encoder cable
14
6
13
17
12
A
A
7
A
A
B
B
View Without Cover 7
16 17 15 18
B- and T-axis internal
wiring harness
U-, R-, B-, and T-axis
power cable
3BC encoder cable
3BC power cable
Air hose
R-axis encoder cable
B- and T-axis power cable
B- and T-axis encoder cable
View Without Cover 1 (Enlarged)
9
Connector of internal user
I/O wiring harness
4
Air hose
Ground wire
R-axis motor
1
2
U-axis power cable
U-axis encoder cable
R-axis power cable
6
19
16
HP20D
10
Cable Wiring
10.1 Disconnecting Cables
HW1480357
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 2 , then remove the cover 1 . Then,
cut off the cable tie which fixes the internal wiring harness.
2. Connect the backup batteries to the S-axis motor and the L-axis motor.
3. Disconnect the connectors (signal, power, brake) connected to the Saxis motor and the L-axis motor.
4. Remove the cross head APS bolts 4 , then remove the tube for grease
exhaust on the back of the cover. Then, remove the cover 3 .
5. Disconnect the connector of the S-axis motor from the internal wiring
harness.
6. Remove the GT-SA bolts 2 . Then, pull out the holder 6 which fixes
the internal wiring harness.
7. Remove the hexagon socket head cap screws 7 , then remove the
saddle 8 .
8. Cut off the cable tie which fixes the internal wiring harness, then
remove the holder 6 .
9. Remove the GT-SA bolts 11 , then remove the cover 12 .
10. Remove the GT-SA bolts 13 , then remove the holder 14 .
11. Pull out the internal wiring harness from the S-head, then remove the
GT-SA bolts 15 . Then, remove the saddle 16 , cut off the cable tie, and
remove the holder 14 .
12. Remove the cross head APS bolts 9 , then pull out the C-base 10 .
13. Remove the tube for grease replenishment installed on the back of the
C-base 10 .
14. Pull out the C-base 10 further, and remove the internal wiring harness.
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Cable Wiring
10.1 Disconnecting Cables
Table 10-3: S-Head Cable Wiring Parts Checklist
No.
Name
Qty.
1
Cover HW0304227-1
1
2
Cross head APS bolt M6
(length: 8 mm)
4
3
Cover HW0305809-1
1
4
Cross head APS bolt M5
(length: 10 mm)
4
5
GT-SA bolt M6
(length: 15 mm)
2
6
Holder HW0305812-1
1
7
Hexagon socket head cap screw M6
(length: 10 mm)
Conical spring washer 2H-6
2
Tightening torque:
each 10 N•m
8
Saddle CD-31
1
9
Cross head APS bolt M5
(length: 10 mm)
6
10
C-base HW0303378-2
1
11
GT-SA bolt M5
(length: 12 mm)
4
12
Cover HW0305698-1
1
13
GT-SA bolt M5
(length: 12 mm)
2
14
Holder HW0305813-1
1
15
GT-SA bolt M5
(length: 12 mm)
2
16
Saddle FCD-31
1
17
Support HW0304226-1
1
Notes
Tightening torque:
10 N•m
Tightening torque:
6 N•m
Tightening torque:
6 N•m
Tightening torque:
6 N•m
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Cable Wiring
10.1 Disconnecting Cables
HP20D
Fig. 10-3: S-Head Cable Wiring
6
5
7
8
S-axis connector
17
1
2
Internal wiring harness
L-axis motor
S-head
4
11
S-axis motor
12
16
3
Cable ties (2 pieces)
T18S
15
Apply sealing
bond to the
hatched area.
10
14
9
13
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Cable Wiring
10.2 Connecting Cables
HP20D
10.2
10.2.1
Connecting Cables
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 10 is attached
through the S-head from the back of the manipulator.
2. Before installing the C-base 10 , insert the tube for grease
replenishment to the back of the C-base 10 , and push the internal
wiring harness to the left.
3. Apply ThreeBond 1206C on the upper part of the matching surface of
the C-base 10 (the hatched area in fig. 10-3 “S-Head Cable Wiring” ).
Then, mount the C-base 10 with the cross head APS bolts 9 .
4. Mount the holder 6 to the internal wiring harness. Hold the spring part
(the second or third coil from the end of the spring) by using the
saddle 8 . Fix it to the holder 6 with the hexagon socket head cap
screws 7 . Then, fix the white marked part of the internal wiring
harness by using cable ties. Tighten the hexagon socket head cap
screws 7 with the tightening torque shown in table 10-3 “S-Head
Cable Wiring Parts Checklist” .
5. Mount the holder 6 on the S-head with the GT-SA bolts 5 . Then,
tighten them with the tightening torque shown in table 10-3 “S-Head
Cable Wiring Parts Checklist” .
6. Mount the holder 14 to the internal wiring harness. Fix the holder 14 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 16 . Fix it to the holder 14 with the GT-SA
bolts 15 . Tighten the GT-SA bolts 15 with the tightening torque shown in
table 10-3 “S-Head Cable Wiring Parts Checklist” .
7. Mount the holder 14 on the S-head with the GT-SA bolts 13 . Then,
tighten them with the tightening torque shown in table 10-3 “S-Head
Cable Wiring Parts Checklist” .
8. Connect the connectors of the S-axis motor and the L-axis motor to
the internal wiring harness.
9. Remove the backup batteries connected to the S-axis motor and the Laxis motor.
10. Connect the tube for grease exhaust to the back of the cover 3 , and
mount the cover 3 with the cross head APS bolts 4 .
11. Mount the cover 12 with the GT-SA bolts 11 .
12. Tighten the GT-SA bolts 11 with the tightening torque shown in
table 10-3 “S-Head Cable Wiring Parts Checklist” .
13. Fix the white marked part of the internal wiring harness to the support
17 by using cable ties.
14. Run the internal wiring harness through the L-arm, then mount the
cover 1 with the cross head APS bolts 2 .
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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 16 .
Then, fix it to the support 18 and 19 with the hexagon socket head cap
screws 17 .
2. Tighten the hexagon socket head cap screws 17 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 18 and 19 to the casing respectively with the GT-SA bolts 15
and 14 .
5. Tighten the GT-SA bolts 15 and 14 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 13 to the casing with the GT-SA
bolts 12 .
7. Tighten the GT-SA bolts 12 with the tightening torque shown in
table 10-2 “U-Arm Cable Wiring Parts Checklist” .
8. Run the internal wiring harness through the S-cover 7 . Hold the
spring by using the stoppers 11 , then fix it to the S-cover 7 with the GTSA bolts 10 .
9. Tighten the GT-SA bolts 10 with the tightening torque shown in
table 10-2 “U-Arm Cable Wiring Parts Checklist” .
10. Fix the white marked part of the internal wiring harness to the
support 8 (which is mounted on the S-cover 7 ) by using a cable tie.
11. Fix the internal wiring harness to the S-cover 7 by using cable ties.
(For the positions of the air line tube, 3BC cable, and U-, R-, B-, and Taxis 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 7 and
the casing. Mount the S-cover 7 to the casing with the GT-SA bolts
and hexagon socket head cap screws 6 .
13. Tighten the GT-SA bolts and hexagon socket head cap screws 6 with
the tightening torque shown in table 10-2 “U-Arm Cable Wiring Parts
Checklist” .
14. Mount the internal wiring harness connector to the N-base 5 with the
pan-head sems screws 4 . At this time, make sure that the main key of
the connector is set upward. Then, insert the air line tube.
15. Mount the N-base 5 to the casing with the cross head APS bolts 3 .
16. Mount the ground wire of the internal wiring harness to the casing with
the cross head APS bolt 9 .
17. Connect the B- and T-axis internal wiring harness to the internal wiring
harness.
18. Mount the cover 1 with the GT-SA bolts 2 .
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Cable Wiring
10.2 Connecting Cables
19. Apply ThreeBond 1206C to the matching surface between the cover 1
and the casing. Tighten the GT-SA bolts 2 with the tightening torque
shown in table 10-2 “U-Arm Cable Wiring Parts Checklist” .
10.2.3
Cables in Wrist Unit
• Refer to table 10-1 “B- and T-Axis Cable Wiring Parts Checklist” and
fig. 10-1 “B- and T- Axis Cable Wiring” .
1. Fix the white marked part of the B- and T-axis internal wiring harness
to the support 4 by using a cable tie.
2. Mount the support 4 to the wrist unit with the GT-SA bolts 3 .
3. Tighten the GT-SA bolts 3 with the tightening torque shown in
table 10-1 “B- and T-Axis Cable Wiring Parts Checklist” .
4. Connect the connectors of the B- and T-axis motors to the internal
wiring harness.
5. Remove the backup batteries connected to the B- and T-axis motors.
Protect the connecting parts of the connectors of the B- and T-axis
motors and the internal wiring harness by using plastic covers, then
put them back. Tie up both ends of each plastic cover by using cable
ties.
6. Apply ThreeBond 1206C to the matching surface between the cover 1
and the wrist unit. Then, mount the cover 1 with the GT-SA bolts 2 .
7. Tighten the GT-SA bolts 2 with the tightening torque shown in
table 10-1 “B- and T-Axis Cable Wiring Parts Checklist” .
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Parts List
11.1 S-Axis Unit
HP20D
11 Parts List
11.1
S-Axis Unit
Fig. 11-1: S-Axis Unit
1008
1001
1011
1012
1010
1034
1013
1036
1020
1035
1031
1032
1014
1024
1023
1022
1021
1026
1009
1030
1024
1023
1027
1030
1033
1002
1016
1004
1015
1017
1003
1006
1018
1025
1005
1014
1020
1007
1028
1029
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Parts List
11.1 S-Axis Unit
Table 11-1: S-Axis Unit
No.
DWG No.
Name
Pcs.
1001
SGMRV-09ANA-YR1*
Motor
1
1002
HW0100545-2
S-head
1
1003
M16X20
Socket screw
1
1004
2H-16
Conical spring washer
1
1005
HW0387753-B
Speed reducer
1
1006
M10X40
GT-SA bolt
16
1007
HW0100544-2
Base
1
1008
M8X30
GT-SA bolt
3
1009
HW0305306-2
M-base
1
1010
M5X10
APS bolt
1
1011
PT1/8
Plug
1
1012
UKM6-01
Union
1
1013
HW0305809-1
Cover
1
1014
NB-0640-0.3
Tube
2
1015
HW0304221-1
Cover
1
1016
M6X15
GT-SA bolt
2
1017
MSB8-15
Shoulder
1
1018
HW0400645-1
Lever
1
1019
M5X10
APS bolt
6
1020
TSH6-01M
Union
2
1021
CD-31
Saddle
1
1022
M6X10
Socket screw
2
1023
TA1-S10
Clamp
2
1024
M5X10
Screw with spring washer
2
1025
EZ5036A0
Cap
1
1026
M6X15
GT-SA bolt
2
1027
HW0305812-1
Holder
1
1028
HW9406775-1
Cover
1
1029
M6X8
APS bolt
1
1030
M12
Eye bolt
2
1031
M8X60
Socket screw
3
1032
2H-8
Conical spring washer
3
1033
M12X35
GT-SA bolt
12
1034
HW0313491-1
Gear
1
1035
M6X60
Socket screw
1
1036
2H-6
Conical spring washer
1
11-2
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Parts List
11.2 L-Axis Unit
HP20D
11.2
L-Axis Unit
Fig. 11-2: L-Axis Unit
2024
2025
2001
2023
2017
2005
2004
2008
2011
2012
2019
2010
2009
2018
2028
2003
2006 2002
2007
2032
2026
2027
2014
2013
2022
2021
2020
2014
2013
2016
2015
2029
1002
2031
2030
2033
2034
2035
2036
2031
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Parts List
11.2 L-Axis Unit
Table 11-2: L-Axis Unit
No.
DWG No.
Name
Pcs.
2001
SGMRV-13ANA-YR2*
Motor
1
2002
M6X90
Socket screw
1
2003
2H-6
Conical spring washer
1
2004
HW0313492-1
Gear
1
2005
HW0304229-1
M-base
1
2006
Y426012.5
Oil seal
1
2007
HW0401506-1
Plate
1
2008
HW0304226-1
Support
1
2009
M6X10
Socket screw
2
2010
2H-6
Conical spring washer
2
2011
HW0304227-1
Cover
1
2012
M6X8
APS bolt
4
2013
M12X40
Socket screw
12
2014
2H-12
Conical spring washer
12
2015
M10X35
Socket screw
6
2016
2H-10
Conical spring washer
6
2017
HW0100546-2
L-arm
1
2018
HW0387753-C
Speed reducer
1
2019
M10X40
GT-SA bolt
14
2020
M12X40
Socket screw
2
2021
2H-12
Conical spring washer
2
2022
HW0404196-4
Washer
1
2023
M8X30
GT-SA bolt
4
2024
M8X25
*DACROTIZED coating*
Socket screw
4
2025
2H-8
*DACROTIZED coating*
Conical spring washer
4
2026
TA1-S10
Clamp
4
2027
M5X10
Screw with spring washer
4
2028
M6X10
Socket screw
1
2029
HW0305813-1
Holder
1
2030
HW0305698-1
Cover
1
2031
M5X12
GT-SA bolt
6
2032
PT1/8
*DACROTIZED coating*
Plug
1
2033
CD-31
Saddle
1
2034
M5X12
GT-SA bolt
2
2035
TA1-S10
Clamp
2
2036
M5X10
Screw with spring washer
2
1002
HW0100545-2
S-head
1
11-4
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Parts List
11.3 U-Axis Unit
HP20D
11.3
U-Axis Unit
Fig. 11-3: U-Axis Unit
3003
3004
3002
3003
3004
3001
3005
3020
3002
3019
3019
3012
3006
2017
3016
3018
3017
3016
3018
3017
3009
3008
3011
3010
3007
3015
3013
3014
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Parts List
11.3 U-Axis Unit
Table 11-3: U-Axis Unit
No.
DWG No.
Name
Pcs.
3001
SGMRV-05A3A-YR1*
Motor
1
3002
HW0313489-1
Cover
1
3003
M4X10
APS bolt
7
3004
M4
Washer
7
3005
HW0102379-1
Casing
1
3006
HW9280880-G
Speed reducer
1
3007
M8X45
GT-SA bolt
16
3008
M5X65
Socket screw
1
3009
2H-5
Conical spring washer
1
3010
M14X35
Socket screw
6
3011
GT-SH-14
GT-SH washer
6
3012
M8X30
GT-SA bolt
4
3013
M10X20
Socket screw
1
3014
H-10
Conical spring washer
1
3015
M6X10
Socket screw
1
3016
HW0404196-2
Washer
2
3017
M10X35
Socket screw
2
3018
2H-10
Conical spring washer
2
3019
PT1/8
Plug
2
3020
EZ2940A0
Cap
1
2017
HW0100546-2
L-arm
1
11-6
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Parts List
11.4 R-Axis Unit
HP20D
11.4
R-Axis Unit
Fig. 11-4: R-Axis Unit
4033
4012
4031
4032
4029
4071
4074
4036
4072
4066
4010
4030 4029
4008
4042
4005
4058
3005
4057
4035
4009
4056
4043
4006
4007
4044
4011
4003
4028
4027
4026
4076
4075
4073
4022
4034
4023
4037
4060
4055
4039
4025
4040 4051
3014
4062
4046
4045
3012
4020
4013
4024
4019
4021
4015
4017
4067
4065
4014
4002
4016
4004
4001
4070
4069
4068
5046
4018
11-7
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Parts List
11.4 R-Axis Unit
Table 11-4: R-Axis Unit (Sheet 1 of 2)
No.
DWG No.
Name
Pcs.
4001
M6X65
Socket screw
8
4002
2H-6
Conical spring washer
8
4003
M5X20
GT-SA bolt
4
4004
M4X12
GT-SA bolt
4
4005
HW0305305-1
M-cover
1
4006
M4X20
Socket screw
12
4007
2H-4
Conical spring washer
12
4008
HW0404196-5
Washer
1
4009
M6X20
GT-SA bolt
8
4010
M4X45
Socket screw
1
4011
M6X6
Socket screw
1
4012
A-MT6X1
G Nipple
1
4013
HW0381872-A
Cross roller bearing
1
4014
M6X35
GT-SA bolt
8
4015
HW0403879-1
Saddle
1
4016
TC941045*A727*
Oil seal
1
4017
HW0403857-1
Shaft
1
4018
HW0405201-2
Block
1
4019
HW0304318-1
Housing
1
4020
HW0304085-1
Shaft
1
4021
HW0304914-1
Support
1
4022
HW0403879-1
Saddle
1
4023
M4X20
Socket screw
2
4024
M4X12
GT-SA bolt
2
4025
HW0200530-1
S-cover
1
4026
HW0404919-1
Support
1
4027
M5X16
Socket screw
2
4028
2H-5
Conical spring washer
2
4029
HW0381463-A
Speed reducer
1
4030
HW0404403-1
Shaft
1
4031
AE1314A0
Oil seal
1
4032
HW0304932-1
M-base
1
4033
HW0404402-1
Shaft
1
4034
2H-4
Conical spring washer
2
4035
HW0404900-1
N-base
1
4036
M4X10
Screw with spring washer
4
4037
M5X16
GT-SA bolt
4
4039
TA1-S8
Clamp
4
4040
M4X8
Screw with spring washer
4
4042
M5X8
APS bolt
1
4043
M6X6
Socket screw
1
4044
LP-M5
Plug
1
4045
M5X35
Socket screw
2
4046
2H-5
Conical spring washer
2
11-8
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Parts List
11.4 R-Axis Unit
Table 11-4: R-Axis Unit (Sheet 2 of 2)
No.
DWG No.
Name
Pcs.
4051
M4X12
GT-SA bolt
2
4055
HW0404918-1
Support
1
4056
SGMPH-02A2A-YR1*
Motor
1
4057
EZ5036A0
Cap
1
4058
M6X20
GT-SA bolt
6
4060
HW0304930-1
Support
1
4062
6811LLU
Bearing
1
4065
M4X20
Socket screw
2
4066
KQE12-03
Union
1
4067
2H-4
Conical spring washer
2
4068
M4X20
Socket screw
2
4069
2H-4
Conical spring washer
2
4070
MS4-10
Pin
2
4071
2H-4
Conical spring washer
1
4072
PT 3/8
Plug
1
4073
M4X12
GT-SA bolt
2
4074
M6X30
GT-SA bolt
3
4075
TA1-S8
Clamp
3
4076
M4X8
Screw with spring washer
3
3005
HW0102378-1
Casing
1
3012
M4X16
GT-SA bolt
4
3014
HW0404179-1
Support
2
5046
HW0100623-1
U-arm
1
11-9
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Parts List
11.5 Wrist Unit
HP20D
11.5
Wrist Unit
Fig. 11-5: Wrist Unit
3005
5045
5046
5005
5001 5002
5003
5006
5007
5011
5008
5008
5007
5045
5026
5044
5006
5037
5064
5003
5035
5071
5043
5005
5048
5038
5014
5019
5039
5049
5040
5013
5012
5036
5018
5041
5062
5016
5031
5032
5063
5017
5047
5023
5071
5042
5029
5020
5022
5053
5028
5050
5027
5024
5034
5033
5021
5025
5026
5065
5030
5066
5052
5060
11-10
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Parts List
11.5 Wrist Unit
Table 11-5: Wrist Unit (Sheet 1 of 2)
No.
DWG No.
Name
Pcs.
5001
HW9406556-1
Support
1
5002
M4X12
GT-SA bolt
2
5003
M5X20
GT-SA bolt
4
5005
HW9200798-1
Cover
2
5006
SGMPH-02A2A-YR12
Motor
2
5007
M4X16
Socket screw
2
5008
HW9482727-A
Pulley
2
5011
80S4.5M518
Belt
1
5012
HW9381658-A
Gear
1
5013
M4X12
GT-SA bolt
4
5014
HW9405452-1
B-cover
1
5016
HW9482725-A
Pulley
1
5017
M5X16
GT-SA bolt
1
5018
M4X16
GT-SA bolt
4
5019
HW9482218-A
Bearing
1
5020
HW9405199-1
B nut
1
5021
SP-0120**
Shim
1
5022
HW9481180-A
Bearing
1
5023
M5X16
GT-SA bolt
1
5024
M5X12
GT-SA bolt
8
5025
HW0304232-1
Shaft
1
5026
TC60747
Oil seal
2
5027
HW9481187-A
Bearing
1
5028
HW0304233-1
Shaft
1
5029
S75
O ring
1
5030
HW0304087-1
Housing
1
5031
HW0382140-A
Speed reducer
1
5032
HW0304086-1
Housing
1
5033
HW9381659-A
Gear
1
5034
HW9482726-A
Pulley
1
5035
M5X16
Socket screw
1
5036
6002ZZ
Bearing
1
5037
6901ZZ
Bearing
1
5038
6814ZZ
Bearing
1
5039
HW9482668-A
Oil seal
1
5040
HW9381633-A
Speed reducer
1
5041
HW9405792-1
Housing
1
5042
HW0200451-1
Wrist base
1
5043
M5X16
GT-SA bolt
11
5044
80S4.5M653
Belt
1
5045
M5X12
GT-SA bolt
24
5046
HW0100623-1
U-arm
1
5047
M6X6
Socket screw
1
5048
M4X16
GT-SA bolt
12
11-11
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Parts List
11.5 Wrist Unit
Table 11-5: Wrist Unit (Sheet 2 of 2)
No.
DWG No.
Name
Pcs.
5049
M4X12
GT-SA bolt
4
5050
M6X6
Socket screw
1
5052
M5X16
GT-SA bolt
5
5053
M6X6
Socket screw
1
5060
M5X16
GT-SA bolt
4
5062
LP-M5
Plug
1
5063
HW9405791-3
Housing
1
5064
6811LLU
Bearing
1
5065
HW0404606-1
Cover
1
5066
HW040605-1
Plug
1
3005
HW0102378-1
Casing
1
11-12
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MOTOMAN-HP20D
MAINTENANCE MANUAL
For inquiries or after-sales service on this product, contact
your local YASKAWA representative as shown below.
YASKAWA ELECTRIC CORPORATION
2-1 Kurosakishiroishi, Yahatanishi-ku, Kitakyushu, 806-0004, Japan
Phone: +81-93-645-7703 Fax: +81-93-645-7802
www.yaskawa.co.jp
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
www.motoman.com
YASKAWA EUROPE GmbH (ROBOTICS DIVISION)
Yaskawastrasse 1, 85391, Allershausen, Germany
Phone: +49-8166-90-0 Fax: +49-8166-90-103
www.yaskawa.eu.com
YASKAWA NORDIC AB
Verkstadsgatan 2, Box 504, SE-385 25 Torsas, Sweden
Phone: +46-480-417-800 Fax: +46-486-414-10
www.yaskawa.se
YASKAWA ELECTRIC (CHINA) CO., LTD.
22F, One Corporate Avenue, No.222 Hubin Road, Huangpu District, Shanghai 200021, China
Phone: +86-21-5385-2200 Fax: +86-21-5385-3299
www.yaskawa.com.cn
YASKAWA SHOUGANG ROBOT CO., LTD.
No.2 Building, No.6 Rongchang East Street, Beijing E&T Development Area, Beijing 100176, China
Phone: +86-10-6788-2858 Fax: +86-10-6788-2878
www.ysr-motoman.cn
YASKAWA ELECTRIC KOREA CORPORATION
6F, 112, LS-ro, Dongan-gu, Anyang-si, Gyeonggi-do, 14118, Korea
Phone: +82-31-8015-4224 Fax: +82-31-8015-5034
www.yaskawa.co.kr
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
www.yaskawa.com.tw
YASKAWA ASIA PACIFIC PTE. LTD.
30A Kallang Place, #06-01, 339213, Singapore
Phone: +65-6282-3003 Fax: +65-6289-3003
www.yaskawa.com.sg
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
www.yaskawa.co.th
PT. YASKAWA ELECTRIC INDONESIA
Secure Building-Gedung B Lantai Dasar & Lantai 1 Jl. Raya Protokol Halim Perdanakusuma,
Jakarta 13610, Indonesia
Phone: +62-21-2982-6470 Fax: +62-21-2982-6471
www.yaskawa.co.id
YASKAWA INDIA PRIVATE LIMITED (ROBOTICS DIVISION)
No.136, Sector-8, Industrial Estate, IMT Manesar, Gurugram, Haryana 122050, India
Phone: +91-124-475-8500
www.yaskawaindia.in
Specifications are subject to change without notice
for ongoing product modifications and improvements.
C Printed in Japan July 2023 11-05
YASKAWA ELECTRIC CORPORATION
MANUAL NO.
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