Motomanhp 20 D

MOTOMAN-HP20D
MAINTENANCE MANUAL
TYPE:
YR-HP0020D-A00 (STANDARD SPECIFICATION FOR DX100)
YR-HP0020D-B00 (ZEROING SPECIFICATIONS FOR DX100)
YR-HP0020D-A10 (LONG U-ARM, 6kg PAYLOAD SPECIFICATION)
Procedures described in this maintenance manual should be carried out by the person who took the
maintenance-relevant trainings offered by YASKAWA.
Upon receipt of the product and prior to initial operation, read these instructions thoroughly, and retain
for future reference.
MOTOMAN INSTRUCTIONS
MOTOMAN-HP20D INSTRUCTIONS
DX100 INSTRUCTIONS
DX100 OPERATOR’S MANUAL
DX100 MAINTENACE MANUAL
The DX100 operator’s manual above corresponds to specific usage.
Be sure to use the appropriate manual.
Part Number: 159281-1CD

Revision: 1
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MANUAL NO.
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159281-1CD
HP20D
Copyright © 2018, 2011 Yaskawa America, Inc.
Terms of Use and Copyright Notice

All rights reserved. This manual is freely available as a service to Yaskawa
customers to assist in the operation of Motoman robots, related equipment
and software This manual is copyrighted property of Yaskawa and may
not be sold or redistributed in any way. You are welcome to copy this
document to your computer or mobile device for easy access but you may
not copy the PDF files to another website, blog, cloud storage site or any
other means of storing or distributing online content.
Printed in the United States of America
First Printing, 2011
Yaskawa America, Inc.

Motoman Robotics Division
100 Automation Way
Miamisburg, OH 45342
Phone: 937-847-6200
www.motoman.com
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HP20D Table of Contents
Table of Contents
1 Introduction ..................................................................................................................................... 1-1
1.1 National Safety Standard for Industrial Robots and Robot Systems ................................. 1-2
1.2 Notes for Safe Operation ................................................................................................... 1-3
1.3 Definition of Terms Used Often in This Manual ................................................................. 1-5
1.4 Registered Trademark ....................................................................................................... 1-5
1.5 Explanation of Warning Labels .......................................................................................... 1-6
1.6 Safeguarding Tips.............................................................................................................. 1-7
1.7 Mechanical Safety Devices................................................................................................ 1-7
1.8 Programming, Operation, and Maintenance Safety........................................................... 1-8
1.9 Maintenance Safety ........................................................................................................... 1-9
1.10 Summary of Warning Information .................................................................................... 1-9
1.11 Customer Support Information....................................................................................... 1-10
2 Notes for Maintenance.................................................................................................................... 2-1
2.1 Wrist Unit ........................................................................................................................... 2-1
2.2 Encoder Connector (with CAUTION Label) ....................................................................... 2-2
2.2.1 Battery Pack Connection for S-, L-, and U-axis Motors........................................ 2-2
2.2.2 Battery Pack Connection for R-, B-, and T-axis Motors........................................ 2-2
3 Home Position Return..................................................................................................................... 3-1
3.1 Home Position Return after Motor Replacement ............................................................... 3-1
3.1.1 Home Position Return by Zeroing Function.......................................................... 3-1
3.1.2 Home Position Return by Robot Calibration (MOTOCALV EG) ........................... 3-1
3.1.3 Home Position Return by Setting Teaching Point

for Home Position Setting before Motor Replacement ......................................... 3-2
3.1.3.1 Preparation before Motor Replacement .................................................. 3-2
3.1.3.2 Motor Replacement ................................................................................. 3-4
3.1.3.3 Home Position Adjustment ...................................................................... 3-5
3.2 Home Position Return in Case of Exhaustion of Robot-Axis Motor Battery ...................... 3-6
3.2.1 Home Position Return at the Time of Battery Backup by Using

the Function: Home Position Calibration Function for Restoration....................... 3-6
3.2.2 Home Position Return by Keys (for S-, L-, U-, and R-Axes)................................. 3-6
3.2.2.1 Calibration Operation .............................................................................. 3-6
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4 Grease Replenishment and Exchange ........................................................................................... 4-1
4.1 Notes on Grease Replenishment and Exchange Procedures ........................................... 4-1
4.2 Grease Replenishment and Exchange for S-Axis Speed Reducer.................................... 4-2
4.2.1 Grease Replenishment ......................................................................................... 4-2
4.2.2 Grease Exchange ................................................................................................. 4-3
4.3 Grease Replenishment and Exchange for L-Axis Speed Reducer .................................... 4-4
4.3.2 Grease Exchange ................................................................................................. 4-5
4.4 Grease Replenishment and Exchange for U-Axis Speed Reducer ................................... 4-6
4.4.2 Grease Exchange ................................................................................................. 4-7
4.5 Grease Replenishment for R-Axis Speed Reducer ........................................................... 4-8
4.6 Grease Replenishment for B- and T-Axis Speed Reducers .............................................. 4-9
4.7 Grease Replenishment for T-Axis Gear........................................................................... 4-10
4.8 Grease Replenishment for R-Axis Cross Roller Bearing ................................................. 4-11
5 Disassembly and Reassembly of Motors ........................................................................................ 5-1
5.1 Disassembly and Reassembly of S-Axis Motor ................................................................. 5-1
5.2 Disassembly and Reassembly of L-Axis Motor.................................................................. 5-4
5.3 Disassembly and Reassembly of U-Axis Motor ................................................................. 5-6
5.4 Disassembly and Reassembly of R-Axis Motor ................................................................. 5-8
5.5 Disassembly and Reassembly of B-Axis Motor ............................................................... 5-11
5.6 Disassembly and Reassembly of T-Axis Motor ............................................................... 5-13
6 Disassembly and Reassembly of Speed Reducer .......................................................................... 6-1
6.1 Disassembly and Reassembly of S-Axis Speed Reducer ................................................. 6-1
6.2 Disassembly and Reassembly of L-Axis Speed Reducer.................................................. 6-3
6.3 Disassembly and Reassembly of U-Axis Speed Reducer ................................................. 6-5
6.4 Disassembly and Reassembly of R-Axis Speed Reducer ................................................. 6-7
6.5 Disassembly and Reassembly of B-Axis Speed Reducer ................................................. 6-9
6.6 Disassembly and Reassembly of T-Axis Speed Reducer................................................ 6-12
7 Disassembly and Reassembly of Wrist Unit ................................................................................... 7-1
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8 Disassembly, Reassembly, and Adjustment of B- and T-axis Timing Belts.................................... 8-1
8.1 Disassembly and Reassembly of B- and T-axis Timing Belts ........................................... 8-1
8.2 Adjustment of Timing Belts ................................................................................................ 8-3
8.2.1 B-Axis ................................................................................................................... 8-3
8.2.2 T-Axis ................................................................................................................... 8-3
9 Battery Pack Replacement ............................................................................................................. 9-1
10 Cable Wiring ............................................................................................................................... 10-1
10.1 Disconnecting Cables .................................................................................................... 10-1
10.1.1 Cables in Wrist Unit .......................................................................................... 10-1
10.1.2 Cables in U-Arm ............................................................................................... 10-3
10.1.3 Cables in S-Head ............................................................................................. 10-6
10.2 Connecting Cables ........................................................................................................ 10-9
10.2.1 Cables in S-Head ............................................................................................. 10-9
10.2.2 Cables in U-Arm ............................................................................................. 10-10
10.2.3 Cables in Wrist Unit ........................................................................................ 10-11
11 Parts List ..................................................................................................................................... 11-1
11.1 S-Axis Unit ..................................................................................................................... 11-1
11.2 L-Axis Unit ..................................................................................................................... 11-3
11.3 U-Axis Unit..................................................................................................................... 11-5
11.4 R-Axis Unit..................................................................................................................... 11-7
11.5 Wrist Unit ..................................................................................................................... 11-10
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HP20D 1 Introduction
1 Introduction
MANDATORY
• This maintenance manual is intended to explain maintenance
procedures primarily for the MOTOMAN-HP20D.
• General items related to safety are listed in Chapter 1: Safety of the
DX100 Instructions. To ensure correct and safe operation, carefully
read the DX100 instructions before reading this manual.
CAUTION
• Some drawings in this manual are shown with the protective covers
or shields removed for clarity. Be sure all covers and shields are
replaced before operating and maintenance this product.
• The drawings and photos in this manual are representative
examples and differences may exist between them and the
delivered product.
• YASKAWA may modify this model without notice when necessary
due to product improvements, modifications, or changes in
specifications. If such modification is made, the manual number will
also be revised.
• If your copy of the manual is damaged or lost, contact a YASKAWA
representative to order a new copy. The representatives are listed
on the back cover. Be sure to tell the representative the manual
number listed on the front cover.
• YASKAWA is not responsible for incidents arising from unauthorized
modification of its products. Unauthorized modification voids your
product's warranty.
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1.1 National Safety Standard for Industrial Robots and Robot Systems
1.1 National Safety Standard for Industrial Robots and Robot

Systems
We suggest that you obtain and review a copy of the ANSI/RIA National
Safety Standard for Industrial Robots and Robot Systems (ANSI/RIA
R15.06-2012). You can obtain this document from the Robotic Industries
Association (RIA) at the following address:
Robotic Industries Association
900 Victors Way
P.O. Box 3724
Ann Arbor, Michigan 48106
TEL: (734) 994-6088
FAX: (734) 994-3338
www.roboticsonline.com
Ultimately, well-trained personnel are the best safeguard against
accidents and damage that can result from improper operation of the
equipment. The customer is responsible for providing adequately trained
personnel to operate, program, and maintain the equipment. NEVER
ALLOW UNTRAINED PERSONNEL TO OPERATE, PROGRAM, OR
REPAIR THE EQUIPMENT!
We recommend approved Yaskawa training courses for all personnel
involved with the operation, programming, or repair of the equipment.
This equipment has been tested and found to comply with the limits for a
Class A digital device, pursuant to part 15 of the FCC rules. These limits
are designed to provide reasonable protection against harmful
interference when the equipment is operated in a commercial
environment. This equipment generates, uses, and can radiate radio
frequency energy and, if not installed and used in accordance with the
instruction manual, may cause harmful interference to radio
communications.
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1.2 Notes for Safe Operation

Read this manual carefully before installation, operation, maintenance, or
inspection of the DX100.
In this manual, the Notes for Safe Operation are classified as
“WARNING”, “CAUTION”, “MANDATORY”, or “PROHIBITED”.
Indicates an imminent hazardous

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

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

CAUTION 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.
Always be sure to follow explicitly the

MANDATORY items listed under this heading.
Must never be performed.

PROHIBITED
Even items described as “CAUTION” may result in a serious accident in

some situations.
At any rate, be sure to follow these important items
To ensure safe and efficient operation at all times, be sure to

NOTE 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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WARNING
• Before operating the manipulator, check that servo power is turned
OFF pressing the emergency stop buttons.
When the servo power is turned OFF, the SERVO ON LED on the
programming pendant is turned OFF.
Injury or damage to machinery may result if the emergency stop circuit
cannot stop the manipulator during an emergency. The manipulator
should not be used if the emergency stop buttons do not function.
Figure 1: Emergency Stop Button
• Once the emergency stop button is released, clear the cell of all
items which could interfere with the operation of the manipulator.
Then turn the servo power ON.
Injury may result from unintentional or unexpected manipulator motion.
Figure 2: Release of Emergency Stop
TURN
• Observe the following precautions when performing teaching

operations within the P-point maximum envelope of the
manipulator:
– Be sure to use a lockout device to the safeguarding when going
inside. Also, display the sign that the operation is being
performed inside the safeguarding and make sure no one closes
the safeguarding.
– View the manipulator from the front whenever possible.
– Always follow the predetermined operating procedure.
– Keep in mind the emergency response measures against the
manipulator’s unexpected motion toward you.
– Ensure that you have a safe place to retreat in case of
emergency.
Improper or unintended manipulator operation may result in injury.
• Confirm that no person is present in the P-point maximum envelope
of the manipulator and that you are in a safe location before:
– Turning ON the power for the DX100.
– Moving the manipulator with the programming pendant.
– Running the system in the check mode.
– Performing automatic operations.
Injury may result if anyone enters the P-point maximum envelope of the
manipulator during operation. Always press an emergency stop button
immediately if there is a problem.
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1.3 Definition of Terms Used Often in This Manual
CAUTION
• Perform the following inspection procedures prior to conducting
manipulator teaching. If problems are found, repair them
immediately,
and be sure that all other necessary processing has been
performed.
– Check for problems in manipulator movement.
– Check for damage to insulation and sheathing of external wires.
• For the DX100, always return the programming pendant to the hook
on the cabinet of the DX100 after use.
For the FS100, always return the programming pendant to a safe
place after use.
The programming pendant can be damaged if it is left in the
manipulator's work area, on the floor, or near fixtures.
• Read and understand the Explanation of Warning Labels in the
DX100 Instructions before operating the manipulator:
1.3 Definition of Terms Used Often in This Manual

The MOTOMAN is the YASKAWA industrial robot product.
The MOTOMAN usually consists of the manipulator, the controller, the
programming pendant, and supply cables.
In this manual, the equipment is designated as follows:
Equipment Manual Designation
DX100 controller DX100
DX100 programming pendant Programming pendant
Cable between the manipulator and the Manipulator cable
controller
1.4 Registered Trademark

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

The following warning labels are attached to the manipulator.
Always follow the warnings on the labels.
Also, an identification label with important information is placed on the
body of the manipulator. Prior to operating the manipulator, confirm the
contents.
Figure 3: Warning Label Locations
Warning label B
Warning label A
Warning label B
Nameplate
Nameplate Warning Label A:
MODEL
MOTOMAN-
WARNING
TYPE
PAYLOAD MASS Moving parts

kg kg
ORDER NO. DATE may cause
SERIAL NO. injury
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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1.6 Safeguarding Tips
1.6 Safeguarding Tips

All operators, programmers, maintenance personnel, supervisors, and
anyone working near the system must become familiar with the operation
of this equipment. All personnel involved with the operation of the
equipment must understand potential dangers of operation. General
safeguarding tips are as follows:
• Improper operation can result in personal injury and/or damage to
the equipment. Only trained personnel familiar with the operation of
this equipment, the operator's manuals, the system equipment, and
options and accessories should be permitted to operate this
equipment.
• Improper connections can damage the equipment. All connections
must be made within the standard voltage and current ratings of the
equipment.
• The system must be placed in Emergency Stop (E-Stop) mode
whenever it is not in use.
• In accordance with ANSI/RIA R15.06-2012, section 4.2.5, Sources of
Energy, use lockout/tagout procedures during equipment
maintenance. Refer also to Section 1910.147 (29CFR, Part 1910),
Occupational Safety and Health Standards for General Industry
(OSHA).
1.7 Mechanical Safety Devices

The safe operation of this equipment is ultimately the users responsibility.
The conditions under which the equipment will be operated safely should
be reviewed by the user. The user must be aware of the various national
codes, ANSI/RIA R15.06-2012 safety standards, and other local codes
that may pertain to the installation and use of this equipment.
Additional safety measures for personnel and equipment may be required
depending on system installation, operation, and/or location. The following
safety equipment is provided as standard:
• Safety barriers
• Door interlocks
• Emergency stop palm buttons located on operator station
Check all safety equipment frequently for proper operation. Repair or
replace any non-functioning safety equipment immediately.
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1.8 Programming, Operation, and Maintenance Safety
1.8 Programming, Operation, and Maintenance Safety

All operators, programmers, maintenance personnel, supervisors, and
anyone working near the system must become familiar with the operation
of this equipment. Improper operation can result in personal injury and/or
damage to the equipment. Only trained personnel familiar with the
operation, manuals, electrical design, and equipment interconnections of
this equipment should be permitted to program, or maintain the system.
All personnel involved with the operation of the equipment must
understand potential dangers of operation.
• Inspect the equipment to be sure no potentially hazardous conditions
exist. Be sure the area is clean and free of water, oil, debris, etc.
• Be sure that all safeguards are in place. Check all safety equipment
for proper operation. Repair or replace any non-functioning safety
equipment immediately.
• Check the E-Stop button on the operator station for proper operation
before programming. The equipment must be placed in Emergency
Stop (E-Stop) mode whenever it is not in use.
• Back up all programs and jobs onto suitable media before program
changes are made. To avoid loss of information, programs, or jobs, a
backup must always be made before any service procedures are
done and before any changes are made to options, accessories, or
equipment.
• Any modifications to the controller unit can cause severe personal
injury or death, as well as damage to the robot! Do not make any
modifications to the controller unit. Making any changes without the
written permission from Yaskawa will void the warranty.
• Some operations require standard passwords and some require
special passwords.
• The equipment allows modifications of the software for maximum
performance. Care must be taken when making these modifications.
All modifications made to the software will change the way the
equipment operates and can cause severe personal injury or death,
as well as damage parts of the system. Double check all
modifications under every mode of operation to ensure that the
changes have not created hazards or dangerous situations.
• This equipment has multiple sources of electrical supply. Electrical
interconnections are made between the controller and other
equipment. Disconnect and lockout/tagout all electrical circuits
before making any modifications or connections.
• Do not perform any maintenance procedures before reading and
understanding the proper procedures in the appropriate manual.
• Use proper replacement parts.
• Improper connections can damage the equipment. All connections
must be made within the standard voltage and current ratings of the
equipment.
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1.9 Maintenance Safety
1.9 Maintenance Safety

Turn the power OFF and disconnect and lockout/tagout all electrical
circuits before making any modifications or connections.
Perform only the maintenance described in this manual. Maintenance
other than specified in this manual should be performed only by Yaskawa-
trained, qualified personnel.
1.10 Summary of Warning Information

This manual is provided to help users establish safe conditions for
operating the equipment. Specific considerations and precautions are also
described in the manual, but appear in the form of Dangers, Warnings,
Cautions, and Notes.
It is important that users operate the equipment in accordance with this
instruction manual and any additional information which may be provided
by Yaskawa. Address any questions regarding the safe and proper
operation of the equipment to Yaskawa Customer Support.
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1.11 Customer Support Information
1.11 Customer Support Information

If you need assistance with any aspect of your HP20D system, please
contact YASKAWA Customer Support at the following 24-hour telephone
number:
(937) 847-3200
For routine technical inquiries, you can also contact YASKAWA Customer
Support at the following e-mail address:
techsupport@motoman.com
When using e-mail to contact YASKAWA Customer Support, please

provide a detailed description of your issue, along with complete contact
information. Please allow approximately 24 to 36 hours for a response to
your inquiry.
Please use e-mail for routine inquiries only. If you have an

NOTE urgent or emergency need for service, replacement parts,
or information, you must contact YASKAWA Customer
Support at the telephone number shown above.
Please have the following information ready before you call Customer
Support:
• System HP20D
• Robots ___________________________
• Primary Application ___________________________
• Controller DX100
• Software Version Access this information on the

Programming Pendant’s LCD
display screen by selecting {MAIN
MENU} - {SYSTEM INFO} -
{VERSION}
• Robot Serial Number Located on the robot data plate
• Robot Sales Order Number Located on the DX100 controller

data plate
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HP20D 2 Notes for Maintenance
2.1 Wrist Unit
2 Notes for Maintenance
• 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
NOTE 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 matching surface

Cover
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2.2 Encoder Connector (with CAUTION Label)

Before disconnecting the encoder connector (with CAUTION label),
connect the battery pack to the motor referring to Fig. 2-2 “Battery Pack
Connection”.
2.2.1 Battery Pack Connection for S-, L-, and U-axis Motors
The connectors (crimped contact-pin) for the battery backup are installed
at the end point of the motor (BAT and OBT are marked). Connect the
battery pack according to the following procedure.
1. Remove the caps attached to the battery backup connectors of the
motor.
2. Connect the battery pack (HW9470932-A) with the battery backup
connectors located at the end point of the encoder cable. (Under this
condition, remove the encoder connector and carry out the
maintenance checks.)
3. After the maintenance check, confirm that all the connectors are
connected, then remove the battery pack. Install the caps attached to
the battery backup connectors of the motor.
2.2.2 Battery Pack Connection for R-, B-, and T-axis Motors
The connectors (crimped contact-pin) for the battery backup are installed
at the end point of the encoder cables for the motor (BAT and OBT are
marked). Connect the battery pack according to the following procedure.
1. Connect the battery pack (HW9470932-A) with the battery backup
connectors located at the end point of the encoder cable. (Under this
condition, remove the encoder connector and carry out the
maintenance checks.)
2. After the maintenance check, confirm that all the connectors are
connected, then remove the battery pack.
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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
Motor R-, B-, T-axis motor
Motor cable, etc.
Internal Power connector

wire
a 0BT1
0BT b b BAT1
BAT a
removing connector.
CAUTION
Encoder connector Battery pack (HW9470932-A)
Battery backup connector

CAUTION label
0BT b a 0BT1
CAUTION Label (Enlarged View)
BAT a b BAT1
CAUTION a: Crimped contact-pin (pin)

b: Crimped contact-pin (socket)

removing connector.
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HP20D 3 Home Position Return
3.1 Home Position Return after Motor Replacement
3 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.
3.1.1 Home Position Return by Zeroing Function

The zeroing function is an optional function which automatically allows the
restoration of the home position data when the manipulator’s home
position data disappears.
For the details of this function, refer to “INSTRUCTIONS FOR ZEROING
FUNCTION”.
3.1.2 Home Position Return by Robot Calibration (MOTOCALV EG)

The MOTOCALV EG allows the home position reset by teaching the five-
point-in-five-posture.
Refer to “MOTOCALV EG for Windows Operator’s Manual” (manual No.
HW0483085) for details on the operation.
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3.1.3 Home Position Return by Setting Teaching Point for Home Position Setting
before Motor Replacement
The DX100 holds the position data of the job program (hereinafter called
JOB) as the pulse number from the home position of each axis. Thus, by
adjusting the home position precisely, the JOB used before motor
replacement can be used after the replacement without correction.
This section explains how to set the DX100.
3.1.3.1 Preparation before Motor Replacement

• Refer to the Fig. 3-1 “Preparation before Motor Replacement
(Example)”.
Before motor replacement, create the standard position (hereinafter called
the check-point) for home position adjustment after the replacement. The
check-point must satisfy the conditions below. Furthermore, create the
JOB so that the manipulator safely moves to the check-point from the
standby position. (The JOB created in this manner will be hereinafter
called the check-JOB.)
1 The position should not be deviated by turning the power ON or OFF,
or lowering air pressure. Do not create the check point in the working
part of the tool (end effecter) or the jigs (related unit including the rotary
table). It is recommended to use a specific jig if necessary.
2 Use pointed jigs to create the position so that the deviation is easily
found.
Keep a distance as long as possible from the rotational center of the
replacing axis.
3 Considering the moving direction of the replacing axis, create the

position at the point where any deviation is easily found and the axis will
not interfere with jigs even if it is deviated.
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Example of Check-Point Creation when Replacing U-Axis’s

Motor of HP20D-A00
• The check-point cannot be created unless each axis operates. Thus,
the check-point cannot be created if the axis does not move because
of failure. Therefore, it is recommended to create the check-point for
each axis under normal operating conditions.
Next, check the home position of the axis whose motor will be
replaced. Refer to the position screen, and move the axis to the 0-
pulse position, the home position. Then, check the position of the
home position mark. If it is deviated, adjust it.
The U-axis of YR-HP0020D-A00 is shown below as an example.
Fig. 3-1: Preparation before Motor Replacement (Example)
Home position mark
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3.1.3.2 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 Home Position Adjustment

After motor replacement, move the axis to the position of the home
position mark. Perform the home position calibration only to the axis
whose motor was replaced.
(For more information, refer to “DX100 INSTRUCTIONS”
(manual No. RE-CTO-A215).)
Move the axis to the check-point by the check-JOB. (Be careful when
moving the axis so that the manipulator does not interfere with jigs.) Move
only the axis whose motor was replaced to correct the deviation from the
check-point created before calibration.
Display the position screen (COMMAND POSITION).
The values of the U-axis is shown below as an example.
By using the above values, calculate the amount of deviation. (Subtract

the CMD (command value) from the CURR (current value).)
CURR - CMD = the amount of deviation
U (-3067) - (-2989) = -78
Perform stepping back, etc. of the check JOB to move the axis whose
motor was replaced to the position where the axis will not interfere with
jigs when it moves to the home position. (Be careful when moving the
axis so that the manipulator does not interfere with jigs.) Refer to the
position screen, and move the axis to the pulse position equal to the
amount of deviation.
An example is shown below.
At this position, perform the home position calibration only for the axis
whose motor was replaced.
(For more information, refer to “DX100 INSTRUCTIONS”
(manual No. RE-CTO-A215).)
Move the axis again to the check-point by the check-JOB. Check if the
axis is at the check-point created before the operation. (If it is deviated,
repeat the adjustment procedures.)
Perform an operation check by using the JOB used before motor
replacement. If no problem is found, write down the modified home
position data (ABSO data) and the date in the label on the inside of the
DX100.
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3.2 Home Position Return in Case of Exhaustion of Robot-Axis Motor
Battery
3.2 Home Position Return in Case of Exhaustion of Robot-Axis Motor Battery
3.2.1 Home Position Return at the Time of Battery Backup by Using the
Function: Home Position Calibration Function for Restoration
To start the home position calibration function for restoration, move the
manipulator to the posture close to the home position (within one motor
rotation), then execute the software program “Backup alarm restoration”
on the programming pendant.
The home position return by this function updates the multi-turn data for
motor.
3.2.2 Home Position Return by Keys (for S-, L-, U-, and R-Axes)
To enable the home position return by using keys, write down the
differential pulse between the key position and the default home position
on the home position label on the inside of the DX100.
If the home position data disappears, move the manipulator to the key
position. Then, as the home position, set the position where the above
differential pulse is added to the key position.
3.2.2.1 Calibration Operation

The parts in Table 3-1 "Parts List"are required for calibration. Prepare
them before calibration operation.
Table 3-1: Parts List
Drawing No. Name Qty. Remark
SFJW6-100 Shaft 1 For S-, L-, and U-

axes
SFJW4-100 Shaft 1 For R-axis
 S-Axis Positioning
As shown in Fig. 3-3 “S-Axis Positioning”, insert the shaft SFJW6-100 in
the hole ( 6 +0.012
0 dia. ) on the S-head. Then, perform positioning with the
programming pendant so that the shaft fits into the hole on the base.
Fig. 3-3: S-Axis Positioning
S-head
Shaft
Base
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 L-Axis Positioning
As shown in Fig. 3-4 “L-Axis Positioning”, insert the shaft SFJW6-100 in
the hole ( 6 +0.012
0 dia. ) on the S-head. Then, perform positioning with the
programming pendant so that the shaft fits into the hole on the L-arm.
Fig. 3-4: L-Axis Positioning
L-arm
Shaft
S-head
 U-Axis Positioning
As shown in Fig. 3-5 “U-Axis Positioning”, insert the shaft SFJW6-100 in
the hole ( 6 +0.012
0 dia. ) on the casing. Then, perform positioning with the
programming pendant so that the shaft fits into the hole on the L-arm.
Fig. 3-5: U-Axis Positioning
Casing
Shaft
L-arm
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 R-Axis Positioning
As shown in Fig. 3-6 “R-Axis Positioning”, insert the shaft SFJW4-100 in
the hole ( 4 +0.012
0 dia. ) on the U-arm. Then, perform positioning with the
programming pendant so that the shaft fits into the hole on the casing.
Fig. 3-6: R-Axis Positioning
U-arm
Shaft
Casing
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HP20D 4 Grease Replenishment and Exchange
4.1 Notes on Grease Replenishment and Exchange Procedures
4 Grease Replenishment and Exchange
4.1 Notes on Grease Replenishment and Exchange Procedures

Make sure to follow the instructions listed below at grease replenishment
or exchange. Failure to observe the following notes may result in damage
to the motor or speed reducer.
• If grease is added without removing the plug or screw from

grease exhaust port, grease will leak inside a motor or an
oil seal of a speed reducer will come off, which may result
in damage to the motor. Make sure to remove the plug.
• Do not install a joint, a hose, etc. to the grease exhaust
port. Failure to observe this instruction may result in
NOTE damage to the motor due to coming off of an oil seal.
• Make sure to use a grease pump to inject grease. Set air
supply pressure to the grease pump at 0.3 MPa or less,
and the grease injection rate at 8 g/s or less.
• Make sure to fill the hose on the grease inlet with grease
beforehand to prevent air from leaking into the speed
reducer.
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4.2 Grease Replenishment and Exchange for S-Axis Speed Reducer

Fig. 4-1: S-Axis Speed Reducer
Grease exhaust port

(Hexagon socket head plug PT1/8)
Grease inlet
S-axis speed reducer
NOTE For ceiling mounted manipulators, the exhaust port and the
grease inlet are inverted.
4.2.1 Grease Replenishment

(Refer to Fig. 4-1 “S-Axis Speed Reducer”.)
1. Remove the hexagon socket head plugs from the grease inlet and the
grease exhaust port.
If grease is injected with the plug on, grease will leak inside
NOTE the motor and may cause a damage. Make sure to remove
the plug before grease injection.
2. Install the grease zerk PT1/8 to the grease inlet.

(The grease zerk is delivered with the manipulator.)
3. Inject grease through the grease inlet using a grease gun.
– Grease type: VIGO Grease RE No.0
– Amount of grease: 30 cc
(60 cc for 1st supply)
– Air supply pressure of grease pump: 0.3 MPa or less
– Grease injection rate: 8 g/s or less
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4. Move the S-axis for a few minutes to discharge excess grease.

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

(Refer to Fig. 4-1 “S-Axis Speed Reducer”.)
1. Remove the hexagon socket head plugs from the grease inlet and the
grease exhaust port.
2. Install the grease zerk PT1/8 to the grease inlet.

– Amount of grease: approx. 1800 cc
4. The grease exchange is completed when new grease appears in the
exhaust port. (The new grease can be distinguished from the old
grease by color.)
5. Move the S-axis for a few minutes to discharge excess grease.
(0.51 kgf•m).
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4.3 Grease Replenishment and Exchange for L-Axis Speed Reducer

Fig. 4-2: L-Axis Speed Reducer
Grease exhaust port

L-arm
L-axis speed reducer
Grease inlet
(Hexagon socket head cap screw M6)

(Refer to Fig. 4-2 “L-Axis Speed Reducer”.)
1. Make the L-arm vertical to the ground.
2. Remove the hexagon socket head cap screw from the grease inlet and
the hexagon socket head plug from the grease exhaust port.
3. Install the grease zerk A-MT6 x 1 to the grease inlet.

– Grease type: VIGO Grease No.0
5. Move the L-axis for a few minutes to discharge excess grease.
6. Remove the grease zerk from the grease inlet and reinstall the screw.
Apply ThreeBond 1206C to the thread part of the screw, and tighten
the screw with a tightening torque of 5 N•m (0.51 kgf•m).
(0.51 kgf•m).
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(Refer to Fig. 4-2 “L-Axis Speed Reducer”.)
1. Make the L-arm vertical to the ground.
the hexagon socket head plug from the grease exhaust port.

grease by color.)
6. Move the L-axis for a few minutes to discharge excess grease.
(0.51 kgf•m).
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4.4 Grease Replenishment and Exchange for U-Axis Speed Reducer

Fig. 4-3: U-Axis Speed Reducer
U-arm
Grease exhaust port

U-axis speed reducer
Grease inlet
NOTE For ceiling mounted manipulators, the exhaust port and the
grease inlet are inverted.

(Refer to Fig. 4-3 “U-Axis Speed Reducer”.)
1. Make the U-arm horizontal to the ground.
2. Remove the hexagon socket head plug from the grease inlet and the
hexagon socket head cap screw from the grease exhaust port.

5. Move the U-axis for a few minutes to discharge excess grease.
7. Wipe the discharged grease with a cloth, and reinstall the screw on the
screw, and tighten the screw with a tightening torque of 5 N•m
(0.51 kgf•m).
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(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.

grease by color.)
6. Move the U-axis for a few minutes to discharge excess grease.
8. Wipe the discharged grease with a cloth, and reinstall the screw on the
screw, and tighten the screw with a tightening torque of 5 N•m
(0.51 kgf•m).
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4.5 Grease Replenishment for R-Axis Speed Reducer
4.5 Grease Replenishment for R-Axis Speed Reducer

Fig. 4-4: R-Axis Speed Reducer
Grease inlet
(Grease zerk A-MT6 x 1)
Exhaust port
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
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 Grease Replenishment for B- and T-Axis Speed Reducers
4.6 Grease Replenishment for B- and T-Axis Speed Reducers

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

(Plug LP-M5)
T-axis speed reducer
T-axis exhaust port

B-axis speed reducer (Hexagon socket set screw M6)
T-axis grease inlet

B-axis grease inlet
the plug LP-M5 or the hexagon socket set screw from the exhaust
port.
NOTE For the B-axis, remove the cover.

(See Fig. 4-5 “B- and T-Axis Speed Reducers”.)
– Amount of grease: B-axis: 10 cc
T-axis: 5 cc
4. Reinstall the plug or screw on the exhaust port. Apply ThreeBond

1206C to the thread part of the plug or screw.
NOTE For the B-axis, mount the cover. (Refer to chapter 2 “Notes
for Maintenance”.)
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4.7 Grease Replenishment for T-Axis Gear
4.7 Grease Replenishment for T-Axis Gear

Fig. 4-6: T-Axis Gear
Exhaust port
(Plug LP-M5)
Gear grease inlet

the plug LP-M5 from the exhaust port.
(See Fig. 4-6 “T-Axis Gear”.)
– Amount of grease: 5cc
4. Reinstall the plug on the exhaust port. Apply ThreeBond 1206C to the
thread part of the plug.
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4.8 Grease Replenishment for R-Axis Cross Roller Bearing
4.8 Grease Replenishment for R-Axis Cross Roller Bearing

Fig. 4-7: R-Axis Cross Roller Bearing
Exhaust port
(Plug LP-M5)
R-axis cross roller bearing
Grease inlet
(Hexagon socket head cap screw M6 x 6)
the plug LP-M5 from the exhaust port.
(See Fig. 4-7 “R-Axis Cross Roller Bearing”.)
4. Reinstall the plug on the exhaust port. Apply ThreeBond 1206C to the
thread part of the plug.
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HP20D 5 Disassembly and Reassembly of Motors
5.1 Disassembly and Reassembly of S-Axis Motor
5 Disassembly and Reassembly of Motors

• Refer to Fig. 5-1 “Disassembly and Reassembly of S-Axis Motor”.
• Refer to chapter 3 “Home Position Return”, chapter 4

“Grease Replenishment and Exchange”, and chapter 8
“Disassembly, Reassembly, and Adjustment of B- and T-
axis Timing Belts”.
NOTE
• 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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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 3 Tightening torque:
(length: 30 mm) 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 1 Tightening torque:
(length: 60 mm) each 16.5 N•m
Conical spring washer 2H-6
7 Cover HW0305809-1 1
8 Cross head APS bolt M5 4
(length: 10 mm)
9 Internal wiring harness 1
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Fig. 5-1: Disassembly and Reassembly of S-Axis Motor
2
1
1
4
8 2
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5.2 Disassembly and Reassembly of L-Axis Motor

• Refer to Fig. 5-2 “Disassembly and Reassembly of L-Axis Motor”.
 Disassembly
1. Turn OFF the DX100 power supply, then drain grease.
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.
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 .)
tighten it with the tightening torque shown in Table 5-2 "L-Axis Motor
Parts Checklist".
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.
9. Remove the chain block, etc. which support the L-arm.
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Table 5-2: L-Axis Motor Parts Checklist

No. Name Qty. Notes
1 L-axis motor HW0387863-A 1 SGMRV-13ANA-YR21
3 M-base HW0304229-1 1
4 Input gear HW0313492-1 1
5 Key 1
7 Plate HW0401506-1 1
Fig. 5-2: Disassembly and Reassembly of L-Axis Motor
S-head
3
1 2
6
7
4
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5.3 Disassembly and Reassembly of U-Axis Motor

• Refer to Fig. 5-3 “Disassembly and Reassembly of U-Axis Motor”.
 Disassembly
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 .
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.
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 .)
tighten it with the tightening torque shown in Table 5-3 "U-Axis Motor
Parts Checklist".
face of the U-axis motor 1 and the casing. Then, mount the U-axis
motor 1 on the casing.
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 .
9. Remove the chain block, etc. which support the U-arm.
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Table 5-3: U-Axis Motor Parts Checklist

No. Name Qty. Notes
1 U-axis motor HW0387860-A 1 SGMRV-05ANA-YR11
3 Input Gear 1
4 Key 1
(length: 65 mm) each 10 N•m
6 Cover HW0305305-1 1
(length: 20 mm) 10 N•m
8 Cover HW0313489-1 1
(length: 10 mm) each
Flat washer 4.3 x 12.0 x 0.8
Fig. 5-3: Disassembly and Reassembly of U-Axis Motor
6 4
9 5
3
1
Casing
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5.4 Disassembly and Reassembly of R-Axis Motor

• Refer to Fig. 5-4 “Disassembly and Reassembly of R-Axis Motor”.
 Disassembly
2. Remove the GT-SA bolts 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 .
part: 40 mm or more) in the tapped holes M6 (2 holes) on the M-
base 4 . Screw the stud bolts in until the gap between the motor and
the matching surface becomes 10 mm or more. Then, remove the M-
base 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 .
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 M-
base 4 and the casing. Then, mount the M-base 4 on the casing.
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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Table 5-4: R-Axis Motor Parts Checklist

No. Name Qty. Notes
1 R-axis motor HW0389298-A 1 SGMPH-02ANA-YR11
4 M-base HW0304932-1 1
5 Shaft HW0404402-1 1
6 Speed reducer 1 Wave generator
HW0381463-A
7 Washer HW0404196-5 1
9 Cover HW0305305-1 1
11 Oil seal AE1314A0 1
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Fig. 5-4: Disassembly and Reassembly of R-Axis Motor
2
1 5 6 7
8
10 3 4
11
Apply ThreeBond 1206C. Fill with Harmonic grease SK-1A.

(See the step 4 of the R-axis (See the step 3 of the R-axis
reassembly procedure.) reassembly procedure.)
Casing
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5.5 Disassembly and Reassembly of B-Axis Motor

• Refer to Fig. 5-5 “Disassembly and Reassembly of B-Axis Motor”.
 Disassembly
2. Remove the GT-SA bolts 6 , then remove the covers 5 .
wiring harness connected to the B-axis motor 1 . Then, connect the
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.
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 .
"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 B-
and T-axis Timing Belts” to adjust the belt tension.)
the B-axis motor 1 , and remove the backup battery. Then, put the
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.)
5-5 "B-Axis Motor Parts Checklist".
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Table 5-5: B-Axis Motor Parts Checklist

No. Name Qty. Notes
1 B-axis motor HW0389298-A 1 SGMPH-02ANA-YR11
3 Pulley HW9482727-A 1
5 Cover HW9200798-1 2
Fig. 5-5: Disassembly and Reassembly of B-Axis Motor
2 1 5
6
6 5 4 3
U-arm
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5.6 Disassembly and Reassembly of T-Axis Motor

• Refer to Fig. 5-6 “Disassembly and Reassembly of T-Axis Motor”.
 Disassembly
2. Remove the B-axis motor 5 . (Perform the steps 2 to 4 of
“Disassembly” in section 5.5 “Disassembly and Reassembly of B-Axis
Motor”.)
wiring harness connected to the T-axis motor 1 . Then, connect the
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.
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 .
"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 B-
and T-axis Timing Belts” to adjust the belt tension.)
the T-axis motor 1 , and remove the backup battery. Then, put the
6. Remove the B-axis motor 5 . (Perform the steps 3 to 7 of
“Reassembly” in section 5.5 “Disassembly and Reassembly of B-Axis
Motor”.)
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Table 5-6: T-Axis Motor Parts Checklist

No. Name Qty. Notes
1 T-axis motor HW0389298-A 1 SGMPH-02ANA-YR11
5 B-axis motor HW0382152-A 1
Fig. 5-6: Disassembly and Reassembly of T-Axis Motor
5 3 4
2 1
U-arm
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HP20D 6 Disassembly and Reassembly of Speed Reducer
6.1 Disassembly and Reassembly of S-Axis Speed Reducer
6 Disassembly and Reassembly of Speed Reducer

• Refer to Fig. 6-1 “Disassembly and Reassembly of S-Axis Speed
Reducer”.
• Refer to chapter 3 “Home Position Return”, chapter 4

“Grease Replenishment and Exchange”, chapter 5
“Disassembly and Reassembly of Motors”, chapter 7
NOTE “Disassembly and Reassembly of Wrist Unit”, and chapter
10 “Cable Wiring”.
• Remove old sealing bond on each part completely before
reassembly.
 Disassembly
2. Remove the S-axis motor 4 . (Perform the steps 2 to 6 of
“Disassembly” in section 5.1 “Disassembly and Reassembly of S-Axis
Motor”.)
3. Remove the hexagon socket head cap screws 6 , then remove the M-
base 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.
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 .
6-1 "S-Axis Speed Reducer Parts Checklist".
5. Remove the old sealing bond on the matching surface between the M-
base 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. 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 section 5.1 “Disassembly
and Reassembly of S-Axis Motor”.)
Table 6-1: S-Axis Speed Reducer Parts Checklist

No. Name Qty. Notes
1 Speed reducer HW0387753-B 1
4 S-axis motor HW0388932-A 1 SGMRV-09ANA-YR11
5 M-base HW0305306-2 1
Fig. 6-1: Disassembly and Reassembly of S-Axis Speed Reducer
3
6
5
S-head
Internal wiring harness
Base
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6.2 Disassembly and Reassembly of L-Axis Speed Reducer

• Refer to Fig. 6-2 “Disassembly and Reassembly of L-Axis Speed
Reducer”.
 Disassembly
2. Before removing the L-arm 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
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.)
6-2 "L-Axis Speed Reducer Parts Checklist".
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".
Table 6-2: L-Axis Speed Reducer Parts Checklist

No. Name Qty. Notes
1 Speed reducer HW0387753-C 1
3 L-arm HW0100546-2 1
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Fig. 6-2: Disassembly and Reassembly of L-Axis Speed Reducer
S-head
L-axis motor
Input gear
4
3 5
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6.3 Disassembly and Reassembly of U-Axis Speed Reducer

• Refer to Fig. 6-3 “Disassembly and Reassembly of U-Axis Speed
Reducer”.
 Disassembly
2. Before removing the U-arm unit, support the U-arm unit with a chain
block, etc. to prevent it from falling.
3. Remove the hexagon socket head cap screws 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 section 5.3 “Disassembly and Reassembly
of U-Axis Motor”.)
5. Remove the GT-SA bolts 2 , then remove the speed reducer 1 .
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.)
"U-Axis Speed Reducer Parts Checklist".
reducer 1 and the U-arm unit. Then, mount the speed reducer 1 on
the U-arm unit.
6-3 "U-Axis Speed Reducer Parts Checklist".
5. Mount the U-axis motor on the U-arm unit. (Perform “Reassembly” in
section 5.3 “Disassembly and Reassembly of U-Axis Motor”.)
reducer 1 and the L-arm. Then, mount the U-arm unit with the speed
reducer 1 on the L-arm.
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.
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Table 6-3: U-Axis Speed Reducer Parts Checklist

No. Name Qty. Notes
1 Speed reducer HW9280880-G 1
Conical spring washer GT-SH-14
5 Input gear 1
Fig. 6-3: Disassembly and Reassembly of U-Axis Speed Reducer
U-arm unit
U-axis motor L-arm
1 2
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6.4 Disassembly and Reassembly of R-Axis Speed Reducer

• Refer to Fig. 6-4 “Disassembly and Reassembly of R-Axis Speed
Reducer”.
 Disassembly
2. Remove the R-axis motor. (Perform the steps 2 to 5 of “Disassembly”
in section 5.4 “Disassembly and Reassembly of R-Axis Motor”.)
3. Remove the GT-SA bolts 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.
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.
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 section 5.4
“Disassembly and Reassembly of R-Axis Motor”.)
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Table 6-4: R-Axis Speed Reducer Parts Checklist

No. Name Qty. Notes
1 Speed reducer 1 Circular spline
HW0381463-A
2 Speed reducer 1 Flex spline
HW0381463-A
HW0381463-A
4 Shaft HW0404403-1 1
Fig. 6-4: Disassembly and Reassembly of R-Axis Speed Reducer
1 3 2
5
R-axis motor Casing
6 4
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6.5 Disassembly and Reassembly of B-Axis Speed Reducer

• Refer to Fig. 6-5 “Disassembly and Reassembly of B-Axis Speed
Reducer”.
 Disassembly
2. Remove the GT-SA bolts 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 .
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.
6-5 "B-Axis Speed Reducer Parts Checklist".
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.
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.)
"B-Axis Speed Reducer Parts Checklist".
7. Insert the wave generator 3 assembled at the step 5 above in the wrist
base.
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 T-axis 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.
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Table 6-5: B-Axis Speed Reducer Parts Checklist

No. Name Qty. Notes
HW9381633-A
HW9381633-A
HW9381633-A
5 Timing belt 80S4.5M653 1
8 Bearing 6002ZZ 1
10 Cover HW9200798-1 2
12 Bearing 6901ZZ 1
15 Housing HW9405792-1 1
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Fig. 6-5: Disassembly and Reassembly of B-Axis Speed Reducer

B-axis motor Wrist base U-arm
14 13 1 12
11
3
15
5 10
6
4 9 8 7
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6.6 Disassembly and Reassembly of T-Axis Speed Reducer

• Refer to Fig. 6-6 “Disassembly and Reassembly of T-Axis Speed
Reducer”.
 Disassembly
2. Remove the GT-SA bolts 10 , then remove the right side part from the
point “A” in chapter 6-6 “Disassembly and Reassembly of T-Axis
Speed Reducer”.
3. Remove the circular spline 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 .
"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 .
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.
6-6 "T-Axis Speed Reducer Parts Checklist".
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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 .
6-6 "T-Axis Speed Reducer Parts Checklist".
13. Replenish grease (Harmonic Grease SK-1A) through the grease inlet.
Table 6-6: T-Axis Speed Reducer Parts Checklist

No. Name Qty. Notes
HW0382140-A
HW0382140-A
HW0382140-A
6 Housing HW0304086-1 1
7 Gear HW9381659-A 1
9 Shim
(Refer to the table in the previous page.)
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Fig. 6-6: Disassembly and Reassembly of T-Axis Speed Reducer
8 9
5
3
1
7 6
Wrist base
A
10
Flange
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HP20D 7 Disassembly and Reassembly of Wrist Unit
7 Disassembly and Reassembly of Wrist Unit

• Refer to Fig. 7-1 “Disassembly and Reassembly of Wrist Unit”.
NOTE Refer to chapter 2 “Notes for Maintenance”, chapter 3

“Home Position Return”, and chapter 10 “Cable Wiring”.
 Disassembly
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.
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 .
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 .
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”.)
cover 5 and the wrist unit 1 . Then, mount the cover 5 on the wrist
unit 1 with the GT-SA bolts 6 .
7-1 "Wrist Unit Parts Checklist".
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HP20D 7 Disassembly and Reassembly of Wrist Unit
Table 7-1: Wrist Unit Parts Checklist

No. Name Qty. Notes
1 Wrist unit 1 Mass: 14.5 kg
3 Support HW9406556-1 1
5 Cover HW9200798-1 1
Fig. 7-1: Disassembly and Reassembly of Wrist Unit
2 6 4 5
3
1
B- and T-axis internal wiring harness
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HP20D 8 Disassembly, Reassembly, and Adjustment of B- and T-axis Timing
Belts
8.1 Disassembly and Reassembly of B- and T-axis Timing Belts
8 Disassembly, Reassembly, and Adjustment of B- and T-axis Timing Belts

• Refer to Table 8-1 "B- and T-Axis Timing Belt Parts Checklist" and
Fig. 8-1 “Disassembly and Reassembly of B- and T-Axis Timing
Belts”.
 Disassembly
(Refer to section 5.5 “Disassembly and Reassembly of B-Axis Motor” and
section 5.6 “Disassembly and Reassembly of T-Axis Motor”.)
1. Remove the B-axis motor 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 section 5.5 “Disassembly and Reassembly of B-Axis Motor” and
section 5.6 “Disassembly and Reassembly of T-Axis Motor”.)
1. Install the T-axis timing belt 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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Belts
Table 8-1: B- and T-Axis Timing Belt Parts Checklist

No. Name Qty. Notes
1 B-axis timing belt 80S4.5M653 1
2 T-axis timing belt 80S4.5M518 1
3 T-axis motor HW0389298-A 1 SGMPH-02ANA-YR11
5 B-axis motor HW0389298-A 1 SGMPH-02ANA-YR11
7 Cover HW9200798-1 2
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 6 5 10 2
8 7 9 4 3 1
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Belts
8.2 Adjustment of Timing Belts
8.2 Adjustment of Timing Belts
8.2.1 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: 34 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: 34 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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HP20D 9 Battery Pack Replacement
9 Battery Pack Replacement

The battery packs are installed in the position shown in Fig. 9-1 “Battery
Pack Location”. If the battery alarm occurs in the DX100, replace the
battery in accordance with the following procedure:
Fig. 9-1: Battery Pack Location
Battery pack
Connector base
Support
Connector base
Connector base fixing screw
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HP20D 9 Battery Pack Replacement
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.
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HP20D 10 Cable Wiring
10.1 Disconnecting Cables
10 Cable Wiring
To prevent loss of the encoder absolute data, make sure to

NOTE connect the new battery pack before disconnecting the
encoder cable connectors. (Refer to chapter 2 “Notes for
Maintenance”.)
10.1.1 Cables in Wrist Unit

• Refer to Table 10-1 "B- and T-Axis Cable Wiring Parts Checklist" and
Fig. 10-1 “B- and T- Axis Cable Wiring”.
2. Remove the plastic covers on the connector parts of the B- and T-axis
motors. Then, connect the backup batteries to the B- and T-axis
motors.
3. Disconnect the connectors of the B- and T-axis motors.
4. Remove the GT-SA bolts 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
4 Support HW9406556-1 1
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Fig. 10-1: B- and T- Axis Cable Wiring
B-axis internal wiring harness, T-axis internal wiring harness, Wrist unit
connector connector
B- and T-axis internal wiring harness
3 4 B-axis motor T-axis motor 1 2
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10.1.2 Cables in U-Arm

• Refer to Table 10-2 "U-Arm Cable Wiring Parts Checklist" and
Fig. 10-2 “U-Arm Cable Wiring”.
2. Connect the backup batteries to the U- and R-axis motors.
3. Remove the cross head APS bolts 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 S-
cover 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 .
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Table 10-2: U-Arm Cable Wiring Parts Checklist

No. Name Qty. Notes
1 Cover HW0305305-1 1
(length: 10 mm)
4 Pan-head sems screw M3 2
(length: 16 mm) each
Nut M3
5 N-base HW0404900-1 1
6 GT-SA bolt M5 4 For part A
(length: 16 mm) 2 For part B
Hexagon socket head cap screw M5 each
(length: 35 mm)
7 S-cover HW0200530-1 1
8 Support HW0404919-1 1
(length: 8 mm)
11 Stopper HW0404179-1 2
13 Support HW0304930-1 1
16 Saddle HW0404503-1 2
18 Support HW0304914-1 1
19 Support HW0304918-1 1
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HP20D
U-axis power cable Internal user I/O R-axis encoder cable

159281-1CD
11 U-axis encoder cable wiring harness B- and T-axis power cable

R-axis power cable B- and T-axis encoder cable B- and T-axis internal 14 17 16
8 2 wiring harness
Air hose
1 3BC power cable
3BC encoder cable

R-axis motor
Ground wire U-, R-, B-, and T-axis

Fig. 10-2: U-Arm Cable Wiring
power cable
Air hose 12 19
9 U-, R-, B-, and T-axis
16 17 15 18 13
encoder cable
View Without Cover 1 (Enlarged) View Without Cover 7
10 Cable Wiring
Casing 3 5 4
1 6 7 6
10-5
A A B
A
Main key position A
B
Connector of internal user
I/O wiring harness
U-axis motor
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10.1.3 Cables in S-Head

• Refer to Table 10-3 "S-Head Cable Wiring Parts Checklist" and Fig.
10-3 “S-Head Cable Wiring”.
1. Remove the cross head APS bolts 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
S-axis 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.
saddle 8 .
8. Cut off the cable tie which fixes the internal wiring harness, then
remove the holder 6 .
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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Table 10-3: S-Head Cable Wiring Parts Checklist

No. Name Qty. Notes
1 Cover HW0304227-1 1
(length: 8 mm)
3 Cover HW0305809-1 1
(length: 10 mm)
6 Holder HW0305812-1 1
8 Saddle CD-31 1
(length: 10 mm)
10 C-base HW0303378-2 1
12 Cover HW0305698-1 1
14 Holder HW0305813-1 1
16 Saddle FCD-31 1
17 Support HW0304226-1 1
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Fig. 10-3: S-Head Cable Wiring
6
5
7
8
S-axis connector
17
1
L-axis motor
S-head
4 11
S-axis motor
12
3 16
Cable ties (2 pieces)
T18S
15
Apply sealing
bond to the
hatched area. 14
13
10 9
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10.2 Connecting Cables
10.2.1 Cables in S-Head

• Refer to Table 10-3 "S-Head Cable Wiring Parts Checklist" and Fig.
10-3 “S-Head Cable Wiring”.
1. Run the internal wiring harness to which the C-base 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
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
8. Connect the connectors of the S-axis motor and the L-axis motor to
the internal wiring harness.
9. Remove the backup batteries connected to the S-axis motor and the L-
axis motor.
10. Connect the tube for grease exhaust to the back of the cover 3 , and
mount the cover 3 with the cross head APS bolts 4 .
11. Mount the cover 12 with the GT-SA bolts 11 .
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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10.2.2 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 .
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 .
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 GT-
SA bolts 10 .
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 T-
axis cables, see Fig. 10-2 “U-Arm Cable Wiring”.)
12. Push the internal wiring harness into the casing, then apply
ThreeBond 1206C to the matching surface between the S-cover 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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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 .
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 .
10-1 "B- and T-Axis Cable Wiring Parts Checklist".
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HP20D 11 Parts List
11.1 S-Axis Unit
11 Parts List
11.1 S-Axis Unit

Fig. 11-1: S-Axis Unit
1008
1001
1011
1012 1010
1034
1013
1036
1035 1031
1020 1032
1014
1022 1024
1023
1021 1030
1026
1009
1024
1023
1027
1030 1033
1002
1016
1004
1015 1003
1017
1006
1018
1025 1005
1014
1020
1007
1028
1029
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HP20D 11 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
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
1017 MSB8-15 Shoulder 1
1018 HW0400645-1 Lever 1
1020 TSH6-01M Union 2
1021 CD-31 Saddle 1
1023 TA1-S10 Clamp 2
1024 M5X10 Screw with spring washer 2
1025 EZ5036A0 Cap 1
1027 HW0305812-1 Holder 1
1028 HW9406775-1 Cover 1
1030 M12 Eye bolt 2
1034 HW0313491-1 Gear 1
11-2 85 of 96
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HP20D 11 Parts List
11.2 L-Axis Unit
11.2 L-Axis Unit

Fig. 11-2: L-Axis Unit
2024
2025 2001
2023
2017 2005
2004
2003
2011 2008
2012 2019 2018 2006 2002 2007
2010
2009
2028
2026 2032
2027
2014
2013
2022
2021
2014 2020
2013
2016
2015
2029 1002
2031
2030
2033
2034
2035
2036
2031
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HP20D 11 Parts List
11.2 L-Axis Unit
Table 11-2: L-Axis Unit

2001 SGMRV-13ANA-YR2* Motor 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
2011 HW0304227-1 Cover 1
2017 HW0100546-2 L-arm 1
2018 HW0387753-C Speed reducer 1
2022 HW0404196-4 Washer 1
*DACROTIZED coating*
2029 HW0305813-1 Holder 1
2030 HW0305698-1 Cover 1
2032 PT1/8 Plug 1
2033 CD-31 Saddle 1
1002 HW0100545-2 S-head 1
11-4 87 of 96
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HP20D 11 Parts List
11.3 U-Axis Unit
11.3 U-Axis Unit

Fig. 11-3: U-Axis Unit
3003
3004
3002 3003
3004
3001
3005
3020
3002
3019
3019
3012
3016
3018
3006 3017
2017 3016
3009
3008 3018
3017
3011
3010
3007
3013
3015 3014
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HP20D 11 Parts List
11.3 U-Axis Unit
Table 11-3: U-Axis Unit

3001 SGMRV-05A3A-YR1* Motor 1
3002 HW0313489-1 Cover 1
3004 M4 Washer 7
3005 HW0102379-1 Casing 1
3006 HW9280880-G Speed reducer 1
3011 GT-SH-14 GT-SH washer 6
3014 H-10 Conical spring washer 1
3016 HW0404196-2 Washer 2
3019 PT1/8 Plug 2
3020 EZ2940A0 Cap 1
2017 HW0100546-2 L-arm 1
11-6 89 of 96
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HP20D 11 Parts List
11.4 R-Axis Unit
11.4 R-Axis Unit

Fig. 11-4: R-Axis Unit
4033 4012
4031 4032
4029
4074 4071
4036
4010 4072
4066
4008 4030 4029
4042 3005
4058 4005
4057
4035
4009
4056 4043
4006
4007 4044
4011
4003
4028
4027 4073
4026
4076
4075 4022
4034
4037 4023 4060
4039 4055
4025
3014 4040 4051
4062
3012 4046
4045 4020
4013
4024
4019
4021
4015
4017 4067
4065
4014
4016 4002
4004 4001
4070
4069
4068
5046
4018
11-7 90 of 96
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HP20D 11 Parts List
11.4 R-Axis Unit
Table 11-4: R-Axis Unit (Sheet 1 of 2)

4005 HW0305305-1 M-cover 1
4008 HW0404196-5 Washer 1
4012 A-MT6X1 G Nipple 1
4013 HW0381872-A Cross roller bearing 1
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
4025 HW0200530-1 S-cover 1
4026 HW0404919-1 Support 1
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
4035 HW0404900-1 N-base 1
4039 TA1-S8 Clamp 4
4044 LP-M5 Plug 1
11-8 91 of 96
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HP20D 11 Parts List
11.4 R-Axis Unit
Table 11-4: R-Axis Unit (Sheet 2 of 2)

4055 HW0404918-1 Support 1
4056 SGMPH-02A2A-YR1* Motor 1
4057 EZ5036A0 Cap 1
4060 HW0304930-1 Support 1
4062 6811LLU Bearing 1
4066 KQE12-03 Union 1
4070 MS4-10 Pin 2
4072 PT 3/8 Plug 1
4075 TA1-S8 Clamp 3
3005 HW0102378-1 Casing 1
3014 HW0404179-1 Support 2
5046 HW0100623-1 U-arm 1
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HP20D 11 Parts List
11.5 Wrist Unit
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
5043 5071
5005
5048 5038
5014
5039 5019
5049
5040 5034
5013
5012
5036
5041 5018
5016 5062 5063
5017
5047
5031
5042 5023
5071
5032 5029
5020
5053 5022
5028
5050
5027 5033
5021
5024
5025
5026 5065
5030
5066
5052
5060
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HP20D 11 Parts List
11.5 Wrist Unit
Table 11-5: Wrist Unit (Sheet 1 of 2)

5001 HW9406556-1 Support 1
5005 HW9200798-1 Cover 2
5006 SGMPH-02A2A-YR12 Motor 2
5008 HW9482727-A Pulley 2
5011 80S4.5M518 Belt 1
5012 HW9381658-A Gear 1
5014 HW9405452-1 B-cover 1
5016 HW9482725-A Pulley 1
5019 HW9482218-A Bearing 1
5020 HW9405199-1 B nut 1
5021 SP-0120** Shim 1
5022 HW9481180-A Bearing 1
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
5032 HW0304086-1 Housing 1
5033 HW9381659-A Gear 1
5034 HW9482726-A Pulley 1
5036 6002ZZ Bearing 1
5039 HW9482668-A Oil seal 1
5041 HW9405792-1 Housing 1
5042 HW0200451-1 Wrist base 1
5044 80S4.5M653 Belt 1
5046 HW0100623-1 U-arm 1
11-11 94 of 96
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HP20D 11 Parts List
11.5 Wrist Unit
Table 11-5: Wrist Unit (Sheet 2 of 2)

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 95 of 96
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MOTOMAN-HP20D
MAINTENANCE MANUAL
HEAD OFFICE
2-1 Kurosakishiroishi, Yahatanishi-ku, Kitakyushu 806-0004, Japan
Phone +81-93-645-7703 Fax +81-93-645-7802
YASKAWA America Inc. (Motoman Robotics Division)

100 Automation Way, Miamisburg, OH 45342, U.S.A.
Phone +1-937-847-6200 Fax +1-937-847-6277
YASKAWA Europe GmbHRobotics Divsion )

Yaskawastrasse 1, 85391 Allershausen, Germany
Phone +49-8166-90-100 Fax +49-8166-90-103
YASKAWA Nordic AB
Verkstadsgatan 2, Box 504 ,SE-385 25 Torsas, Sweden
Phone +46-480-417-800 Fax +46-486-414-10
YASKAWA Electric (China) Co., Ltd.

22F, One Corporate Avenue, No.222, Hubin Road, Huangpu District, Shanghai 200021, China
Phone +86-21-5385-2200 Fax 㸩86-21-5385-3299
YASKAWA SHOUGANG ROBOT Co. Ltd.
No7 Yongchang North Road, Beijing E&T Development AreaChina 100176
Phone +86-10-6788-2858 Fax +86-10-6788-2878
YASKAWA India Private Ltd. (Robotics Division)

#426, Udyog Vihar, Phase- IV,Gurgaon, Haryana, India
Phone +91-124-475-8500 Fax +91-124-475-8542
YASKAWA Electric Korea Corporation

35F, Three IFC, 10 Gukjegeumyung-ro, Yeongdeungpo-gu, Seoul, Korea 07326
Phone +82-2-784-7844 Fax +82-2-784-8495
YASKAWA Electric Taiwan Corporation

12F, No.207, Sec. 3, Beishin Rd., Shindian District, New Taipei City 23143, Taiwan
Phone +886-2-8913-1333 Fax +886-2-8913-1513
YASKAWA Electric (Singapore) PTE Ltd.

151 Lorong Chuan, #04-02A, New Tech Park, Singapore 556741
Phone +65-6282-3003 Fax +65-6289-3003
YASKAWA Electric (Thailand) Co., Ltd.

59,1st-5th Floor, Flourish Building, Soi Ratchadapisek 18,Ratchadapisek Road,
Huaykwang, Bangkok 10310, THAILAND
Phone +66-2-017-0099 Fax +66-2-017-0199
PT. YASKAWA Electric Indonesia

Secure Building-Gedung B Lantai Dasar & Lantai 1 JI. Raya Protokol Halim Perdanakusuma,
Jakarta 13610, Indonesia
Phone +62-21-2982-6470 Fax +62-21-2982-6741
Specifications are subject to change without notice

for ongoing product modifications and improvements.
96 of 96
MANUAL NO.
HW1480357 3

Motomanhp 20 D

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MOTOMAN-HP20D

Part Number: 159281-1CD

Copyright © 2018, 2011 Yaskawa America, Inc.

Terms of Use and Copyright Notice

Printed in the United States of America

First Printing, 2011

Yaskawa America, Inc.

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

3.1.3 Home Position Return by Setting Teaching Point

3.2.1 Home Position Return at the Time of Battery Backup by Using

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

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

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

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

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

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

4.4.1 Grease Replenishment ......................................................................................... 4-6

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

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

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

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

8.2 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