Motoman - Yaskawa - MPX2600 Robot - Maintenance Manuakl

MOTOMAN-MPX2600
MAINTENANCE MANUAL
TYPE:
YR-MPX2600-***
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-MPX2600 INSTRUCTIONS
MOTOMAN-MPX2600 MAINTENANCE MANUAL
MOTOMAN-MPX2600 INSTRUCTIONS FOR MANIPULATOR OPTIONAL SPECIFICATIONS
MANIPULATOR INSTRUCTIONS FOR EXPLOSION-PROOF SPECIFICATIONS
DX200 INSTRUCTIONS
DX200 OPERATOR’S MANUAL (for each purpose)
DX200 MAINTENANCE MANUAL
DX200 INSTRUCTIONS FOR EXPLOSION-PROOF SPECIFICATIONS
180789-1CD
2
MANUAL NO.
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Contents
1 Introduction ..................................................................................................................................... 1-1
2 Notes for Maintenance .................................................................................................................... 2-1
2.1 Inspection of Gasket .......................................................................................................... 2-1
2.2 Battery Pack Replacement ................................................................................................ 2-4
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 the Teaching Point for Home Position Setting
before Replacement ............................................................................................. 3-2
3.2 Homing Method When the Robot-Axis Motor Battery Runs Out........................................ 3-7
3.2.1 With the Home Position Calibration Function for Restoration from the Battery
Back Up ................................................................................................................ 3-7
3.2.2 With the Home Position Keys (S-, L-, U-, R-, B-, and T-Axes) ............................. 3-7
4 Grease Replenishment and Exchange ........................................................................................... 4-1
4.1 Grease Replacement Procedures for Wrist Gears ............................................................ 4-1
4.2 Grease Replacement Procedures for S-, L-, and U-Axis Speed Reducers ....................... 4-2
4.3 Grease Replenishment Procedures for S-, L-, and U-Axis Speed Reducers .................... 4-8
5 Disassembly and Reassembly of the Motor.................................................................................... 5-1
5.1 Disassembly and Reassembly of the S-Axis Motor ........................................................... 5-1
5.2 Disassembly and Reassembly of the L-Axis Motor............................................................ 5-5
5.3 Disassembly and Reassembly of the U-axis Motor ........................................................... 5-9
5.4 Disassembly and Reassembly of the R-, B-, and 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.................................................. 6-6
6.3 Disassembly and Reassembly of U-Axis Speed Reducer ............................................... 6-13
6.4 Disassembly and Reassembly of R-, B-, and T-Axis Speed Reducer ............................. 6-18
7 Disassembly and Reassembly of Wrist Unit ................................................................................... 7-1
8 Battery Replacement....................................................................................................................... 8-1
8.1 Battery Replacement ......................................................................................................... 8-1
8.1.1 YR-MPX2600 (Except for “-B**”) .......................................................................... 8-1
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Contents
8.1.2 YR-MPX2600-B** ................................................................................................. 8-4
9 Gasket Replacement ...................................................................................................................... 9-1
10 Parts List ..................................................................................................................................... 10-1
10.1 S- and L-Axes Unit......................................................................................................... 10-1
10.2 U-Axis Unit..................................................................................................................... 10-7
10.3 U-Arm Unit ................................................................................................................... 10-10
10.4 Wrist Unit ..................................................................................................................... 10-13
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1 Introduction
1 Introduction
MANDATORY
• This maintenance manual is intended to explain maintenance
procedures primarily for the MOTOMAN-MPX2600.
• General items related to safety are listed in Chapter 1: Safety of the
DX200 Instructions. To ensure correct and safe operation, carefully
read the DX200 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 Introduction
Notes for Safe Operation

Read this manual carefully before installation, operation, maintenance, or
inspection of your manipulator.
In this manual, the Notes for Safe Operation are classified as
“DANGER”, “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

NOTE to follow all instructions, even if not designated as “DAN-
GER”, “WARNING” and “CAUTION”.
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1 Introduction
DANGER
• The inspection and maintenance of explosion-proof electric
equipments must be performed by experienced maintenance
personnel who have been trained on different types of explosion-
proof enclosures, installation of electric equipment, related laws and
regulations, and general principles for hazardous area
classifications.
• 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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1 Introduction
WARNING
• Before maintenance, inspection, or wiring, be sure to turn the main
power supply OFF, and put up a warning sign. (ex. DO NOT TURN
THE POWER ON.)
Failure to observe this warning may result in electric shock or injury.
• After maintenance, check the home position before operating the
manipulator.
Injury may result from unexpected manipulator motion.
• Before operating the manipulator, check that servo power is turned
OFF by pressing the emergency stop buttons on the front door of
the DX200 and the programming pendant.
When the servo power is turned OFF, the SERVO ON LED on the
programming pendant is turned OFF.
Injury or damage to machinery may result if the emergency stop circuit
cannot stop the manipulator during an emergency. The manipulator
should not be used if the emergency stop buttons do not function.
Fig. : Emergency Stop Button
• Once the emergency stop button is released, clear the cell of all
items which could interfere with the operation of the manipulator.
Then turn the servo power ON.
Injury may result from unintentional or unexpected manipulator motion.
Fig. : Release of Emergency Stop
TURN
• Observe the following precautions when performing teaching

operations within the P-point maximum envelope of the
manipulator:
– Be sure to use a lockout device to the safeguarding when going
inside. Also, display the sign that the operation is being
performed inside the safeguarding and make sure no one closes
the safeguarding.
– View the manipulator from the front whenever possible.
– Always follow the predetermined operating procedure.
– Keep in mind the emergency response measures against the
manipulator’s unexpected motion toward you.
– Ensure that you have a safe place to retreat in case of
emergency.
Improper or unintended manipulator operation may result in injury.
• Confirm that no person is present in the P-point maximum envelope
of the manipulator and that you are in a safe location before:
– Turning ON the power for the DX200.
– Moving the manipulator with the programming pendant.
– Running the system in the check mode.
– Performing automatic operations.
Injury may result if anyone enters the P-point maximum envelope of the
manipulator during operation. Always press an emergency stop button
immediately if there is a problem.
The emergency stop buttons are located on the right of front door of the
DX200 and the programming pendant.
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1 Introduction
CAUTION
• Perform maintenance inspection with the specific person who took
the maintenance training course in YASKAWA.
Failure to observe this may result in electric shock or injury.
• When the maintenance inspection is performed, be sure to mount
the battery pack before removing the motor encoder connector.
Failure to observe this caution may result in disappearance of the home
position data.
• 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.
• Always return the programming pendant to the hook on the cabinet
of the DX200 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
DX200 Instructions before operating the manipulator:
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1 Introduction
Definition of Terms Used Often in This Manual

The MOTOMAN manipulator is the YASKAWA industrial robot product.
The manipulator usually consists of the controller, the programming
pendant, and supply cables.
In this manual, the equipment is defined as follows:
Equipment Manual Definition
DX200 Controller DX200
DX200 Programming Pendant Programming pendant
Cable between the manipulator and the Manipulator cable
controller
Registered Trademark
In this manual, names of companies, corporations, or products are
trademarks, registered trademarks, or brand names for each company or
corporation. The indications of (R) and TM are omitted.
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1 Introduction
Explanation of Warning Labels

The following warning labels are attached to the manipulator.
Always follow the warnings on the labels.
Also, an identification label with important information is placed on the
body of the manipulator. Prior to operating the manipulator, confirm the
contents.
Fig. 1-1: Warning Label Locations
Warning label A
Warning label B
Pressure switch unit A

M4X6
Battery warning label Nameplate
M4
View A
M6X12
M6X12
M4X8
M4X8
Pressure switch unit warning label
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1 Introduction
Fig. 1-2: List of Warning Labels
Type YR-MPX2600-A00 YR-MPX2600-B00 YR-MPX2600-C00
MODEL MOTOMAN-
MODEL MODEL TYPE DATE
MOTOMAN- MOTOMAN-
TYPE TYPE PAYLOAD MASS
kg kg
SERIAL NO. ORDER NO.
PAYLOAD MASS PAYLOAD MASS
kg kg kg kg PNEUMATIC PRESSURE MAX.
kPa
ORDER NO. DATE ORDER NO. DATE
Nameplate POWER SUPPLY AC 400V
3-phase 50/60Hz
SERIAL NO. SERIAL NO. Average kVA
YASKAWA ELECTRIC CORPORATION
2-1 Kurosakishiroishi, Yahatanishi-ku,
YASKAWA ELECTRIC CORPORATION YASKAWA ELECTRIC CORPORATION Kitakyushu 806-0004 Japan MADE IN JAPAN
2-1 Kurosakishiroishi, Yahatanishi-ku, 2-1 Kurosakishiroishi, Yahatanishi-ku,
Kitakyushu 806-0004 Japan Kitakyushu 806-0004 Japan Authorised Representative:
YASKAWA Europe GmbH
MADE IN JAPAN NJ3878 MADE IN JAPAN NJ3878 Yaskawastr.1
D-85391 Allershausen Germany NJ3880
WARNING
AVERTISSEMENT
WARNING When replacing battery instruction
manual details are to be followed.
WARNING
Battery Warning This pressurized enclosure contains a battery which remains connected after
the external power has been isolated. Battery only to be replaced when
This pressurized enclosure contains a battery which remains connected after
the external power has been isolated.
Refer to instructions in the manual before carrying
the area is known to be safe. Refer to instructions in the manual before carrying
Label out frequent inspection and exchanging periodically.

The battery is only to be replaced by Licensee when the area is known to be safe.
out frequent inspection and exchanging periodically.
The battery is only to be replaced by Licensee when the area is known to be safe.
Battery unit type Battery type Manufacturer Suivez les instructions du manuel Battery unit type Battery type Manufacturer
HW1372692-A,-B,-C ENERGIZER L91 YASKAWA Electric Corporation pour remplacer la batterie. HW1372692-A,-B,-C ENERGIZER L91 YASKAWA Electric Corporation
NJ4051-* La batterie peut etre remplacee NJ4051-*
seulment si la place est connue

D'etre en securite.
NJ4069-1
WARNING
Pressure Switch WARNING AVERTISSEMENT WARNING
Unit Warning Explosion-proof safety Device
Label Explosion-proof safety Device Do not change any Parameters. Explosion-proof safety Device
Do not change any Parameters. Dispositif de securite antideflagrant Do not change any Parameters.
NJ3840-*
ne changez pas ancun Parametre. NJ3840-*
NJ4070-1
Warning Label A
NJ4032 NJ4032 NJ4032
Warning Label B
NJ4036 NJ4036 NJ4036
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2 Notes for Maintenance

2.1 Inspection of Gasket
• When an encoder connector for a motor needs to be dis-

connected, be sure to connect a battery pack before dis-
connecting the encoder connector. If the encoder
NOTE
connector is disconnected without connecting the battery
pack, the home position data will disappear.
• Never remove the battery pack in the connector base.
• Never insert a flat tip screwdriver, an edged tool, etc. into

NOTE the gasket to remove the motor cover so as not to damage
the gasket. If the gasket is damaged, air leak will result.
CAUTION
• Be sure to turn OFF the DX200 power and shut off supply of com-
pressed air before removing the motor cover. Always remove the
motor cover in a safe condition.
 Cover Gasket
The motor cover of each drive may not be uninstalled due to gasket
absorption power even cover mounting screws are removed. In such a
case, use a tapped through hole to remove the cover.
Fig. 2-1: S-, L-Axis Gasket
-Hexagon socket head cap screw M6
*trivalent chromate*
(length: 25 mm) (19 screws)
-Conical spring washer 2H-6
*trivalent chromate* (19 washers)
Tightening torque 10 Nm (1.0 kgfm) Motor cover
Surface to bond
Gasket
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Fig. 2-2: L-Arm Motor Gasket
Cover
-Hexagon socket button head screw M8 Gasket
Tightening torque 20.6 Nm (2.1 kgfm)
Surface to bond
Gasket
Cover
-Hexagon socket button head screw M8
Surface *trivalent chromate* (8 washers)
to bond Tightening torque 20.6 Nm (2.1 kgfm)
Surface to bond
-Hexagon socket button head screw M8

Tightening torque 20.6 Nm (2.1 kgfm)
Cover
Gasket
Fig. 2-3: U-Axis and U-Arm Gasket

*trivalent chromate* (length: 25 mm) (16 screws)
Tightening torque 10 N•m (1.0 kgf•m)
Motor cover
Gasket
Surface to bond
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Fig. 2-4: Gaskets at Base Section

Cover
Surface to bond
Gasket
Cover
Surface
to bond
Gasket
Surface to bond
Tightening torque 10 N•m (1.0 kgf•m) Gasket
Cover
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2.2 Battery Pack Replacement
MANDATORY
• Be sure to disconnect the battery pack of the motor after
maintenance, then start the manipulator.
DANGER
• Be sure to connect the battery pack of the motor in non-hazardous
location.
Table 2-1: Battery Pack (Spare Parts)

Manipulator Type Battery Pack Axis
(Spare Parts)
YR-MPX2600 (Except for -B**, -C**) HW1471600-CA S, L-axes
HW1471600-CB U, R-axes
HW1471600-CC B, T-axes
YR-MPX2600-B** HW1471600-BA S, L-axes
HW1471600-BB U, R-axes
HW1471600-BC B, T-axes
YR-MPX2600-C** HW1471600-DA S, L-axes
HW1471600-DB U, R-axes
HW1471600-DC B, T-axes
• When an encoder connector for a motor needs to be dis-

connected, be sure to connect a battery pack before dis-
connecting the encoder connector. If the encoder
NOTE
connector is disconnected without connecting the battery
pack, the home position data will disappear.
• Never remove the battery pack in the connector base.
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 Battery Pack Connection for SLU-axis Motors

The connectors (crimped contact-pin) for battery backup are installed on
each motor. Connect the battery pack by following the instructions below
(see fig. 2-5 “Battery Pack Connection for SLU-Axis Motors” ).
1. Remove the cover mounting screws to uninstall the connector cover
attached to the encoder groove.
2. Connect the battery pack (see table 2-1 “Battery Pack (Spare Parts)” )
with the battery backup connectors (crimped contact-pin) that are
located inside the connector cover.
3. Verify that all connectors are connected and remove the battery pack
after the maintenance.
Fig. 2-5: Battery Pack Connection for SLU-Axis Motors
S-, L-, and U-axes Motors
Filter
Power connector Encoder connector
Encoder
Motor
Connector cover for the backup battery

Internal cables
Cover mounting screw
Conversion cable
Connect to
Battery (+) a F BAT* BAT* New
Battery (-) b
M OBT* battery pack
Caution label
Battery pack (spare parts)
Connection Diagram
(Motor)
(Internal cables)
BAT M F BAT*
New battery pack
OBT F M OBT*
Caution Label
(Enlarged View)
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 Battery Pack Connection for RBT-Axis Motors

The connectors (crimped contact-pin) for battery backup are attached to
the encoder connector of each motor. Connect the battery pack by
following the instructions below (see fig. 2-6 “Battery Pack Connection for
RBT-Axis Motors” ).
1. Connect the battery pack (see table 2-1 “Battery Pack (Spare Parts)” )
with the battery backup connectors (crimped contact-pin) attached to
the encoder connector.
2. Verify that all connectors are connected and remove the battery pack
after the maintenance.
Fig. 2-6: Battery Pack Connection for RBT-Axis Motors

R-Axis Motor
Encoder
Filter
Motor
Motor cable, etc.
Internal Power connector

cables
BAT a
OBT b
Encoder connector
B-, T-axes Motor
Encoder
Filter
Motor
Motor cable, etc.
Internal Power connector

cables
BAT a
OBT b
Encoder connector
CAUTION label (Enlarged view)

Caution label
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3 Home Position Return

3.1 Home Position Return after Motor Replacement
In the following cases, perform calibration and set the

manipulator geometrical position.
• Change in the combination of the manipulator and the
DX200
• Replacement of the motor
• Clearing stored memory
• Home position deviation caused by hitting the manipulator
NOTE against a workpiece, etc.
• Replacement, disassembly, and reassembly of the main
parts such as speed reducers etc.
Before the calibration, be sure that the manipulator satisfies
the following conditions.
• No external force is exerted on the manipulator.
• The hand and other parts attached to 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.
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 the Teaching Point for Home Position Setting before Replacement
The DX200 holds the position data of the job program (hereinafter called
as JOB) as the pulse number from the home position of each axis. Stated
differently, the precise adjustment of home position allows use of the JOB,
which had been used before the motor replacement, without correction
even after the motor replacement.
This section explains how to set the DX200.
 Preparation before Replacement

• Refer to the fig. 3-1 “Preparation before Replacement (Example)” .
Before replacement, create the standard position (hereinafter called the
check-point) for home position adjustment after 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.)
1The 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 effector) or the jigs (related unit including the rotary
table). It is recommended to use a specific jig if necessary.
Use pointed jigs to create the position so that the deviation is easily
2
found.
Keep a distance as long as possible from the rotational center of the
replacing axis.
Considering the moving direction of the replacing axis, create the
3
position at the point where any deviation is easily found and the axis will
not interfere with jigs even if it is deviated.
• The check-point cannot be created unless each axis moves to oper-
ate. Stated differently, the check-point cannot be created if the axis
does not move due to a failure. It is, therefore, recommended to
create the check-point for each axis under normal operating condi-
tions.
Check the home position of the replacing axis. Use the position screen
and move the replacing axis to the 0-pulse position: the home position,
then check the position of the home position key. Please execute the
adjustment if it is deviated.
MANDATORY
• Verify all the home positions of the RBT-axes.
The figure fig. 3-1 “Preparation before Replacement (Example)” shows

the MPX2600-*0* U-axis replacement as an example.
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Fig. 3-1: Preparation before Replacement (Example)
6 +0.012
0
Ra1.6
Position of the home position key
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 Replacement
Since the motor is removed, the manipulator cannot keep its posture
during the replacement operation. Therefore, when replacing the motor,
hold the manipulator arm with fixing jigs, etc.
Failure to observe this caution may cause a hazardous condition. Also,
when replacing the motor with due care.
Fig. 3-2: Replacement (Example)

U-axis fixing jig
U-axis
L-axis fixing jig
L-axis
S-axis fixing jig
S-axis
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 Home Position Adjustment

After replacement, move the replaced axis to the position of the home
position key. Perform the home position alignment only to the replaced
axis.
MANDATORY
• If you perform home position alignment to any one of R-, B- and T-
axes, align all the three home positions in the order: R-axis Þ B-axis
Þ T-axis.
(For more detailed information, refer to “DX200 INSTRUCTIONS” (manual

No. RE-CTO-A220).)
Move the axis to the check-point by the check-JOB. (Be careful when
moving the axis so that the manipulator may not interfere with jigs.) Move
only the replaced axis to adjust the deviation from the check-point created
before alignment.
Display the position screen (command value).
The following figure shows the position screen for U-axis.
Using the above values, calculate the amount of deviation. (Subtract the
command value from the present value.)
Present value - Command value = the amount of deviation
U (-3067) - (-2989) = -78
Perform stepping back, etc. of the check JOB and move the replaced axis
to the position where the replaced axis will not interfere with jigs when it
moves to the home position. (Be careful when moving the axis so that the
manipulator may not interfere with jigs.) Use the position screen and
move the replaced axis to the pulse position equal to the amount of
deviation.
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Perform the home position alignment only for the replaced axis on this
position. (For more detailed information, refer to “DX200
INSTRUCTIONS” (manual No. RE-CTO-A220).)
Move the axis again to the check-point by the check-JOB. Check if the
axis is in the check-point created before the operation to complete the
adjustment. (If it is deviated, repeat the adjustment procedures.)
Perform an operation check by using the JOB program used before the
replacement. If no problem is found, write down the modified home
position data (ABSO data) and the date in the label attached inside the
DX200.
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3.2 Homing Method When the Robot-Axis Motor Battery Runs Out
3.2.1 With the Home Position Calibration Function for Restoration from the Battery Back Up
This is the method to return the manipulator to its home position by
executing the “Backup alarm restoration” software on the programming
pendant after moving the manipulator close to its home position (within the
motor rotation).
The home position returned by this function updates the multi-turn data for
motor.
3.2.2 With the Home Position Keys (S-, L-, U-, R-, B-, and T-Axes)
This is the method to return the manipulator to its home position by writing
down the difference of the pulse between the position of the home position
key and the home position, which is set when MOTOMAN is delivered, on
the home position label affixed inside of the DX200.
When the home position data disappears, move the manipulator to the
position of the home position key and set the position where the above
mentioned difference of the pulse is reflected in the key position as the
home position.
 Calibration Operation
A home position key is required for calibration. Prepare the key before
calibration.
1. S-Axis Positioning
Perform positioning with the programming pendant so that a home
position key fits into the groove that is located as shown in fig. 3-3 “S-
Axis Positioning” .
Fig. 3-3: S-Axis Positioning
Ra1.6 6 +0.012
0
0
6 dia. -0.1
80 mm or more
View A Detail view

The tip of the home position key
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2. L-Axis Positioning
Perform positioning with the programming pendant so that a
home position key fits into the groove that is located as shown in
fig. 3-4 “L-Axis Positioning” .
Fig. 3-4: L-Axis Positioning
Ra1.6 6 +0.012
0
0
6 dia. -0.1
80 mm or more
A Details of A
Detail view
3. U-Axis Positioning
fig. 3-5 “U-Axis Positioning” .
Fig. 3-5: U-Axis Positioning
6 +0.012
0
Ra1.6
6 dia. -0.1
0
60 mm or more
Detail view
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4. R-Axis Positioning
fig. 3-6 “R-Axis Positioning” .
Fig. 3-6: R-Axis Positioning
Home position key
A
6 +0.012
0
Ra1.6
View A
5. B-Axis Positioning
fig. 3-7 “B-Axis Positioning” .
Fig. 3-7: B-Axis Positioning
A
Home position key
Ra1.6
View A
6 +0.01
0 2
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6. T-Axis Positioning
fig. 3-8 “T-Axis Positioning” .
Fig. 3-8: T-Axis Positioning
Home position key

A
6 +0.012
0
Ra1.6
View A
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4 Grease Replenishment and Exchange

4.1 Grease Replacement Procedures for Wrist Gears

Replenish or replace the grease for the following sections:
I) Wrist gears
II) S-, L-, and U-axis speed reducers
III) R-, B-, and T-axis speed reducers
4.1 Grease Replacement Procedures for Wrist Gears

Remove the plugs each plug and cover, apply Alvania EP grease 2 on the
gear teeth of gears R1, B1, B2, T1, T2, and T3 by using a grease gun.
Apply seal tape on the thread part of each plug, then reinstall the plugs.
(Each plug must be tightened with the specified tightening torque.)
Fig. 4-1: Wrist Gears
Plug
Hexagon socket head plug PT1/2
Tightening torque 39 N•m (4 kgf•m)
Grease inlet
B-axis gear B2
T-axis gear T2
T- axis gear T1
B- axis gear B1
T-axis gear T3
R- axis gear R1
Grease inlet
Cover
Plug
Hexagon socket head cap screw M4
Hexagon socket head plug PT1/2 *trivalent chromate* (length: 12 mm) (6 screws)
Tightening torque 39 N•m (4 kgf•m) Conical spring washer 2H-4
Grease gun Tightening torque 2.4 N•m (0.24 kgf•m)
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4.2 Grease Replacement Procedures for S-, L-, and U-Axis Speed
Reducers
4.2 Grease Replacement Procedures for S-, L-, and U-Axis
Speed Reducers
Make sure to follow the instructions listed below at grease replenishment/
replacement. Failure to observe the following notes may result in damage
to motor and speed reducer.
• If grease is injected without removing the plug from the

grease exhaust port, the grease will leak inside a motor, or
an oil seal of a speed reducer will come off. Make sure to
remove the plug and inject grease.
Also, when using a tube, the length must be 150 mm or
shorter and the inside diameter must be 6 mm or longer.
If the tube is too long, the exhaust resistance at the tube
part is increased, and the inner pressure of the grease
bath is raised. It may result in 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 7 g/s or less.
• When using extrusion air for discharging the grease, set
air supply pressure at 0.025 MPa or less.
If the air supply pressure is higher than above mentioned
value, an oil seal of a speed reducer will come off, and it
may result in a failure.
NOTE
• When using extrusion air for discharging grease, grease
may be vigorously discharged from the exhaust port.
Perform an operation such as using a tube at the grease
exhaust port to pour into an appropriate container.
• Make sure to fill the hose on the grease inlet with grease
beforehand to prevent air from leaking into the speed
reducer.
• After injecting grease, discharge the specified amount of
grease. If insufficient, the inner pressure is raised during
the operation, and grease may leak. When discharged
too much, the speed reducer is not lubricated sufficiently
during the operation, and it may cause the early failure of
the speed reducer.
• When filling/replacing grease, the grease may flow out
from the grease inlet or the grease exhaust port. Prepare
a container to receive the grease and a waste cloth to
wipe the grease in advance.
WARNING
When operating the manipulator, do not enter into the working area of
the manipulator. Injury may result if anyone enter into the working area
during operation.
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Reducers
Fig. 4-2(a): S-, L-, U-Axis Speed Reducer Diagram (Floor-Mounted)
Grease exhaust port (U-axis) Grease inlet (U-axis)
Plug PT3/8 (Stainless) Plug PT3/8 (Stainless)
Tightening torque: Tightening torque:
23 N•m (2.34 kgf•m) 23 N•m (2.34 kgf•m)
Grease inlet (L-axis)

Plug PT3/8 (Stainless)
Tightening torque:
23 N•m (2.34 kgf•m)
Grease exhaust port (S-axis)
Grease exhaust port (L-axis)
Grease inlet (S-axis) Plug PT3/8 (Stainless)
Plug PT3/8 (Stainless) Tightening torque:
Tightening torque:
Tightening torque: 23 N•m (2.34 kgf•m)
23 N•m (2.34 kgf•m)
23 N•m (2.34 kgf•m)
Fig. 4-2(b): S-, L-, U-Axis Speed Reducer Diagram (Wall-Mounted) (Optional)
Grease exhaust port Grease inlet (U-axis) Grease exhaust port Grease exhaust port
(U-axis) Plug PT3/8 (Stainless) (L-axis) (S-axis)
Plug PT3/8 (Stainless) Tightening torque: Plug PT3/8 (Stainless) Plug PT3/8 (Stainless)
Tightening torque: 23 N•m (2.34 kgf•m) Tightening torque: Tightening torque:
23 N•m (2.34 kgf•m) 23 N•m (2.34 kgf•m) 23 N•m (2.34 kgf•m)

Tightening torque:
23 N•m (2.34 kgf•m)
Grease inlet (S-axis)

Tightening torque:
23 N•m (2.34 kgf•m)
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Reducers
Fig. 4-2(c): S-, L-, U-Axis Speed Reducer Diagram (Ceiling-Mounted) (Optional)
Grease exhaust port (S-axis)

Tightening torque:
23 N•m (2.34 kgf•m)
Grease exhaust port

(L-axis)
Tightening torque:
23 N•m (2.34 kgf•m)
Grease inlet (S-axis)

Tightening torque:
23 N•m (2.34 kgf•m) A
Grease inlet (U-axis)

Grease exhaust port Plug PT3/8 (Stainless)
(U-axis) Tightening torque:
Plug PT3/8 (Stainless) 23 N•m (2.34 kgf•m)
Tightening torque:
23 N•m (2.34 kgf•m)

Tightening torque:
23 N•m (2.34 kgf•m)
View A
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Reducers
1. Before injecting grease, the posture of the manipulator must be set as
indicated in table 4-1 “Recommended Posture for Grease Injection” .
If it is difficult to make the recommended posture because of external
cabling or etc., adjust the posture as much as possible to make the
position of grease inlet located in the lower part and the position of
exhaust port located in the upper part. If the exhaust port is located in
the lower part, grease may not be exchanged properly.
Table 4-1: Recommended Posture for Grease Injection
Posture
Mounting Condition Axis to inject S-axis L-axis U-axis R-axis B-axis T-axis
Floor-mounted S-axis 0° Any Any
Wall-mounted L-axis Any 0° Any Any Any Any
Ceiling-mounted U-axis Any 0° 0°
2. Remove the hexagon socket head plugs from the grease inlet and
grease exhaust port.
The positions of grease inlet and exhaust port are different

NOTE depending on the mounting condition of the manipulator.
Confirm the positions beforehand.
3. Install a grease zerk A-PT3/8 to the grease inlet.

(The grease zerk is delivered with the manipulator.)
4. Inject the grease through the grease inlet using a grease gun.
– Grease type: VIGO grease RE No.0
– Recommended grease lubricator: Powerlube P3C (made by
Macnaught)
– Amount of grease: 7 g/s or less
(For example, if grease is supplied from the lubricator at 2 times/s,
set the amount to 3.5 g/time or less.)
– Air supply pressure of grease pump: Approximately 0.3 MPa or less
Table 4-2: Amount of Grease
Axis to exchange grease Amount of grease
S-axis Approx.4200 g
L-axis Approx.2300 g
U-axis Approx.1650 g
5. The old grease is discharged from the grease exhaust port. At this
time, stop injection when the mixture of the old grease and the new
grease in an equal ratio is seen.
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Reducers
6. Discharge the specified amount of grease from the grease inlet or
grease exhaust port. (Refer to table 4-3 “Amount of Grease
Discharged from Each Axis” .) In order to discharge the specified
amount of grease, receive the discharged grease by using a container,
and then measure the weight of the discharged grease by weighing
the container till the amount reaches to the specified amount.
Use one of the following methods to discharge grease.
Method 1: Extruding grease by air
(1) Connect the joint and the hose to the grease inlet.
(2) Connect the regulator to the grease exhaust port.
(3) Inject air from the grease exhaust port to extrude grease by air.
(Extrusion air pressure: 0.025 MPa or less)
(4) If the grease is not discharged enough by injecting air, operate the
manipulator about 5 times in the teach mode as shown in table 4-4
“Grease Discharging Operation for Each Axis” .
Method 2: Suctioning grease out
(1) Keep the inlet open and insert the tube into the exhaust port.
(2) Discharge grease by suctioning grease out of the exhaust port.
(Suction pressure: 0.025 MPa or less)
(3) If grease is not discharged by suctioning, operate the manipulator
again about 5 times in the teach mode as shown in table 4-4
“Grease Discharging Operation for Each Axis” .
Table 4-3: Amount of Grease Discharged from Each Axis
Posture Axis Amount of exhausted grease
[g] [cc]
Floor-mounted S-axis 384±5 427±4
L-axis 110±5 122±4
U-axis 0 0
Wall-mounted S-axis 11±5 13±4
L-axis 100±5 111±4
U-axis 49±5 54±4
Ceiling-mounted S-axis 0 0
L-axis 110±5 122±4
U-axis 0 0
Table 4-4: Grease Discharging Operation for Each Axis

Axis to exchange Angle for teaching Speed for teaching
grease operation operation
S-, L-, U-axis ±45° User-specified
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Reducers
7. For the axis where grease is exchanged, perform a playback operation
indicated in table 4-5 “Running-In Operation for Each Axis” for
running-in the speed reducer with grease.
At this time, grease may be discharged during the operation.
Remove the grease zerk from the grease inlet, and clean and
degrease the tap part and the thread part of the plug. Wrap the seal
tape TB4501 around the plug. Tighten the plug on the grease inlet
with the designated tightening torque. Also, discharge the excess
grease in order not to increase the inner pressure of the speed
reducer. Attach a bag to receive grease such as indicated in fig. 4-3
“Grease Receiving Bag (Rough Standard)” , and then perform the
running-in operation.
Table 4-5: Running-In Operation for Each Axis
Axis to exchange Running-in operation
grease Operation Operation speed Timer after each Operating
angle operation time
S, L, U-axes ±45° MOVJ VJ=50.00 1.0 s 15 minutes
Fig. 4-3: Grease Receiving Bag (Rough Standard)
Grease receiving bag

Cut one corner to remove air.
To prevent grease from scattering from the cut corner,
cover the receiving bag with a plastic bag etc. without
being sealed.
Bond for fixing a grease receiving bag
Tube (inside dia.: 6 mm or more)
Union (inside dia.: 6 mm or more)

PT3/8
8. Wipe the discharged grease with a cloth, and reinstall the plug. Clean
and degrease the tap part and the thread part of the plug. Wrap the
seal tape TB4501 around the plug, attach it to the grease inlet, and
then tighten the plug with the designated tightening toque.
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4.3 Grease Replenishment Procedures for S-, L-, and U-Axis Speed
Reducers
4.3 Grease Replenishment Procedures for S-, L-, and U-Axis
Speed Reducers
 Grease Replenishment
1. Remove the plug on the Ro (Bo, To) exhaust port.
If grease is injected with the plug (Ro, Bo, To) on, the
grease will go inside the motor and may cause a damage.
NOTE Make sure to remove the plug (Ro, Bo, To) before the
grease injection.
Note that grease replacement is not necessary for R-, B-,
and T-axes.
2. Remove the plug on the Ri (Bi, Ti) grease inlet, and install the grease
zerk PT1/8. Inject grease by using a grease gun.
– Grease type: VIGO grease RE No. 0
– Amount of grease: R-axis: 25 cc (22 g)
(35 cc (30 g) for the 1st supply)
B-axis: 25 cc (22 g)
T-axis: 20 cc (17 g)
– Air supply pressure of grease pump: 0.3 MPa or less
– Grease injection rate: 8 g/s or less
3. Before re-installing a plug to Ro (Bo, To) exhaust port, move each axis
for a few minutes to discharge excessive grease.
4. Wipe the discharged grease with the cloth when the grease is
discharged completely, and reinstall the plug. (Apply seal tape on the
thread part of each plug.)
Fig. 4-4: R-, B-, and T-Axis Speed Reducer
Grease inlet (R-axis) Ri Grease exhaust port (R-axis) Ro

Hexagon socket head plug PT1/8 Hexagon socket head plug PT1/4
Tightening torque: Tightening torque:
4.9 N•m (0.5 kgf•m) 12 N•m (1.2 kgf•m)
Grease inlet (B-axis) Bi

Tightening torque:
4.9 N•m (0.5 kgf•m) Grease exhaust port (B-axis) Bo
Tightening torque:
12 N•m (1.2 kgf•m)
Grease exhaust port (T-axis) To
Grease inlet (T-axis) Ti
Tightening torque:
Tightening torque:
12 N•m (1.2 kgf•m)
4.9 N•m (0.5 kgf•m)
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5 Disassembly and Reassembly of the Motor

5.1 Disassembly and Reassembly of the S-Axis Motor
Refer to chapter 3 “Home Position Return” , chapter 4

“Grease Replenishment and Exchange” and in this manual.
NOTE If you replace the motor, you don’t need to insert the backup
battery.
Remove old sealing bond from each part before starting
assembling.
• Refer to fig. 5-1 “Disassembly & Assembly of S-Axis Motor” .
DANGER
• If you remove a motor, the axis corresponding to the removed motor
will move freely, which leads to falling of the axis due to gravity.
• Steady the axis with a chain block, etc. so that the axis does not
move.
CAUTION
• Before removing a cover, be sure to shut off supply of compressed
air.
 Disassembly
1. Turn OFF the DX200 power supply and exhaust the grease. (Refer to
chapter 4.2 “Grease Replacement Procedures for S-, L-, and U-Axis
Speed Reducers” .)
2. Unscrew the hexagon socket head cap screws and the conical spring
washers 1 , and then remove the cover 3 from the S-head 2 by using
the tapped hole.
3. Disconnect the internal wiring harness from the S-axis motor 4 .
washers 15 , and then remove the plate 14 from the S-head 2 by using
the tapped hole.
5. Mount the jig 16 on the S-head 2 to fix the gear, and then lock the arm.
Put the conical spring washers through the hexagon socket head cap
screws 15 , and then tighten them with the tightening torque shown in
table 5-1 “S-Axis Motor Parts Checklist” .
washers 5 , and then remove the S-axis motor 4 from the S-head 2
by using the tapped hole.
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7. Unscrew the hexagon socket head cap screws 7 and 17 , and then
remove the M-base 6 and the gear 9 from the S-axis motor 4 by
using the tapped hole.
8. Remove the key 8 from the S-axis motor 4 .
9. Unscrew the hexagon socket head cap screws 10 , and then remove
the washers 11 , the oil seals 12 , the collar 13 , and the O-ring 186 from the
M-base 6 .
10. Remove the old sealing bond.
 Reassembly
1. Mount the key 8 on the S-axis motor 4 .
(The key 8 is delivered with the S-axis motor 4 .)
2. Mount the oil seals 12 , the collar 13 , the washers 11 , and the O-ring 18
11
on the M-base 6 . Replenish MP-1 grease to the lip part and the inside
of the oil seals 12 .
3. Put the conical spring washers through the hexagon socket head cap
screws 12
10 , and then tighten them with the tightening torque shown in
table 5-1 “S-Axis Motor Parts Checklist” .

4. Apply ThreeBond 1206C thinly on the joining surface of the gear 129
with the S-axis motor 124 . Then assemble the gear 129 to the M-base 1246 ,
and mount them on the S-axis motor 124 .
5. Put the conical spring washer through the hexagon socket head cap
screw 127 , then apply LOCTITE 243 to its thread part and tighten it with
10
the tightening torque shown in table 5-1.

10
17
table 5-1.
7. Apply ThreeBond 1206C on the joining surface of the M-base 12 67 and
10
the S-head 12
7 , and mount the S-axis motor 12
2
3
10 47 on the S-head 12
2
3
10 7 .
2
3
10
screws 12
2
3
10
table 5-1.
washers 15 , and then remove the jig 12 2
37 from the S-head 12
16
10 2
37 . If it is
10
difficult to remove the jig, insert the M6 bolt to the center of tapped hole
of the jig 16 to remove the jig.
10. Apply ThreeBond 1206C on the joining surface of the S-head 12 2
37 with
10
the plate 14 , and then mount the plate 12

7 on the S-head 12
2
3
14
10 7 . Put the
2
3
10
conical spring washers through the hexagon socket head cap

screws 12
2
15
10
table 5-1.
11. Connect the internal wiring harness to the S-axis motor 12
47 .
2
3
15
10
12. Mount the cover 12

2
37 on the S-head 12
10 7 . Put the conical spring washers
2
3
10
through the hexagon socket head cap screws 1 , and then tighten
them with the tightening torque shown in table 5-1.
13. Replenish VIGO grease RE No.0. (Refer to chapter 4.2 “Grease
Replacement Procedures for S-, L-, and U-Axis Speed Reducers” .)
14. Turn ON the DX200 power supply.
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Table 5-1: S-Axis Motor Parts Checklist

No. Item Qty. Remark
1 Hexagon socket head cap screw M6 19 Tightening torque
(length: 25 mm) *trivalent chromate* each 10 N•m
Conical spring washer 2H-6
2 S-head HW1100841-1 1
3 Cover HW1200466-1 1
4 S-axis motor 1 SGMRV-37ANA-YRA2
(length: 65 mm) each 84 N•m
6 M-base HW1305562-1 1
Conical spring washer 2L-8
8 Key 1
9 Gear HW1305613-1 1
(length: 12 mm) each 2.8 N•m
11 Washer HW0404196-1 4
12 Oil seal HW9481329-A 2
13 Collar HW0415325-2 1
14 Plate HW1407881-1 1
16 Jig HW1306449-1 1
18 O-ring S100 1
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Fig. 5-1: Disassembly & Assembly of S-Axis Motor
15
1
14
2
4
3
15 10 8
16
11
18
17
12
13
Details of A
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5.2 Disassembly and Reassembly of the L-Axis Motor

• Refer to fig. 5-2 “Disassembly & Assembly of L-Axis Motor” .
DANGER
move.
CAUTION
air.
 Disassembly
washers 1 , and then remove the cover 3 from the S-head 2 by using
the tapped hole.
3. Disconnect the internal wiring harness from the L-axis motor 4 .
washers 15 , and then remove the plate 14 from the S-head 2 by using
the tapped hole.
5. Mount the jig 16 on the S-head 2 to fix the gear, and then lock the arm.
table 5-2 “L-Axis Motor Parts Checklist” .
washers 5 , and then remove the L-axis motor 4 from the S-head 2
by using the tapped hole.
washers 7 and 17 , and then remove the M-base 6 and the gear 9
from the L-axis motor 4 by using the tapped hole.
8. Remove the key 8 from the L-axis motor 4 .
washers 10 , and then remove the washers 11 , the oil seals 12 , the
collar 13 , and the O-ring 18 from the M-base 6 .
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 Reassembly
1. Mount the key 8 on the L-axis motor 4
(The key 8 is delivered with the L-axis motor 4 .).
2. Mount the oil seals 12 , the collar 13 , the washers 11 , and the O-ring 18
11
on the M-base . Replenish MP-1 grease to the lip part and the inside
6
of the oil seals 12 .
screws 12
table 5-2 “L-Axis Motor Parts Checklist” .

9
10
with the L-axis motor . Then assemble the gear to the M-base 12
4 9
12
10 69 ,
10
and mount them on the L-axis motor .

4
screw 12
67 , and then apply LOCTITE 243 on its thread part and tighten it
9
10
with the tightening torque shown in table 5-2.

screws 12
9
10
17
table 5-2.
7. Apply ThreeBond 1206C on the joining surface of the M-base 6 and
the S-head 2 , and mount the L-axis motor 4 on the S-head 2 .
table 5-2.
washers 15 , and then remove the jig 16 from the S-head 2 . If it is
10. Apply ThreeBond 1206C on the joining surface of the S-head 2 with
the plate 14 . Then put the conical spring washers through the hexagon
socket head cap screws 15 , and then tighten them with the tightening
torque shown in table 5-2.
11. Connect the internal wiring harness to the L-axis motor 4 .
12. Mount the cover 3 on the S-head 2 . Put the conical spring washers
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Table 5-2: L-Axis Motor Parts Checklist

2 S-head HW1100841-1 1
3 Cover HW1200466-1 1
4 L-axis motor 1 SGMRV-37ANA-YRA2
6 M-base HW1305562-1 1
8 Key 1
9 Gear HW1305613-1 1
11 Washer HW0404196-1 4
12 Oil seal HW9481329-A 2
13 Collar HW0415325-2 1
14 Plate HW1407881-1 1
16 Jig HW1306449-1 1
18 O-ring S100 1
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Fig. 5-2: Disassembly & Assembly of L-Axis Motor
18
9
8
10
11 12 13
17
Details of A
5 6
4 A
15 14 15 14
1
2
15
3
16
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5.3 Disassembly and Reassembly of the U-axis Motor

• Refer to fig. 5-3 “Disassembly & Assembly of U-Axis Motor” .
DANGER
move.
CAUTION
air.
 Disassembly
washers 1 , and then remove the cover 3 from the casing 2 by using
the tapped hole.
3. Disconnect the internal wiring harness from the U-axis motor 4 .
washers 17 , and then remove the plate 16 from the casing 2 by using
the tapped hole.
5. Mount the jig 18 on the casing 2 to fix the gear, and then lock the arm.
table 5-3 “U-Axis Motor Parts Checklist” .
washers 5 , and then remove the U-axis motor 4 from the casing 2 by
using the tapped hole.
washers 6 and 10 , and then remove the M-base 11 and the gear 8
from the U-axis motor 4 by using the tapped hole.
8. Remove the key 7 and the collar 9 from the U-axis motor 4 .
washers 12 , and then remove the cover 13 , the oil seals 14 , the
collar 15 , and the O-ring 19 from the M-base 11 .
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 Reassembly
1. Mount the key 7 on the U-axis motor 4 . (The key which is delivered
with the U-axis motor 4 is not used.)
2. Apply ThreeBond 1206C on the joining surface of the collar 9 with the
U-axis motor 4 . Then mount the collar 9 on the U-axis motor 4 .
3. Mount the oil seals 14 , the collar 15 , the cover 13 , and the O-ring 19 on
the M-base 11 .
Replenish MP-1 grease to the lip part and the inside of the oil seal 14 .
table 5-3 “U-Axis Motor Parts Checklist” .
with the collar 9 . Then assemble the gear 8 to the M-base 11 , and
then mount them on the U-axis motor 4 .
screw 6 , then apply LOCTITE 243 on its thread part and tighten it with
table 5-3.
8. Mount the U-axis motor 4 on the casing 2 . Put the conical spring
washers through the hexagon socket head cap screws 5 , and then
tighten them with the tightening torque shown in table 5-3.
washers 17 , and then remove the jig 18 from the S-head 2 . If it is
10. Apply ThreeBond 1206C on the joining surface of the casing 2 with
the plate 16 . Then put the conical spring washers through the hexagon
11. Connect the internal wiring harness to the U-axis motor 4 .
12. Mount the cover 3 on the casing 2 . Put the conical spring washers
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Table 5-3: U-Axis Motor Parts Checklist

2 Casing HW1100843-1 1
3 Cover HW1200467-1 1
4 U-axis motor 1 SGMRV-13ANA-YRA1
7 Key KEY-C 8×7×50 (parallel key) 1
8 Gear HW1305619-1 1
9 Collar HW0400470-2 1
11 M-base HW1305563-1 1
13 Cover HW0409965-1 1
14
13 Oil seal Y426012.5 2
15
13 Collar HW0415325-1 1
16 Plate HW1407882-1 1
18 Jig HW1306450-1 1
19 O-ring G90 1
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Fig. 5-3: Disassembly & Assembly of U-Axis Motor
2 40
17
16
9
3 4
2 7
12
5
14
1 10
15
13
17 19
16 11
8
A
17
18
6
Details of A
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5.4 Disassembly and Reassembly of the R-, B-, and T-Axis Motor
• Refer to fig. 5-4 “Disassembly & Assembly of R-, B-, and T-Axis
Motor” .
DANGER
move.
CAUTION
air.
 Disassembly
1. Turn OFF the DX200 power supply.
washers 1 , and then remove the cover 3 from the casing 2 .
3. Remove the protective plastic cover from the cable connector of the R-,
B-, and T-axis motor 4 .
4. Disconnect the cables (both encoder and power-cables) of the R-, B-,
and T-axis motor 4 from the internal wiring harness.
washers 5 , and then remove the R-, B-, and T-axis motor 4 from the
M-base 6 .
6. Unscrew the hexagon socket head cap screw and the conical spring
washer 7 , and then remove the gear 8 from the R-, B-, and T-axis
motor 4 .
washers 9 , and then remove the oil seals 12 and the collar 11 from the
M-base 6 .
 Reassembly
1. Apply ThreeBond 1206C on the joining surface of the gear 8 with the
R-, B-, and T-axis motor 4 . Then mount the gear 8 on the R-, B-, and
T-axis motor 4 .
screw 7 , then apply LOCTITE 243 to its thread part and tighten it with
the tightening torque shown in table 5-4 “R-, B-, and T-Axis Motor
Parts Checklist” .
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3. Wipe off the excess ThreeBond 1206C run off the edges in the
reassembling procedure.
4. Mount the oil seals 12 , the collar 11 , and the plate 10 on the M-base 6 .
Replenish MP-1 grease to the lip part and the inside of the oil seal 12 .
table 5-4 “R-, B-, and T-Axis Motor Parts Checklist” .
6. Mount the R-, B-, and T-axis motor 4 on the M-base 6 .
table 5-4.
8. Connect the cables (both encoder and power-cables) of the R-, B-,
and T-axis motor 4 with the internal wiring harness.
9. Wrap the protective plastic cover around the cable connector and fix it
with cable ties.
Table 5-4: R-, B-, and T-Axis Motor Parts Checklist

(length: 25mm) *trivalent chromate* each 10 N•m
Conical spring washer 2H-6 *trivalent
chromate*
2 Casing HW1100843-1 1
3 Cover HW1200467-1 1
4 R-, B-, and T-axis motor 1 SGMAV-04ANA-YR2
6 M-base HW1305620-2 1
8 Gear HW1304354-1 1
10 Plate HW1406944-1 1
11 Collar HW0409966-4 1
12 Oil seal Y234010.5 2
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Fig. 5-4: Disassembly & Assembly of R-, B-, and T-Axis Motor
A R-axis motor
2 1 3
Section A-A 5
6 A
T-axis motor
B-axis motor
10 11
12
9
Details of B
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6 Disassembly and Reassembly of Speed Reducer
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 “Disas-
NOTE sembly and Reassembly of the Motor” and chapter 7 “Dis-
assembly and Reassembly of Wrist Unit” . Remove old
sealing bond from each part before assembling.
• Refer to fig. 6-1 “Disassembly & Reassembly of the S-Axis Speed

Reducer” .
DANGER
will move freely, which leads to falling due to gravity.
Steady the axis with a chain block, etc. so that the axis does not
move.
CAUTION
air.
 Disassembly
1. Set the S-axis to the 0-degree posture, turn OFF the DX200 power
supply, and exhaust the grease of S- and L-axis. (Refer to chapter 4.2
“Grease Replacement Procedures for S-, L-, and U-Axis Speed
Reducers” .)
washers 1 , and then remove the cover 3 from the S-head 2 .
3. Connect the backup battery to the S-, L-, U-, R-, B-, and T-axes
respectively. (Refer to chapter 2.2 “Battery Pack Replacement” .)
4. Disconnect the manipulator cable. Remove the C base 5 , the plastic
cover 14 and 15 , the connector of the internal wiring harness 9 , the
ground terminal, and the bracket 12 and cut the cable ties 16 fixing the
internal wiring harness 159 .
5. Remove the cover 10 which is mounted the battery, and the connector
for the internal wiring harness 9 and the battery.
6. Cut the cable ties 8 .
washers 6 , and then remove the saddle 7 .
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washers 22 , and remove the plate 23 .
10. Pull out the internal wiring harness 9 upward.
11. Remove the S-axis motor 18 and the L-axis motor 35 . (Refer to
chapter 5.1 “Disassembly and Reassembly of the S-Axis Motor” ,
chapter 5.2 “Disassembly and Reassembly of the L-Axis Motor” .)
washers 31 and the washers, and then remove the shaft unit 32 .
washers 24 , 27 , and 29 . Then, by using the chain block, lift up the
upper part of the manipulator including the S-head 2 , separate the S-
head unit from the speed reducer 17 by using the tapped hole.
washers 19 , and remove the speed reducer 17 from the base 20 .
 Reassembly
1. Set the S-axis to the 0-degree posture.
Attach the O-ring 33 to the groove of the speed reducer 17 .
2. Mount the speed reducer 17 on the base 20 .
table 6-1 “S-Axis Speed Reducer Parts Checklist” .
4. Apply Threebond 1206C to the joining surface of the speed reducer 17
with the S-head 2 , and mount the S-head unit on the speed
reducer 17 .
screws 24 , 27 , and 29 , and then tighten them with the tightening torque
shown in table 6-1.
table 6-1. Then mount the shaft unit 32 on the S-head 2 .
7. Mount the S-axis motor 18 and the L-axis motor 35 . (Refer to
chapter 5.1 “Disassembly and Reassembly of the S-Axis Motor” .)
8. Apply Multemp PS2A to the protective spring of the internal wiring
harness 9 and its contact surface with the protective spring.
9. Run the internal wiring harness 9 through the speed reducer 17 .

10. Attach the saddle 7 , and fix the protective spring of the internal wiring
harness 9 .
11. Put the conical spring washers and washers through the hexagon
12. Set the internal wiring harness 9 with an untwisted state, and fix the
internal wiring harness 9 with the cable tie 8 .
13. Mount the plastic covers 14 and 15 , and fix the internal wiring
harness 9 with the cable ties 16 .
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14. Mount the bracket 12 on the manipulator cable side bracket by using
the hexagon socket head cap screws with the conical spring washers
11 attached, and tighten it with the tightening torque shown in table 6-1
“S-Axis Speed Reducer Parts Checklist” .

15. Connect the manipulator cable and the connector of the internal wiring
harness 9 .
16. Connect the ground wire (2 wires) of the manipulator cable to the
tapped hole for mounting ground wire of the bracket 12
16 . (Tightening
torque 5 N•m)
17. Cover the unbound part of the internal wiring harness 9 with the
plastic cover 14 and 15 and fix it with the cable ties 13 . (The encoder
cable and the power cable)
18. Connect the purging tube to the joint of the IN-side on the C base 5 .
19. Mount the gasket face of the C-base 5 on the base so that the
protective gas force feeding tube is not bended in the manipulator.
screws 4 , and tighten them with the tightening torque shown in
table 6-1.
20. Connect the internal wiring harness 9 to the battery, and then fix it
with the cable ties 16 .
21. Mount the cover 10 . Put the conical spring washers through the
hexagon socket head cap screws 4 , and then tighten them with the
tightening torque shown in table 6-1.
22. Disconnect the backup batteries from the S-, L-, U-, R-, B-, and T-
axes. (Refer to chapter 2.2 “Battery Pack Replacement” .)
24. Replenish VIGO grease RE No.0 from the grease inlet. (Refer to
Table 6-1: S-Axis Speed Reducer Parts Checklist

2 S-head HW1100841-1 1
3 Cover HW1200466-1 1
5 C base HW1305611-1 1 Manipulator cable
6 Hexagon socket head cap screw M6 2 each Tightening torque
(length: 10 mm) 10 N•m
Washer M6 *trivalent chromate*
7 Saddle CD42 1
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Table 6-1: S-Axis Speed Reducer Parts Checklist

8 Cable tie T120 2
9 Internal wiring harness HW1172448-A 1
10 Cover HW1306460-A 1
(length: 12 mm) 4.8 N•m
12 Bracket HW1407831-1 1
13 Cable tie T50L 4
14 Plastic cover HW1408387-1 1 Small_for the encoder
(for 1BC)
15 Plastic cover HW1408387-2 1 Big_for the power cable
(for 2BC)
16 Cable tie T18L 12+1
17 Speed reducer HW1384511-A 1
20 Base HW1100840-1 1
21 Cable tie T120 2
(length: 8 mm) 2.8 N•m
23 Plate HW1406837-1 1
Conical spring washer 2H-16 Bolt for part a
25 Plate HW1406941-2 2
26 Plate HW1406942-2 1
Conical spring washer 2H-16 Bolt for part c
28 Plate HW1407683-2 1
Conical spring washer 2H-16 Bolt for part d
30 Washer HW0411968-8 3
32 Shaft unit 1
33 O-ring Gs335 1
34 Joint KQ2L12-16A 1
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HW1484372
Fig. 6-1: Disassembly & Reassembly of the S-Axis Speed Reducer
32 Tapped hole for removing (M6)
24 28
27
29 30
d
d c c
25
a
a
a
a
d
a
a
35
a a
a a a
25
24 26
24
1
34 2
32
31 18 3
24 27 29
21
22
19
23
33
12
11
10
17
5
4
4
9 16
7 8 6 20
14 15 16 15
13
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6.2 Disassembly and Reassembly of L-Axis Speed Reducer
• Refer to fig. 6-2 “Disassembly & Reassembly of the L-Axis Speed

Reducer” .
DANGER
move.
CAUTION
air.
 Disassembly
1. Set the L- and U-axis to the 0-degree posture.

Before detaching the L-arm 1 , to avoid the L-arm 1 from falling down,
support it with a chain block, etc.
2. Turn OFF the DX200 power supply, and exhaust the grease of S- and
L-axis. (Refer to chapter 4.2 “Grease Replacement Procedures for S-
, L-, and U-Axis Speed Reducers” .)
washers 2 , and then remove the cover 4 from the S-head 3 .
4. Unscrew the hexagon socket button head screws and the conical
spring washers 5 , and then remove the cover 16 from the L-arm 1 .
8. Connect the backup battery to the S-, L-, U-, R-, B-, and T-axes
9. For U-, R-, B-, and T-axis motor, remove the plastic cover 42 from the
cable connector of the internal wiring harness 9 , and separate the
internal wiring harness 9 .
10. Separate the air tube of the internal wiring harness 9 and the joint 40 .
11. Cut the cable ties 12 , 13 , 20 , 25 , and 37 .
12. Unscrew the hexagon socket head cap screws, the conical spring
washers, and the washers 26 , and then remove the plate 27 .
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washers, and the washers 18 , and then remove the saddle 19 .
washers, and the washers 10 , and then remove the saddle 11 .
16. Pull out the internal wiring harness 9 to L-axis motor 28 side.
17. Remove the L-axis motor 28 and the S-axis motor 44 . (Refer to
washers 38 , and then remove the shaft unit 39 .
washers 30 . Then, by using the chain block, lift up the upper part of the
manipulator including the L-arm 1 , separate the L-arm unit from the
speed reducer 29 by using the tapped hole.
washers 31 , 35 , and 36 , and then remove the speed reducer 29 from
the S-head 3 .
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 Reassembly
1. Attach the O-ring 43 to the groove of the speed reducer 29 .
2. Set the L- and U-axis to the 0-degree posture.
Apply Threebond 1206C to the joining surface of the speed reducer 29
with the S-head 3 , and mount the speed reducer 29 on the S-head 3 .
screws 31 , 35 , and 36 , and then tighten them with the tightening torque
shown in table 6-2 “L-Axis Speed Reducer Parts Checklist” .
4. Mount the L-arm unit on the S-head 3 .
table 6-2.
table 6-2. Then mount the shaft unit 39 on the S-head 3 .
7. Mount the L-axis motor 28 and the S-axis motor 44 . (Refer to

8. Apply Multemp PS2A to the protective spring of the internal wiring
harness 9 and its contact surface with the protective spring.
9. Run the internal wiring harness 9 through the casing 22 . Be careful
not to twist the internal wiring harness 9 .
10. Mount the protective spring of the internal wiring harness 9 with the
plate 15 . Put the conical spring washers and the washers through the
internal wiring harness 9 with the cable ties 13 .
saddle 11 . Put the conical spring washers and the washers through
the hexagon socket head cap screws 10 , and then tighten them with
15. Mount the protective spring of the internal wiring harness 9 by using
the saddle 19 , and tighten the hexagon socket head cap screws 18 with
plate 27 . Put the conical spring washers and the washers through the
saddle 19 . Put the conical spring washers through the hexagon socket
head cap screws 18 , and then tighten them with the tightening torque
shown in table 6-2.
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20. Connect the air tube of the internal wiring harness 9 to the joint 40 .
21. Connect the each connector of the internal wiring harness 9 end to
the L-, U-, R-, B-, and T-axis motor.
22. Wrap the plastic cover 42 around the connector of the U-, R-, B-, and T-
axis, and fix it with the cable ties 41 .
23. Disconnect the backup batteries from the S-, L-, U-, R-, B-, and
T-axes. (Refer to chapter 2.2 “Battery Pack Replacement” .)
them with the tightening torque shown in table 6-2 “L-Axis Speed
Reducer Parts Checklist” .
25. Mount the cover 17 on the L-arm 1 . Put the conical spring washers
through the hexagon socket button head screws 16 , and then tighten
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Table 6-2: L-Axis Speed Reducer Parts Checklist

1 L-arm HW1100842-1 1
3 S-head HW1100841-1 1
4 Cover HW1200466-1 1
5 Hexagon socket button head screw M8 8 Tightening torque
(length: 25 mm) *trivalent chromate* each 20.6 N•m
6 Cover HW1407878-1 1
8 Cover HW1407877-1 1
11 Saddle CD39 1
12 Cable tie T120 2
13 Cable tie T120 2
15 Plate HW1406837-1 1
17 Cover HW1407876-1 1
19 Saddle CD36 1
20 Cable tie T120 2
22 Casing HW1100843-1 1
23 Cover HW1200467-1 1
25 Cable tie T120 2
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Table 6-2: L-Axis Speed Reducer Parts Checklist

27 Plate HW1406847-1 1
Conical spring washer 2H-16 Screw for part a
32 Plate HW1406941-2 2
33 Plate HW1406942-2 1
34 Washer HW0411968-8 4
Conical spring washer 2H-16 Screw for part b
Conical spring washer 2H-16 Screw for part c
37 Cable tie T120 2
39 Shaft unit 1
41 Cable tie T18R 16
42 Plastic cover HW9405566-A 8
43 O-ring Gs335 1
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Fig. 6-2: Disassembly & Reassembly of the L-Axis Speed Reducer
21
23
40 22
16
17
25
24
19
18 26
41
27
20 42
37
31 35 36 Details for the cable connector
1 for U-, R-, B-, and T-axis motor
6
39
43
12 38 31
5 32
10 15 33 31
14
13 34 36 a 39 Tapped hole for removing (M6)
11 a a a
a
a
4 28 a
c a
8 a 44
a
a
9 2 a a
b 31
7
3 32
30
29
34 35 31 34
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6.3 Disassembly and Reassembly of U-Axis Speed Reducer
• Refer to fig. 6-3 “Disassembly & Reassembly of the U-Axis Speed

Reducer” .
DANGER
move.
CAUTION
air.
 Disassembly
1. Set the U-axis to the 0-degree posture.
Before detaching the L-arm unit 1 , to avoid the L-arm unit 1 from
falling down, support it with a chain block, etc.
4. Unscrew the hexagon socket button head screws, the conical spring
washers, and the washers 5 , and then remove the cover 7 from the
L-arm 6 .
5. Connect the backup battery to the U-, R-, B-, and T-axes respectively.
(Refer to chapter 2.2 “Battery Pack Replacement” .)
6. Remove the plastic cover 25 from the cable connector of the internal
wiring harness 8 , and separate the internal wiring harness 8 .
7. Separate the air tube of the internal wiring harness 8 from the joint 11 .
washers 9 , and then remove the bracket 10 .
11. Remove the internal wiring harness 8 from the speed reducer 12 .
12. Remove the U-axis motor 13 . (Refer to chapter 5.2 “Disassembly and
Reassembly of the L-Axis Motor” .)
washers 14 , and then remove the U-arm unit 1 from the L-arm 6 .
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washers 22 , and then remove the plates 23 and the shaft 21 from the L-
arm 6 .
washers 16 , and then remove the speed reducer 12 from the casing 3 .
 Reassembly
1. Attach the O-ring 20 to the groove of the speed reducer 12 .
2. Mount the speed reducer 12 on the casing 3 . Mount the speed
reducer unit so that the position of the grease inlet hole A for the
speed reducer 12 is matched.
table 6-3 “U-Axis Speed Reducer Parts Checklist” .
4. Insert the shaft 21 . Use the plates 23 to hold the shaft 21 , then put the
conical spring washers through the hexagon socket head cap
screws 22 . Then tighten them with the tightening torque shown in
table 6-3.
5. Apply ThreeBond 1206C to each joining surface between the speed
reducer 12 and the L-arm 6 . Then lift up the L-arm unit 1 with a chain
block, etc. and mount it on the L-arm 6 . Mount it so that the positions
of the grease inlet hole A for the speed reducer 12 and of the grease
inlet hole A for the L-arm 6 are matched.
table 6-3.
7. Mount the U-axis motor 13 . (Refer to chapter 5.3 “Disassembly and

Reassembly of the U-axis Motor” .)
8. Apply grease (Multemp PS2A) to the protective spring of the internal
wiring harness 8 and its contact surface with the protective spring.
9. Run the internal wiring harness 8 through the speed reducer 12 .
10. Mount the bracket 10 on the L-arm 6 . Put the conical spring washers
plate 19 . Put the conical spring washers through the hexagon socket
head cap screws 18 , and then tighten them with the tightening torque
shown in table 6-3.
(Set the U-axis to the 0-degree posture.)
13. Connect the air tube of the internal wiring harness 8 to the joint 11 .
14. Connect the connector of the internal wiring harness 8 end to the U-,
R-, B-, and T-axis motor.
15. Wrap the plastic cover 25 around the connector of the U-, R-, B-, and T-
axis motor, and fix them with the cable ties 24 .
16. Disconnect the backup batteries from the U-, R-, B-, and T-axes.
(Refer to chapter 2.2 “Battery Pack Replacement” .)
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and the washers through the hexagon socket button head screws 5 ,
and then tighten them with the tightening torque shown in table 6-3
“U-Axis Speed Reducer Parts Checklist”
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Table 6-3: U-Axis Speed Reducer Parts Checklist

1 U-arm unit 1
3 Casing HW1100843-1 1
4 Cover HW1200467-1 1
6 L-arm HW1100842-1 1
7 Cover HW1407876-1 1
10 Bracket HW1305618-1 1
15 Washer HW0411968-6 12
17 Cable tie T120 2
19 Plate HW1406847-1 1
20 O-ring AS568-173 1
21 Shaft HW1305944-1 1
23 Plate HW1407245-1 2
24 Cable tie T18R 16
25 Plastic cover HW9405566-A 8
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Fig. 6-3: Disassembly & Reassembly of the U-Axis Speed Reducer
18 19
1 4
3 13
17
11 12
24
25 20
16
6
22 14 15
Details for the cable connector
for U-, R-, B-, and T-axis motor 23 7
21 5
A 30° 8
A 30°
10 9
a
a
a
a
Top view of the reducer
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6.4 Disassembly and Reassembly of R-, B-, and T-Axis Speed Reducer
6.4 Disassembly and Reassembly of R-, B-, and T-Axis Speed

Reducer
• Refer to fig. 6-4 “Disassembly & Reassembly of the R-, B-, and T-
Axis Speed Reducer” .
DANGER
move.
CAUTION
air.
 Disassembly
3. In order to secure a space to insert the tools, pull the motor connector
and the internal wiring harness out of the casing 2 .
4. Connect the backup batteries to the R-, B-, and T-axes motors 4
5. Mark the grease hoses connected with the joints 6 and 7 to see
which grease hoses are connected with which joints 6 and 7 , then
disconnect the grease hoses from the joints 6 and 7 . Wipe off the
oil content overspilling from the grease hose and the joints 6 and 7 .
washers 10 , and then remove the speed reducer 9 from the casing 2 .
washers 8 , and then remove the M-base 5 from the speed reducer
9 .
washers 11 , and then remove the shaft 12 from the speed reducer 9 .
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 Reassembly
1. Apply VIGO grease to the tooth surface of the speed reducer 9 .
2. Apply ThreeBond 1206C to the joining surface of the shaft 12 with the
speed reducer 9 . Then mount the shaft 12 on the speed reducer 9 .
table 6-4 “R-, B-, and T-Axis Speed Reducer Parts Checklist” .
Wipe off the excess ThreeBond 1206C in the reassembling procedure.
4. Apply Alvania EP2 to the A part of the shaft 12 and replenish the
grease in the B part.
5. Insert the gasket 13 to the joining surface of the M-base 5 and the
speed reducer 9 . Put the conical spring washers through the
hexagon socket head cap screws 8 and then tighten them with the
6. Apply ThreeBond 1206C to the joining surface of the speed reducer 9
with the casing 2 . Then mount the speed reducer 9 on the casing 2 .
table 6-4.
Wipe off the excess ThreeBond 1206C protruded in the reassembling
procedure.
8. Disconnect the backup batteries from the R-, B-, and T-axes motors 4
9. According to the marks on the grease hoses made in the step 6 of
“Disassembly” in chapter 6.4 “Disassembly and Reassembly of R-,
B-, and T-Axis Speed Reducer” , connect the grease hoses to the
joints 6 and 7 .
10. Store the motor connector and the internal wiring harness in the
casing 2 .
chapter 4.3 “Grease Replenishment Procedures for S-, L-, and U-Axis
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Table 6-4: R-, B-, and T-Axis Speed Reducer Parts Checklist
2 Casing HW1100843-1 1
3 Cover HW1200467-1 1
4 R-, B-, and T-axis motor 1 SGMAV-04ANA-YR2
5 M-base HW1305620-2 1
6 Joint KFL10N-02S 1
7 Joint KFL08N-01S 1
12 Shaft HW1405350-1 1
13 Gasket 1 Delivered with the
speed reducer
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Fig. 6-4: Disassembly & Reassembly of the R-, B-, and T-Axis Speed Reducer
A R-axis motor
2 1
3
C Section A-A
A
13 T-axis motor
9 B-axis motor
11 7
A 8
12
B
6
Details of C
10
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7 Disassembly and Reassembly of Wrist Unit
• Refer to fig. 7-1 “Disassembly & Reassembly of Wrist Unit” .
NOTE Refer to chapter 2 “Notes for Maintenance” and chapter 3

“Home Position Return” .
 Disassembly
2. Remove the paint gun, etc. and pull out the hose, etc. in the wrist
unit 1 to the U-arm 2 side.
washers 8 , and then remove the cover 9 from the wrist unit 1 .
washers 3 and 10 .
5. Remove the wrist unit 1 from the U-arm 2 by using two tapped holes
M6 which are on the U-arm 2 .
6. Remove the pin 4 and retain it.
 Reassembly
1. Apply Alvania EP grease No.2 to each tooth surface of the
gears 5 6 7 in the wrist unit 1 .
2. Attach the pin 4 to the U-arm 2 and apply ThreeBond 1206C to the
joining surface of the U-arm 2 with the wrist unit.
3. Attach the wrist unit 1 to the U-arm 2 , put the conical spring washers
through the hexagon socket head cap screws 3 , apply ThreeBond
1206C to their thread part, and then tighten them with the tightening
torque shown in table 7-1 “Wrist Unit Parts Checklist” .
table 7-1.
screws 28 , tighten them with the tightening torque shown in table 7-1,
and then mount the cover 29 on the wrist unit 1 .
6. Refer to chapter 3 “Home Position Return” and calibrate home

positioning of R-, B- and T-axes.
7. Run the hose, etc. through the wrist unit 1 and mount the paint gun,
etc.
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Table 7-1: Wrist Unit Parts Checklist

1 Wrist unit HW1171980-C 1
2 U-arm HW1100844-1
chromate*
4 Pin HW1408948-6-15 1
5 Gear HW1304313-1 1
6 Gear HW1304312-1 1
7 Gear HW1304311-1 1
(length: 12mm) *trivalent chromate* each 2.8 N•m
chromate*
9 Cover HW0414759-1 1
Fig. 7-1: Disassembly & Reassembly of Wrist Unit
4
3
1 2
10
5 View A
8
6
9 7
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8 Battery Replacement
8.1 Battery Replacement
8.1.1 YR-MPX2600 (Except for “-B**”)
WARNING
Before replacing the battery pack, turn OFF the power supply to the
DX200, and check that no explosive atmosphere exists around the
battery pack.
Three batteries are installed in the locations shown in fig. 8-1 “Battery
Location (Except for “-B**”)” .
Type Battery pack type

YR-MPX2600 (Except for “-B**” and “-C**”) HW1372692-A,B,C
YR-MPX2600-C** HW1373234-A,B,C
If a battery alarm occurs in the DX200, replace the battery in the following
procedures.
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Fig. 8-1: Battery Location (Except for “-B**”)
Gasket
Cover which the battery is mounted
(with the battery warning label) Battery plate
WARNING
This pressurized enclosure contains a battery which remains connected after
Base
the external power has been isolated.
Refer to instructions in the manual before carrying
out frequent inspection and exchanging periodically.
Battery only to be replaced by Licensee when the area is known to be safe.
Battery unit type Battery type Manufucturere
HW1372692-A,-B,-C ENERGIZER L91 YASKAWA Electric Corporation
Cable tie Cable tie

(4 places) (2 places)
For fixing the
battery lead *trivalent chromate*
Washer M4
Tightening torque 1.2 N•m (0.12 kgf•m)
Battery for S-, L-axes
HW1372692-A (Except for “-C**”)
HW1373234-A (-C**)
Battery for U-, R-axes
HW1372692-B (Except for “-C**”)
HW1373234-B (-C**)
Battery for B-, T-axes
HW1372692-C (Except for “-C**”)
HW1373234-C (-C**)
1. Turn OFF the power to the DX200.
2. Ventilate the environment around the manipulator to remove explosive

gas.
3. Remove the cover (the battery warning label attached) on which the
battery is mounted.
4. Unscrew the bolts fixing the battery and remove the cable ties.
5. Remove an vinyl tape (insulation tape) protecting connection part of

the battery in the manipulator.
6. Connect the new battery.
7. Remove the old battery.
NOTE Be sure to connect the new batteries before disconnecting

the old one so that the data does not disappear.
8. Protect the connection part of the battery in the manipulator with the
vinyl tape (insulation tape).
9. Mount the battery to the bracket by using the bolt M4 (length: 85 mm)
and the cable ties (T50L for two places and T18R for four place).
10. Re-install the cover.
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Fig. 8-2: Battery Connection
Battery for S-, L-axis

See step 7 before replacement
See step 8
New battery board
BAT 1 BAT 1
BAT 1 BAT 1
See step 6
See step 5
Battery for U-, R-axis

See step 8
New battery board
BAT 3 BAT 3
BAT 3 BAT 3
See step 6
See step 5
Battery for B-, T-axis

See step 8
New battery board
BAT 5 BAT 5
BAT 5 BAT 5
See step 6
See step 5
Conversion cable
F BAT* BAT* New battery pack

M OBT*
For the battery for the spare parts, the cable to convert to the contact pin for
connecting the backup connector of the motor are attached in the standard
specification. (Refer to chapter 2.2 “Battery Pack Replacement” .) When
connecting the battery, remove the conversion cable to connect the battery.
8-3 HW1484372 76/100

HW1484372
8.1.2 YR-MPX2600-B**
WARNING
Before replacing the battery pack, turn OFF the power supply to the
DX200, and check that no explosive atmosphere exists around the
battery pack.
Three batteries are installed in the locations shown in fig. 8-3 “Battery
Location (For “-B**”)” .
Type Battery pack type

YR-MPX2600-B** HW1470715-BA,BB,BC
If a battery alarm occurs in the DX200, replace the battery in the following
procedures.
Fig. 8-3: Battery Location (For “-B**”)

Fig. 8-4:
Cover which the battery is mounted Battery plate
(with the battery warning label) Gasket
WARNING
AVERTISSEMENT
When replacing battery instruction
Battery only to be replaced when
Base
the area is known to be safe.
Suivez les instructions du manuel
pour remplacer la batterie.
La batterie peut etre remplacee
D'etre en securite.
WARNING
AVERTISSEMENT
When replacing battery instruction
Battery only to be replaced when
A
the area is known to be safe.
Suivez les instructions du manuel
pour remplacer la batterie.
La batterie peut etre remplacee
D'etre en securite.

3 x Battery Holder
Cable tie
(2 places)
Battery for S-, L-axes
HW1470715-BA
Battery for U-, R-axes
HW1470715-BB
Battery for B-, T-axes
HW1470715-BC
Cable tie (connector)
View A
8-4 HW1484372 77/100

HW1484372
1. Turn OFF the power to the DX200.

2. Ventilate the environment around the manipulator to remove explosive
gas.
3. Remove the cover (the battery warning label attached) on which the
battery is mounted.
4. Remove the cable ties.
5. Remove an vinyl tape (insulation tape) protecting connection part of
the battery in the manipulator.
6. Connect the new battery.
7. Remove the old batteries.
NOTE Be sure to connect the new batteries before disconnecting

the old one so that the data does not disappear.
8. Protect the connection part of the battery in the manipulator with the
vinyl tape (insulation tape).
9. Mount the battery to the bracket by using the cable ties (T50L for two
places and T18R for one place).
10. Re-install the cover.
8-5 HW1484372 78/100

HW1484372
Fig. 8-5: Battery Connection
Battery for S-, L-axis

See step 8
New battery board
BAT 1 BAT 1
BAT 1 BAT 1
See step 6
See step 5
Battery for U-, R-axis

See step 8
New battery board
BAT 3 BAT 3
BAT 3 BAT 3
See step 6
See step 5
Battery for B-, T-axis

See step 8
New battery board
BAT 5 BAT 5
BAT 5 BAT 5
See step 6
See step 5
Conversion cable
F BAT* BAT* New battery pack

M OBT*
For the battery for the spare parts, the cable to convert to the contact pin for
connecting the backup connector of the motor are attached in the standard
specification. (Refer to chapter 2.2 “Battery Pack Replacement” .) When
connecting the battery, remove the conversion cable to connect the battery.
8-6 HW1484372 79/100

HW1484372
9 Gasket Replacement
DANGER
The MOTOMAN-MPX2600 is a pressurized explosion-proof apparatus
in which high-pressure air is contained.
Do not loosen the fixing bolt of the cover on the manipulator when high-
pressure air remains inside the manipulator.
Failure to observe this instruction may result in serious personal injury.
Before loosening the fixing bolt of the cover on the manipulator, make
sure to confirm that the air supply to the manipulator is stopped and
that there is no residual pressure in the manipulator.
NOTE Refer to chapter 2 “Notes for Maintenance” .
• Never insert a flat tip screwdriver, an edged tool, etc. into

NOTE the gasket to remove the motor cover so as not to damage
the gasket. If the gasket is damaged, air leak will result.
• Refer to fig. 9-1 “Gasket in Base Part” and fig. 9-2 “Gasket in Rotat-
ing Head, Lower-Arm, Casing Part” .
1. Remove the cover of the gasket to replace from the manipulator.
(Refer to chapter 2.1 “Inspection of Gasket” .)
2. Remove the gasket from the cover.
Since this gasket is adhered by DB bond DB1600, remove the gasket
carefully.
3. Thoroughly remove DB bond DB1600 adhered to the cover.
4. Check that attached surface of the cover and the gasket matches.
5. Degrease each attached surface of the cover and the gasket.
6. Apply DB bond DB1600 to each attached surface of the cover and the
gasket by using a brush, or the like, and dry the surface for 5 to 10
minutes.
7. Attach the gasket to the cover and press it lightly.
Arrange the position so that the bolt holes of the cover and the gasket
matches.
8. Thoroughly remove excess DB bond DB1600 on the surfaces between
the cover and the gasket, and the bolt holes.
9. Leave it as is for one hour until DB bond DB1600 dries.
10. Check that the gasket is adhered to the cover, tighten the hexagon
socket head cap screws with the specified tightening torque, and then
mount the cover on the manipulator.
9-1 HW1484372 80/100

HW1484372
Fig. 9-1: Gasket in Base Part

Rotating head
Gasket HW1406834-1
(Adhered to the cover) Cover
Rotating head
Cover
Base Cover Gasket HW1406834-1 Base

Gasket HW1406834-1 (Adhered to the cover)
(Adhered to the cover) Manipulator cable
Hexagon socket head cap screw M6 Hexagon socket head cap screw M6
*trivalent chromate* (length: 25 mm) (14 screws) *trivalent chromate* (length: 25 mm) (14 screws)
Conical spring washer 2H-6 Conical spring washer 2H-6
*trivalent chromate* (14 washers) *trivalent chromate* (14 washers)
Tightening torque: 10 N•m (1.0 kgf•m) Tightening torque: 10 N•m (1.0 kgf•m)
9-2 HW1484372 81/100

HW1484372
Fig. 9-2: Gasket in Rotating Head, Lower-Arm, Casing Part
Gasket HW1406940-1
(Adhered to the cover)
Cover

*trivalent chromate* (length: 25 mm)
(16 screws)
Casing *trivalent chromate* (16 washers)
Gasket HW1406844-1 Tightening torque: 10 N•m (1.0 kgf•m)
(Adhered to the cover)
Cover
Hexagon socket button
head screw M8 Gasket HW1407885-1 (Adhered to the cover)
Hexagon socket button head screw M8
Cover (length: 25 mm) (8 screws)
Lower arm
Cover *trivalent chromate* (8 washers)
Gasket HW1406841-1 Hexagon socket head cap screw M6
(Adhered to the cover) *trivalent chromate* (length: 25 mm)
Cover (19 screws)
Gasket HW1406836-1
Hexagon socket button (Adhered to the cover)
head screw M8 Rotating head
*trivalent chromate* (13 washers) Base
9-3 HW1484372 82/100

HW1484372
10 Parts List
10.1 S- and L-Axes Unit
10 Parts List

Fig. 10-1(a): S- and L-Axes Unit
1006
1028
1008
1029 1007 1009
1030 1026
1027
1010
1011
1012
1001
1005
1004 1019
1020
1023
1021
1024
1003
1025
1002 1022
1017
1018
1013 1016
1015
1014
10-1 HW1484372 83/100

HW1484372
10 Parts List
Fig. 10-1(b): S- and L-Axes Unit
1133
1126
1127
1111 1128
1125 1129
1123
1133 1124 1131
1122 1132
1117
1118 1133 1130
1112 1120
1121
1113 1119
1116
1115 1114
1135
1133
1136
1137
1110 1134 1075
1076
1055 1052 1077

1056
1057 1073
1053 1070 1074
1054
1072
1051 1071
1048 1070
1047 1079
1101 1078 1069
1049 1067
1050 1061
1062 1068 1080
1040
1064 1081
1102 1061
1041 1066 1065 1082
1062
1042 1059 1083
1063
1043 1059 1084
1042 1061 1085

1060
1044 1062
1098
1103 1046
1099
1104
1045 1105 1100
1097
1108
1109
1107
1106
1087
1090 1105
1089 1084
1085
1082 1083
1086
1081
1094 1080
1096 1078 1090
1079 1089
1095
1069 1088
1093 1090
1092 1045 1086
1089 1046
1091 1105 1090
1089
1070 1038
1071 1098 1097 1039
1070 1099 1106
1072 1044
1074 1042 1107
1073 1036 1109
1043
1108
1042
1053 1058
1075 1052
1077 1041
1076 1054
1057
1056 1040
1050 1037
1055
1047 1049
1048
1031
1001
1032
1034
1035
1033
10-2 HW1484372 84/100

HW1484372
10 Parts List
Table 10-1: S- and L-Axes (Sheet 1 of 4)

No. DWG No. Name Pcs.
1001 HW1100840-1 Base 1
1002 HW1406833-1 Cover 1
1003 HW1406834-1 Gasket 1
1004 M6×25 Socket screw 14
*TRIVALENT CHROMATE*
1005 2H-6 Conical spring washer 14
1006 HW1306460-A Cover 1
1007 HW1406834-1 Gasket 1
1010 HW1407879-1 Plate 1
1012 2L-3 Conical spring washer 4
1013 HW1305610-1 Bracket 1
1016 HW1406831-1 Bracket 1
1021 M5 Washer 2
1022 CD-42 Saddle 1
1025 M6 Washer 2
1026 HW1406838-1 Mechanical stopper 1
1027 HW1406835-1 Washer 1
1028 M20×45 Conical spring washer 1
1029 2H-20 Washer 1
1030 HW1407831-1 Bracket 1
1031 HW1305941-1 Shaft 1
1032 G80 O ring 1
1033 HW1407832-1 Plate 1
1036 HW1384511-A Speed reducer 1
1037 Gs335 O ring 1
1040 HW1305614-1 Shaft 2
10-3 HW1484372 85/100

HW1484372
10 Parts List

1041 G120 O ring 2
1042 BE4698-E00X4 Oil seal 4
1043 HW1406939-1 Collar 2
1044 HW1406832-1 Plate 2
1047 6817ZZ Bearing 2
1048 RTW-110 Retaining ring 2
1051 HW1305615-2 Support 1
1054 HW1406837-1 Plate 2
1057 M4 Washer 4
1058 HW1305615-1 Support 1
1059 HW1406941-2 Plate 2
1060 HW1406942-2 Plate 1
1063 HW1407683-2 Plate 1
1066 HW0411968-8 Washer 3
1069 HW1305562-1 M base 2
1070 HW9481329-A Oil seal 4
1071 HW0415325-2 Collar 2
1072 HW0404196-1 Washer 8
1075 SGMRV-37ANA-YRA* Motor 2
1080 S100 O ring 2
1081 STW-60 Retaining ring 2
1083 HW1305613-1 Gear 2
10-4 HW1484372 86/100

HW1484372
10 Parts List

1086 HW1406941-2 Plate 2
1087 HW1406942-2 Plate 1
1088 HW0411968-8 Washer 2
1091 HW0411968-8 Washer 1
1094 HW0411968-8 Washer 1
1097 HW1407881-1 Plate 2
1100 HW1100841-1 S head 1
1101 HW1200466-1 Cover 1
1102 HW1406836-1 Gasket 1
1105 PT3/8 Plug 3
1106 HW1406835-1 Washer 4
1111 HW1100842-1 L arm 1
1112 HW1305997-1 Shaft 1
1113 S85 O ring 1
1114 HW1305942-1 Shaft 1
1119 HW0411968-6 Washer 14
1122 HW1406839-1 Support 1
1125 CD-39 Saddle 1
10-5 HW1484372 87/100

HW1484372
10 Parts List

1128 M6 Washer 2
1129 HW1407877-1 Cover 1
1130 HW1406841-1 Gasket 1
1131 M8×25 Hexagon socket button 13
head screw
1133 PT3/8 Plug 4
1137 M20 Washer 1
10-6 HW1484372 88/100

HW1484372
10 Parts List
10.2 U-Axis Unit
10.2 U-Axis Unit

Fig. 10-2: U-Axis Unit
2030
2031
2078 2075 2076
2028
2077
2029
2079 2036
2037
2079 2079
2059
2060 2032
2058 2033
2057 2072 2034
2074 2035
2055 2073
2054 2041 2089
2061 2040
2062 2056 2039 2022
2061 2038 2023
2063
2065 2068
2071 2069 2084 2021 2020
2064
2070
2049 2046 2043 2084
2067 2048 2008
2066 2044 2042 2082 2009
2045 2085 2083 2080
2044 2081 2007
2045 2086
2047 2088 2006
2050
2053 2087 2011 2005
2012
2052
2051 2010 2008
2009
2024 2007
2018
2025
2027 2019 2017
2026 2016
2014
2015
2013
2002
2001
1110
2004
2003
10-7 HW1484372 89/100

HW1484372
10 Parts List
10.2 U-Axis Unit
Table 10-2: U-Axis Unit (Sheet 1 of 2)

2001 HW1407878-1 Cover 1
2002 HW1407885-1 Gasket 1
head screw
2005 HW1305944-1 Shaft 1
2006 S70 O ring 1
2007 HW1407245-1 Plate 2
2010 HW0411968-6 Washer 12
2013 HW1305618-1 Bracket 1
2016 CD-36 Saddle 1
2019 M6 Washer 2
2020 HW1407876-1 Cover 1
2021 HW1406844-1 Gasket 1
head screw
2024 PT3/8 Plug 1
2025 HW0411968-8 Washer 2
2029 AS568-173 O ring 1
2032 HW1305704-1 Gear 1
2033 HW1406846-1 B holder 1
2038 HW1305623-1 Shaft 1
2039 G90 O ring 1
2041 IRTW-78 Retaining ring 1
2044 AE3148-F13X9 Oil seal 2
2045 HW1406946-1 Collar 2
10-8 HW1484372 90/100

HW1484372
10 Parts List
10.2 U-Axis Unit
Table 10-2: U-Axis Unit (Sheet 2 of 2)

2047 HW1305625-1 Support 1
2050 HW1406847-1 Plate 1
2053 M4 Washer 2
2054 HW1305563-1 M base 1
2055 G90 O ring 1
2058 HW1305619-1 Gear 1
2061 Y426012.5 Oil seal 2
2062 HW0415325-1 Collar 1
2063 HW0409965-1 Cover 1
2066 HW0400470-2 Collar 1
2067 HW0388933-A Motor 1
2072 HW1407882-1 Plate 1
2075 HW1200467-1 Cover 1
2076 HW1406940-1 Gasket 1
2079 PT3/8 Plug 3
2080 KQ2E10-02 Joint 3
2081 PT1/4(STAINLESS) Plug 3
2082 KQ2E08-01 Joint 3
2084 HW1405948-6-15 Pin 2
2086 HW0411968-8 Washer 1
2089 HW1100843-1 Casing 1
10-9 HW1484372 91/100

HW1484372
10 Parts List
10.3 U-Arm Unit
10.3 U-Arm Unit

Fig. 10-3: U-Arm Unit
3018
3019 3019
3020 3020
3018 3019
3020
3018
3021 3021
3023 3023
3022 3022 3021
3011 3023
3024 3025 3011 3022 3011
3012 3012 3012
3025 3010
3010 3010 3025
3013
3013 3024 3024
3014 3014 3013
3013 3013 3014
3017 3013
3015
3016 3015
3017
3017 3016 3015
3005 3016
3006 3005
3006
3005
3004 3004 3006
3004
3007 3007
3009 3009
3008 3008 3007
3034 3009
3035 3008
3033 3034 3033
3035 3034
3032 3032 3035
3031 3033
3031
3029 3032
3029 3031
3030 3030
3027 3029
3027 3029 3029
3028
3028 3030
3026 3026
3029 3027
3028
3026
3036 3041
3036
3037 3042
3043 3037
3038 3038
3044 3039
3045
3039 3040
3046
3048
3047
3040
3049
3049
3003
3060 3002
3058 3061 3051
3059 3050 2089
3055
3056 3001
3057
3062
3052
3052
3054
3053 3054
3053
10-10 HW1484372 92/100

HW1484372
10 Parts List
10.3 U-Arm Unit
Table 10-3: U-Arm Unit (Sheet 1 of 2)

3001 HW1100844-1 U-arm 1
3007 HW1405350-1 Shaft 3
3010 HW1305620-2 M base 3
3013 Y234010.5 Oil seal 6
3014 HW0409966-4 Collar 3
3015 HW1406944-1 Plate 3
3018 HW0388651-A Motor 3
3021 HW1304354-1 Gear 3
3024 KFL10N-02S Joint 3
3025 KFL08N-01S Joint 3
3026 HW0415046-2 Collar 3
3030 HW0415044-1 Washer 3
3031 HW1405418-1 Collar 3
3033 HW0414771-1 B holder 3
3036 HW1305627-1 Shaft 2
3038 HW1405418-1 Collar 2
3040 HW1405419-1 Shaft 2
3041 HW1305626-1 Shaft 1
3044 HW1405348-1 Collar 1
10-11 HW1484372 93/100

HW1484372
10 Parts List
10.3 U-Arm Unit
Table 10-3: U-Arm Unit (Sheet 2 of 2)

3045 HW1405418-1 Collar 1
3047 HW1405295-1 Shaft 1
3049 SC47-7A Sealing cap 1
3050 HW1405374-1 Cover 1
3051 M4×10(STAINLESS) Hexagon socket button 4
head screw
3052 HW1405420-1 Collar 2
3055 HW1305606-1 Shaft 1
3056 HW1383653-H O ring 1
3057 XK70 X ring 1
3062 HW1405948-6-15 Pin 1
10-12 HW1484372 94/100

HW1484372
10 Parts List
10.4 Wrist Unit
10.4 Wrist Unit

Fig. 10-4: Wrist Unit
4032 4033
4029 4077
4027
4028 4076
4030
4031
4075
4026 4024
4025 4023
4074 4073
4022 4072 4145
4071 4144 4145
4021 4142
4140 4143 4145
4020 4137 4116 4144 4145
4070 4119 4133 4142
4147 4141 4143
4019 4125
4146 4138
4126 4148 4128
4069 4144 4118 4148
4018 4146 4145 4142 4146 4129
4066 4068
4124 4146 4145 4143 4117
4134 4147
4017 4067 4139 4141 4146
4122
4065 4120 4136 4146
4016
4015 4064 4119 4135 4131 4127
4014 4116 4139 4132 4121 4123
4013 4062 4115
4114 4130 4118
4113 4149 4117
4012 4146 4115
4114
4114
4011
4063 4113 4146
4010 4110 4112
4009 4111
4008 4007 4105
4061 4060
4006 4058 4106
4059 4108
4005 4057 4109
4004 4107
4056
4003
4002 4055
4104
4102 4103
4001
4054
4101
4053
4099
4098 4100
4052
4097
4051
4096 4094
4095
4050 4093
4049 4092
4048
4047 4091
4045 4089
4048 4090
4046 4042 4088
4044
4043
4039 4087
4041
4040
4038 4086 4084
4037 4085
4083
4036
4082
4035 4080
4081
4034 4079
4078
10-13 HW1484372 95/100

HW1484372
10 Parts List
10.4 Wrist Unit
Table 10-4: Wrist Unit (Sheet 1 of 4)

4001 M4×8 Flat head screw 4
4002 HW0401761-1 Cover 1
4005 HW0302270-3 Flange 1
4006 GJ3618KO Oil seal 1
4007 HW1405947-4-10 Pin 1
4010 HW0302272-3 Shaft 1
4011 AS568:251 O ring 1
4012 HW1383653-P O ring 1
4013 HW1383654-B X ring 1
4016 HW0302274-1 B holder 1
4017 S120 O ring 1
4018 HW0400570-* Shim *
4019 RA1008UUCC0S Cross roller bearing 1
4020 HW0301437-2 Housing 1
4021 HW0400573-* Shim *
4022 HW0302293-2 Gear 1
4025 HW0302271-1 Shaft 1
4026 HW1405947-4-10 Pin 1
4029 C8 Cap 8
4032 PT1/2 Plug 1
4033 HW0100292-2 Case 1
4034 AS568:261 O ring 1
4035 HW1383653-AA O ring 1
4036 HW1383654-E X ring 1
4037 HW1383653-K O ring 1
4038 XK75 X ring 1
4039 HW0302273-2 Gear 1
4042 HW0300487-1 B cover 1
10-14 HW1484372 96/100

HW1484372
10 Parts List
10.4 Wrist Unit

4045 HW0400570-* Shim *
4049 HW0300486-1 B cover 1
4050 RB13015UUCC00S Cross roller bearing 1
4051 HW0300493-1 Housing 1
4052 HW0300491-1 Housing 1
4053 RA1008UUCC0S Cross roller bearing 1
4054 HW0400571-* Shim *
4055 HW0300435-1 Gear 1
4056 HW0302280-3 Gear 1
4057 HW0302275-2 Shaft 1
4060 XK75 X ring 1
4061 HW1383653-K O ring 1
4062 HW1100081-1 Case 1
4063 PT1/2 Plug 1
4064 HW1383653-K O ring 1
4065 XK75 X ring 1
4066 HW0314877-2 Gear 1
4069 HW0414751-* Shim *
4070 HW0314871-2 Shaft 1
4071 6817VV Bearing 1
4074 HW0314876-1 Gear 1
4075 HW0414752-* Shim *
4076 HW0314870-2 Shaft 1
4078 HW1405947-6-15 Pin 1
4079 HW0313769-1 Shaft 1
4082 RU155-3203372 Cross roller bearing 1
4083 HW1405941-1 B holder 1
4086 HW1383653-AD O ring 1
4087 HW1383654-F X ring 1
4088 HW1304311-1 Gear 1
10-15 HW1484372 97/100

HW1484372
10 Parts List
10.4 Wrist Unit

4092 HW0414754-* Shim *
4093 HW1304312-1 Gear 1
4097 HW0414755-* Shim *
4098 HW1304313-1 Gear 1
4101 AS568:264 O ring 1
4102 HW1200375-3 Gear case 1
4107 HW0414759-1 Cover 1
4110 HW1304263-1 Gear 1
4111 HW1304264-1 Gear 1
4112 HW1304265-1 Gear 1
4113 P21 O ring 2
4114 HW1405347-* Shim *
4115 AR42 Circlip 2
4116 GD37×47×4 Oil seal 2
4117 GD32×42×4 Oil seal 2
4120 HW1405376-1 Collar 1
4121 HW1405376-2 Collar 1
4122 NA5906 Bearing 1
4123 NA4905R Bearing 1
4124 HW1306487-1 Holder 1
4127 HW1306486-1 Holder 1
4130 HW1305351-1 Holder 1
10-16 HW1484372 98/100

HW1484372
10 Parts List
10.4 Wrist Unit

4133 HW1405415-1 Collar 1
4134 HW1405416-1 Collar 1
4135 HW1405294-1 Collar 1
4136 HW1405294-2 Collar 1
4140 HW1405375-1 B holder 1
4141 HW1405349-1 B holder 2
4144 HW1405346-1 B nut 3
4145 M5×8 H set screw 6
4146 PT1/8 Plug 8
4147 LF-C Joint 2
4148 C-PT1/8 Grease nipple 2
4149 4 dia. length: 25 mm Pin 2
*Note: The thickness and the number of the shim depend on the
adjustment of the backlash.
10-17 HW1484372 99/100

MOTOMAN-MPX2600
MAINTENANCE MANUAL
For inquiries or after-sales service on this product, contact

your local YASKAWA representative as shown below.
YASKAWA ELECTRIC CORPORATION

2-1 Kurosakishiroishi, Yahatanishi-ku, Kitakyushu, 806-0004, Japan
Phone: +81-93-645-7703 Fax: +81-93-645-7802
http://www.yaskawa.co.jp
YASKAWA AMERICA, INC. (MOTOMAN ROBOTICS DIVISION)
100 Automation Way, Miamisburg, OH 45342, U.S.A.
Phone: +1-937-847-6200 Fax: +1-937-847-6277
http://www.motoman.com
YASKAWA EUROPE GmbH (ROBOTICS DIVISION)
Yaskawastrasse 1, 85391, Allershausen, Germany
Phone: +49-8166-90-100 Fax: +49-8166-90-103
http://www.yaskawa.eu.com
YASKAWA NORDIC AB
Verkstadsgatan 2, Box 504, SE-385 25 Torsas, Sweden
Phone: +46-480-417-800 Fax: +46-486-414-10
http://www.yaskawa.se
YASKAWA ELECTRIC (CHINA) CO., LTD.
22F, One Corporate Avenue, No.222 Hubin Road, Huangpu District, Shanghai 200021, China
Phone: +86-21-5385-2200 Fax: +86-21-5385-3299
http://www.yaskawa.com.cn
YASKAWA SHOUGANG ROBOT CO., LTD.
No.7 Yongchang North Road, Beijing E&T Development Area, Beijing 100076, China
Phone: +86-10-6788-2858 Fax: +86-10-6788-2878
http://www.ysr-motoman.cn
YASKAWA ELECTRIC KOREA CORPORATION
35F, Three IFC, 10 Gukjegeumyung-ro, Yeongdeungpo-gu, Seoul, 07326, Korea
Phone: +82-2-784-7844 Fax: +82-2-784-8495
http://www.yaskawa.co.kr
YASKAWA ELECTRIC TAIWAN CORPORATION
12F, No.207, Sec. 3, Beishin Rd., Shindian District, New Taipei City 23143, Taiwan
Phone: +886-2-8913-1333 Fax: +886-2-8913-1513
http://www.yaskawa.com.tw
YASKAWA ASIA PACIFIC PTE. LTD.
30A Kallang Place, #06-01, 339213, Singapore
Phone: +65-6282-3003 Fax: +65-6289-3003
http://www.yaskawa.com.sg
YASKAWA ELECTRIC (THAILAND) CO., LTD.
59, 1st-5th Floor, Flourish Building, Soi Ratchadapisek 18, Ratchadapisek Road, Huaykwang,
Bangkok 10310, Thailand
Phone: +66-2-017-0099 Fax: +66-2-017-0199
http://www.yaskawa.co.th
PT. YASKAWA ELECTRIC INDONESIA
Secure Building-Gedung B Lantai Dasar & Lantai 1 Jl. Raya Protokol Halim Perdanakusuma,
Jakarta 13610, Indonesia
Phone: +62-21-2982-6470 Fax: +62-21-2982-6471
http://www.yaskawa.co.id
YASKAWA INDIA PRIVATE LIMITED (ROBOTICS DIVISION)
#426, Udyog Vihar Phase-IV, Gurgaon, Haryana 122016, India
Phone: +91-124-475-8500 Fax: +91-124-475-8542
http://www.yaskawaindia.in
C 2017 YASKAWA ELECTRIC CORPORATION

Published by YASKAWA
September 2019 17-06
MANUAL NO.
HW1484372 2
100/100

Motoman - Yaskawa - MPX2600 Robot - Maintenance Manuakl

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Motoman - Yaskawa - MPX2600 Robot - Maintenance Manuakl

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MOTOMAN-MPX2600

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

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

2.1 Inspection of Gasket .......................................................................................................... 2-1

2.2 Battery Pack Replacement ................................................................................................ 2-4

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

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

4.1 Grease Replacement Procedures for Wrist Gears ............................................................ 4-1

5 Disassembly and Reassembly of the Motor.................................................................................... 5-1

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

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

5.3 Disassembly and Reassembly of the U-axis Motor ........................................................... 5-9

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.................................................. 6-6

6.3 Disassembly and Reassembly of U-Axis Speed Reducer ............................................... 6-13

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

8 Battery Replacement....................................................................................................................... 8-1

8.1 Battery Replacement ......................................................................................................... 8-1

8.1.1 YR-MPX2600 (Except for “-B**”) .......................................................................... 8-1

8.1.2 YR-MPX2600-B** ................................................................................................. 8-4

9 Gasket Replacement ...................................................................................................................... 9-1

10 Parts List ..................................................................................................................................... 10-1

10.1 S- and L-Axes Unit......................................................................................................... 10-1

10.2 U-Axis Unit..................................................................................................................... 10-7

10.3 U-Arm Unit ................................................................................................................... 10-10

10.4 Wrist Unit ..................................................................................................................... 10-13

iii HW1484372 3/100

1-1 HW1484372 4/100

Notes for Safe Operation

Indicates an imminent hazardous

Indicates a potentially hazardous

Indicates a potentially hazardous

Always be sure to follow explicitly the

Must never be performed.

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

To ensure safe and efficient operation at all times, be sure

1-2 HW1484372 5/100

1-3 HW1484372 6/100

• Observe the following precautions when performing teaching

1-4 HW1484372 7/100

1-5 HW1484372 8/100

Definition of Terms Used Often in This Manual

1-6 HW1484372 9/100

Explanation of Warning Labels

Pressure switch unit A

Battery warning label Nameplate

Pressure switch unit warning label

1-7 HW1484372 10/100

Fig. 1-2: List of Warning Labels

Type YR-MPX2600-A00 YR-MPX2600-B00 YR-MPX2600-C00

Label out frequent inspection and exchanging periodically.

seulment si la place est connue

NJ4032 NJ4032 NJ4032

NJ4036 NJ4036 NJ4036

1-8 HW1484372 11/100

2 Notes for Maintenance

2 Notes for Maintenance

• When an encoder connector for a motor needs to be dis-

• Never insert a flat tip screwdriver, an edged tool, etc. into