YASKAWA Motoman GP50 Maintenance Manual
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YASKAWA Motoman GP50 Maintenance Manual

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MOTOMAN-GP50,GP35L
MAINTENANCE MANUAL
TYPE:
YR-1-06VX50-A00
(MOTOMAN-GP50 STANDARD SPECIFICATION)
YR-1-06VXL35-A00
(MOTOMAN-GP35L STANDARD SPECIFICATION)
Procedures described in this maintenance manual should be carried out by the person who took
the maintenance-relevant trainings offered by YASKAWA.
Upon receipt of the product and prior to initial operation, read these instructions thoroughly, and
retain for future reference.
MOTOMAN INSTRUCTIONS
MOTOMAN-GP50,GP35L INSTRUCTIONS
YRC1000 INSTRUCTIONS
YRC1000 OPERATOR'S MANUAL (GENERAL) (SUBJECT SPECIFIC)
YRC1000 MAINTENANCE MANUAL
YRC1000 ALARM CODES (MAJOR ALARMS) (MINOR ALARMS)
The YRC1000 operator's manual above corresponds to specific usage. Be sure to use the appropriate manual.
The YRC1000 operator's manual above consists of "GENERAL" and "SUBJECT SPECIFIC".
The YRC1000 alarm codes above consists of "MAJOR ALARMS" and "MINOR ALARMS".
182738-1CD
0
MANUAL NO.
HW1484673
1/109

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Summary of Contents for YASKAWA Motoman GP50

  • Page 1 (MOTOMAN-GP35L STANDARD SPECIFICATION) Procedures described in this maintenance manual should be carried out by the person who took the maintenance-relevant trainings offered by YASKAWA. Upon receipt of the product and prior to initial operation, read these instructions thoroughly, and retain for future reference.

  • Page 2: Table Of Contents

    HW1484673 Contents 1 Introduction ............................. 1-1 2 Notes for Maintenance ........................2-1 2.1 Details of Internal Connections ..................2-1 2.2 Multi-Port Connector ......................2-3 3 Home Position Return ........................3-1 3.1 Home Position Posture of Manipulator ................3-1 3.2 Types of Methods for Home Position Return ..............3-2 3.2.1 Using a Teaching Point for Setting the Home Position.........
  • Page 3 HW1484673 Contents 5.3 Disassembly and Reassembly of the U-Axis Motor............5-12 5.4 Disassembly and Reassembly of the R-Axis Motor............5-15 5.5 Disassembly and Reassembly of the B-Axis Motor ............5-18 5.6 Disassembly and Reassembly of the T-Axis Motor ............5-21 6 Disassembly and Reassembly of the Speed Reducer..............

  • Page 4: Introduction

    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.
  • Page 5 HW1484673 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”, or “NOTICE”. Indicates an imminently hazardous DANGER situation which, if not avoided, will result in death or serious injury.
  • Page 6 WARNING • 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. HW1484673 6/109...
  • Page 7 HW1484673 Introduction DANGER • Before operating the manipulator, make sure the servo power is turned OFF by performing the following operations. When the servo power is turned OFF, the SERVO ON LED on the programming pendant is turned OFF. – Press the emergency stop buttons on the front door of the YRC1000, on the programming pendant, on the external control device, etc.
  • Page 8 Failure to observe this instruction may result in the loss of home position data. Definition of Terms Used Often in This Manual The MOTOMAN is the YASKAWA industrial robot product. The MOTOMAN usually consists of the manipulator, the YRC1000, the programming pendant, and supply cables.
  • Page 9 Also, an identification label with important information is placed on the body of the manipulator. Prior to operating the manipulator, confirm the contents. Note: Taking the maintenance-relevant trainings offered by YASKAWA is indispensable for replacing the L-axis of the balancer-equipped manipulator.
  • Page 10 HW1484673 Introduction Fall down hazard label Description Make sure to secure the manipulator base by using the bolts of the specified sizes and by tightening the bolts with the specified tightening torques. If the power is turned ON and the manipulator is operated without securing the manipulator properly, the manipulator may fall down, which may result in personal injury and/or equipment damage.
  • Page 11 HW1484673 Introduction Crush hazard label Description Keep clear of moving parts when performing a teaching operation within the manipulator's operating range. Failure to observe this instruction may result in personal injury. HW1484673 11/109...

  • Page 12: Notes For Maintenance

    HW1484673 Notes for Maintenance Details of Internal Connections Notes for Maintenance Details of Internal Connections For the encoder and the power supply of the motor of each axis, lead wires are connected to each part of the manipulator. When replacing a motor or lead wire, prepare the necessary parts and perform maintenance operations by referring to fig.
  • Page 13 HW1484673 Notes for Maintenance Details of Internal Connections Table 2-1: Details of Internal Connections Item Qty. Note S-axis motor Encoder cable: Not provided with the motor Power cable: Not provided with the motor L-axis motor Encoder cable: Not provided with the motor Power cable: Not provided with the motor U-axis motor Encoder cable: Not provided with the motor...

  • Page 14: Multi-Port Connector

    HW1484673 Notes for Maintenance Multi-Port Connector Multi-Port Connector Three multi-port connectors (refer to fig. 2-2 “Multi-Port Connector” ) for the encoders of the motors are provided on the manipulator. (For the locations, refer to fig. 2-4 “Locations of Battery Pack and Multi-Port Connector”...
  • Page 15 HW1484673 Notes for Maintenance Multi-Port Connector Fig. 2-4: Locations of Battery Pack and Multi-Port Connector Battery pack for B-, T-axes Battery pack for U-, R-axes Cable tie Protective tube Cover for U-, R-, B-, T-axes Cable tie Multi-port When the Cover for U-, R-, B-, T-axes is Removed Fixing bolt for the cover Cross head APS bolt M4 (length: 8 mm) (3 bolts)

  • Page 16: Home Position Return

    HW1484673 Home Position Return Home Position Posture of Manipulator Home Position Return Reset the home position of the manipulator if the home position is cleared or deviated. The YRC1000 stores the position data of the job program (hereinafter called JOB) as the pulse number from the home position of each axis.

  • Page 17: Types Of Methods For Home Position Return

    HW1484673 Home Position Return Types of Methods for Home Position Return Types of Methods for Home Position Return This section explains the types of methods for home position return in detail. 3.2.1 Using a Teaching Point for Setting the Home Position As a preparation, create the standard position for home position adjustment under normal operating conditions.

  • Page 18: Methods For Home Position Return

    HW1484673 Home Position Return Methods for Home Position Return Methods for Home Position Return 3.3.1 Using a Teaching Point for Setting the Home Position 3.3.1.1 Preparation Before the replacement of a motor or a speed reducer, the standard position (hereinafter called the check-point) must be created for home position adjustment.

  • Page 19: Home Position Adjustment

    HW1484673 Home Position Return Methods for Home Position Return 3.3.1.3 Home Position Adjustment After the replacement, move the axis whose motor or speed reducer was replaced to the position of the home position mark, and register the home position tentatively. For details, refer to chapter 8.1 “Home Position Calibration”...

  • Page 20: Using Keys

    HW1484673 Home Position Return Methods for Home Position Return 3.3.2 Using Keys The parts in table 3-2 “Parts List (YR-1-06VX50-A00)” and table 3-3 “Parts List (YR-1-06VXL35-A00)” are required. Prepare them beforehand. Table 3-2: Parts List (YR-1-06VX50-A00) Drawing No. Name Qty. Note HW0409786-2 Shaft...
  • Page 21 HW1484673 Home Position Return Methods for Home Position Return 1. S-Axis Positioning As shown in fig. 3-2 “S-Axis Positioning” , insert the shaft +0.018 (HW0409786-2) from the pin hole ( ) on the S-head and 12 dia. perform positioning by using the programming pendant so that the shaft fits into the slot of the base.
  • Page 22 HW1484673 Home Position Return Methods for Home Position Return 3. U-Axis Positioning As shown in fig. 3-4 “U-Axis Positioning” , insert the shaft +0.018 (HW0409786-2) from the pin hole ( ) on the casing and 12 dia. perform positioning by using the programming pendant so that the shaft fits into the slot of the L-arm.

  • Page 23: Using Encoder Backup Error Recovery Function

    Pin hole (6 dia. 3.3.3 Using Encoder Backup Error Recovery Function For details on the encoder backup error recovery function, refer to “YRC1000 INSTRUCTIONS (RE-CTO-A221)”. 3.3.4 Robot Calibration (MOTOCALV EG) Contact your YASKAWA representative for the procedure of robot calibration. HW1484673 23/109...

  • Page 24: Notes On Grease Replenishment/Exchange Procedures

    HW1484673 Notes on Grease Replenishment/Exchange Procedures Grease Exchange Procedures for Speed Reducers and Gears Notes on Grease Replenishment/Exchange Procedures Grease Exchange Procedures for Speed Reducers and Gears 4.1.1 Notes on Grease Exchange Procedures Make sure to follow the instructions listed below at grease replenishment/ exchange.

  • Page 25: Grease Exchange Procedure

    HW1484673 Notes on Grease Replenishment/Exchange Procedures Grease Exchange Procedures for Speed Reducers and Gears 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. 4.1.2 Grease Exchange Procedure Fig.
  • Page 26 HW1484673 Notes on Grease Replenishment/Exchange Procedures Grease Exchange Procedures for Speed Reducers and Gears 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.
  • Page 27 HW1484673 Notes on Grease Replenishment/Exchange Procedures Grease Exchange Procedures for Speed Reducers and Gears Table 4-2: Amount of Grease Axis to exchange grease Amount of grease S-axis Approx. 2750 g L-axis Approx. 1410 g U-axis Approx. 640 g R-axis (YR-1-06VX50-A00) Approx.
  • Page 28 HW1484673 Notes on Grease Replenishment/Exchange Procedures Grease Exchange Procedures for Speed Reducers and Gears 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 4-3...
  • Page 29 HW1484673 Notes on Grease Replenishment/Exchange Procedures Grease Exchange Procedures for Speed Reducers and Gears Table 4-6: Plug Type and Tightening Torque for Each Axis Axis to exchange grease Plug for the grease inlet Plug for the grease exhaust port Plug type Tightening torque Plug type Tightening torque...

  • Page 30: Removing, Applying, Assembling Of Sealing Bond

    HW1484673 Notes on Grease Replenishment/Exchange Procedures Removing, Applying, Assembling of Sealing Bond Removing, Applying, Assembling of Sealing Bond 4.2.1 Removing Sealing Bond from Sealing Surface and Cleaning 1. Remove the sealing bond of the sealing surface of the manipulator on which the speed reducer or the motor was mounted by using a spatula etc.

  • Page 31: Applying Sealing Bond To Sealing Surface

    HW1484673 Notes on Grease Replenishment/Exchange Procedures Removing, Applying, Assembling of Sealing Bond 4.2.2 Applying Sealing Bond to Sealing Surface 1. Check that the degreasing and cleaning agent of the sealing surface is dried. (Refer to fig. 4-4 “Checking the Dryness” .) If not dried, wipe the agent with a new cloth.

  • Page 32: Assembling After Applying Sealing Bond

    HW1484673 Notes on Grease Replenishment/Exchange Procedures Removing, Applying, Assembling of Sealing Bond 4.2.3 Assembling After Applying Sealing Bond 1. After applying sealing bond, pay attention to the following and immediately perform assembling. • Remove any dust, dirt, foreign objects, and oil on the sealing surface.

  • Page 33: Disassembly And Reassembly Of The Motor

    HW1484673 Disassembly and Reassembly of the Motor Disassembly and Reassembly of the Motor WARNING Because the motor is removed, the manipulator cannot keep its posture during the replacement of the motor or the speed reducer. When replacing the motor or speed reducer, hold the manipulator arm by using a hanging tool (e.g., chain block).

  • Page 34: Disassembly And Reassembly Of The S-Axis Motor

    HW1484673 Disassembly and Reassembly of the Motor Disassembly and Reassembly of the S-Axis Motor Disassembly and Reassembly of the S-Axis Motor • Refer to fig. 5-2(a) “Disassembly and Reassembly of the S-Axis Motor” .  Disassembly 1. Turn OFF the power supply of the YRC1000. 2.
  • Page 35 HW1484673 Disassembly and Reassembly of the Motor Disassembly and Reassembly of the S-Axis Motor Table 5-1: S-Axis Motor Parts Checklist Item Qty. Note S-axis motor HW1385396-A SGM7G-30APK-YR1* Hexagon socket head cap screw Tightening torque 84 N•m M12 (length: 55 mm) *trivalent each chromate* Conical spring washer 2H-12...
  • Page 36 HW1484673 Disassembly and Reassembly of the Motor Disassembly and Reassembly of the S-Axis Motor Fig. 5-2(a): Disassembly and Reassembly of the S-Axis Motor Tapped hole for motor and spacer (2 places) (diagonal) Tapped hole for eyebolt (2 places) (diagonal) Apply sealing bond here. Apply sealing bond here.
  • Page 37 HW1484673 Disassembly and Reassembly of the Motor Disassembly and Reassembly of the S-Axis Motor Fig. 5-2(d): Removing the Key and Gear Put the flat head screw driver into the hole of the side of the gear and tilt it in the direction of the arrow mark to make a space between the shaft and the motor.

  • Page 38: Disassembly And Reassembly Of The L-Axis Motor

    HW1484673 Disassembly and Reassembly of the Motor Disassembly and Reassembly of the L-Axis Motor Disassembly and Reassembly of the L-Axis Motor 5.2.1 YR-1-06VX50-A00 • Refer to fig. 5-3(a) “Disassembly and Reassembly of the L-Axis Motor (YR-1-06VX50-A00)” .  Disassembly 1. Turn OFF the power supply of the YRC1000. 2.
  • Page 39 HW1484673 Disassembly and Reassembly of the Motor Disassembly and Reassembly of the L-Axis Motor Table 5-2: L-Axis Motor Parts Checklist Item Qty. Note L-axis motor HW1385397-A SGM7G-37APK-YR1* Hexagon socket head cap screw Tightening torque 84 N•m M12 (length: 65 mm) *trivalent each chromate* Conical spring washer 2H-12...
  • Page 40 HW1484673 Disassembly and Reassembly of the Motor Disassembly and Reassembly of the L-Axis Motor Fig. 5-3(b): Surface to Apply Sealing Bond on the L-Axis Motor Apply sealing bond evenly to whole surface. Surface to apply sealing bond 2 Apply sealing bond evenly to whole surface.

  • Page 41: Yr-1-06Vxl35-A00

    HW1484673 Disassembly and Reassembly of the Motor Disassembly and Reassembly of the L-Axis Motor 5.2.2 YR-1-06VXL35-A00 • Refer to fig. 5-4(a) “Disassembly and Reassembly of the L-Axis Motor (YR-1-06VXL35-A00)” . Disassembly  1. Turn OFF the power supply of the YRC1000. 2.
  • Page 42 HW1484673 Disassembly and Reassembly of the Motor Disassembly and Reassembly of the L-Axis Motor Table 5-3: L-Axis Motor Parts Checklist Item Qty. Note L-axis motor HW1385397-A SGM7G-37APK-YR1* Hexagon socket head cap screw Tightening torque 84 N•m M12 (length: 65 mm) *trivalent each chromate* Conical spring washer 2H-12...
  • Page 43 HW1484673 Disassembly and Reassembly of the Motor Disassembly and Reassembly of the L-Axis Motor Fig. 5-4(b): Surface to Apply Sealing Bond on the L-Axis Motor Apply sealing bond evenly to whole surface. Surface to apply sealing bond 2 Apply sealing bond evenly to whole surface.

  • Page 44: Disassembly And Reassembly Of The U-Axis Motor

    HW1484673 Disassembly and Reassembly of the Motor Disassembly and Reassembly of the U-Axis Motor Disassembly and Reassembly of the U-Axis Motor • Refer to fig. 5-5(a) “Disassembly and Reassembly of the U-Axis Motor” .  Disassembly 1. Turn OFF the power supply of the YRC1000. 2.
  • Page 45 HW1484673 Disassembly and Reassembly of the Motor Disassembly and Reassembly of the U-Axis Motor Table 5-4: U-Axis Motor Parts Checklist Item Qty. Note U-axis motor HW1385395-A SGM7G-13APK-YR1* Hexagon socket head cap screw M8 Tightening torque 24.5 N•m (length: 55 mm) *trivalent chromate* each Conical spring washer 2H-8 *trivalent chromate*...
  • Page 46 HW1484673 Disassembly and Reassembly of the Motor Disassembly and Reassembly of the U-Axis Motor Fig. 5-5(b): Surface to Apply Sealing Bond on the U-Axis Motor Apply sealing bond evenly to whole surface. Surface to apply sealing bond 2 Surface to apply sealing bond 1 Fig.

  • Page 47: Disassembly And Reassembly Of The R-Axis Motor

    HW1484673 Disassembly and Reassembly of the Motor Disassembly and Reassembly of the R-Axis Motor Disassembly and Reassembly of the R-Axis Motor • Refer to fig. 5-6(a) “Disassembly and Reassembly of the R-Axis Motor” . • For the layout of the R-, B-, and T-axis motors, refer to fig. 5-9 “Lay- out of the U-, R-, B-, and T-Axis Motors”...
  • Page 48 HW1484673 Disassembly and Reassembly of the Motor Disassembly and Reassembly of the R-Axis Motor 7. As shown in fig. 5-6(d) “Motor Power Cable” , insert the power connector to the R-axis motor by aligning the key position, and then turn the coupling nut on the cable side until it makes a clicking sound. Confirm that the arrow marks on the connector on the motor side and the connector on the wiring harness side match.
  • Page 49 HW1484673 Disassembly and Reassembly of the Motor Disassembly and Reassembly of the R-Axis Motor Fig. 5-6(b): Surface to Apply Sealing Bond on the R-Axis Motor Apply sealing bond evenly to whole surface. Apply sealing bond here. Fig. 5-6(c): Removing the Key and Gear Put the flat head screw driver into the hole of the side of the gear and tilt it in the direction of the arrow mark to make a space between...

  • Page 50: Disassembly And Reassembly Of The B-Axis Motor

    HW1484673 Disassembly and Reassembly of the Motor Disassembly and Reassembly of the B-Axis Motor Disassembly and Reassembly of the B-Axis Motor • Refer to fig. 5-7(a) “Disassembly and Reassembly of the B-Axis Motor” . • For the layout of the R-, B-, and T-axis motors, refer to fig. 5-9 “Lay- out of the U-, R-, B-, and T-Axis Motors”...
  • Page 51 HW1484673 Disassembly and Reassembly of the Motor Disassembly and Reassembly of the B-Axis Motor 7. As shown in fig. 5-7(d) “Motor Power Cable” , insert the power connector to the B-axis motor by aligning the key position, and then turn the coupling nut on the cable side until it makes a clicking sound. Confirm that the arrow marks on the connector on the motor side and the connector on the wiring harness side match.
  • Page 52 HW1484673 Disassembly and Reassembly of the Motor Disassembly and Reassembly of the B-Axis Motor Fig. 5-7(b): Surface to Apply Sealing Bond on the B-Axis Motor Apply sealing bond evenly to whole surface. Apply sealing bond here. Fig. 5-7(c): Removing the Key and Gear Put the flat head screw driver into the hole of the side of the gear and tilt it in the direction of the arrow mark to make a space between...

  • Page 53: Disassembly And Reassembly Of The T-Axis Motor

    HW1484673 Disassembly and Reassembly of the Motor Disassembly and Reassembly of the T-Axis Motor Disassembly and Reassembly of the T-Axis Motor • Refer to fig. 5-8(a) “Disassembly and Reassembly of the T-Axis Motor” . • For the layout of the R-, B-, and T-axis motors, refer to fig. 5-9 “Lay- out of the U-, R-, B-, and T-Axis Motors”...
  • Page 54 HW1484673 Disassembly and Reassembly of the Motor Disassembly and Reassembly of the T-Axis Motor 7. As shown in fig. 5-8(c) “Motor Power Cable” , insert the power connector to the T-axis motor by aligning the key position, and then turn the coupling nut on the cable side until it makes a clicking sound. Confirm that the arrow marks on the connector on the motor side and the connector on the wiring harness side match.
  • Page 55 HW1484673 Disassembly and Reassembly of the Motor Disassembly and Reassembly of the T-Axis Motor Fig. 5-8(b): Surface to Apply Sealing Bond on the T-Axis Motor Apply sealing bond evenly to whole surface. Apply sealing bond here. Fig. 5-8(c): Motor Power Cable Main key Arrow mark Coupling nut...

  • Page 56: Disassembly And Reassembly Of The Speed Reducer

    HW1484673 Disassembly and Reassembly of the Speed Reducer Disassembly and Reassembly of the S-Axis Speed Reducer Disassembly and Reassembly of the Speed Reducer When replacing the S-, L-, and U-axis speed reducers, dis- NOTE connect the internal wiring harness. For the procedure, refer to chapter 8 “Cable Wiring”...
  • Page 57 HW1484673 Disassembly and Reassembly of the Speed Reducer Disassembly and Reassembly of the S-Axis Speed Reducer 6. Tighten the hexagon socket head cap screws with the tightening torque shown in table 6-1. If the S-axis mechanical stoppers , and were removed during disassembly, mount them and tighten them with the tightening torque shown in table 6-1.
  • Page 58 HW1484673 Disassembly and Reassembly of the Speed Reducer Disassembly and Reassembly of the S-Axis Speed Reducer Fig. 6-1(a): Disassembly and Reassembly of the S-Axis Speed Reducer View A Internal wire harness S-axis rotation center S-head Section B-O-B Base Fig. 6-1(b): Surface to Apply Sealing Bond on the S-Axis Speed Reducer Apply sealing bond evenly to whole surface.

  • Page 59: Disassembly And Reassembly Of The L-Axis Speed Reducer

    HW1484673 Disassembly and Reassembly of the Speed Reducer Disassembly and Reassembly of the L-Axis Speed Reducer Disassembly and Reassembly of the L-Axis Speed Reducer • Refer to fig. 6-2(a) “Disassembly and Reassembly of the L-Axis Speed Reducer” .  Disassembly 1.
  • Page 60 HW1484673 Disassembly and Reassembly of the Speed Reducer Disassembly and Reassembly of the L-Axis Speed Reducer 9. Replenish grease (Molywhite RE No.00) from the grease inlet. Mount the hexagon socket head plugs at grease inlets and the grease exhaust ports after the replenishment of grease. (Refer to chapter 4.1.2 “Grease Exchange Procedure”...
  • Page 61 HW1484673 Disassembly and Reassembly of the Speed Reducer Disassembly and Reassembly of the L-Axis Speed Reducer Fig. 6-2(a): Disassembly and Reassembly of the L-Axis Speed Reducer Fig. 6-2(b): Surface to Apply Sealing Bond on the L-Axis Speed Reducer L-axis speed reducer ThreeBond 1206C Border line for applying sealing...
  • Page 62 HW1484673 Disassembly and Reassembly of the Speed Reducer Disassembly and Reassembly of the L-Axis Speed Reducer Fig. 6-2(c): Surface to Apply Sealing Bond on the L-Arm on the Other Side of the L-Axis Speed Reducer Apply sealing bond in the bead shape. Bead Cross-section (Indicated in the figure, the bead height should...

  • Page 63: Disassembly And Reassembly Of The U-Axis Speed Reducer

    HW1484673 Disassembly and Reassembly of the Speed Reducer Disassembly and Reassembly of the U-Axis Speed Reducer Disassembly and Reassembly of the U-Axis Speed Reducer • Refer to fig. 6-3(a) “Disassembly and Reassembly of the U-Axis Speed Reducer” .  Disassembly 1.
  • Page 64 HW1484673 Disassembly and Reassembly of the Speed Reducer Disassembly and Reassembly of the U-Axis Speed Reducer 9. Replenish grease (Molywhite RE No.00) from the grease inlet. Mount the hexagon socket head plugs at grease inlets and the grease exhaust ports after the replenishment of grease. (Refer to chapter 4.1.2 “Grease Exchange Procedure”...
  • Page 65 HW1484673 Disassembly and Reassembly of the Speed Reducer Disassembly and Reassembly of the U-Axis Speed Reducer Fig. 6-3(a): Disassembly and Reassembly of the U-Axis Speed Reducer U-axis rotation center U-axis motor U-arm unit Apply sealing bond here. L-arm Fig. 6-3(b): Surface to Apply Sealing Bond on the U-Axis Speed Reducer Apply sealing bond evenly Apply sealing bond evenly to whole surface.
  • Page 66 HW1484673 Disassembly and Reassembly of the Speed Reducer Disassembly and Reassembly of the U-Axis Speed Reducer Fig. 6-3(c): Surface to Apply Sealing Bond on the L-Arm on the Other Side of the U-Axis Speed Reducer Apply sealing bond in the bead shape. Bead Cross-section (Indicated in the figure, the bead height should...

  • Page 67: Disassembly And Reassembly Of The R-Axis Speed Reducer

    HW1484673 Disassembly and Reassembly of the Speed Reducer Disassembly and Reassembly of the R-Axis Speed Reducer Disassembly and Reassembly of the R-Axis Speed Reducer • Refer to fig. 6-4(a) “Disassembly and Reassembly of the R-Axis Speed Reducer” .  Disassembly 1.
  • Page 68 HW1484673 Disassembly and Reassembly of the Speed Reducer Disassembly and Reassembly of the R-Axis Speed Reducer Table 6-4: R-Axis Speed Reducer Parts Checklist Item Qty. Note Speed reducer HW0387754-A Hexagon socket head cap screw M6 16　 Tightening torque 16.5 (length: 35 mm) each N•m Conical spring washer 2L-6...
  • Page 69 HW1484673 Disassembly and Reassembly of the Speed Reducer Disassembly and Reassembly of the R-Axis Speed Reducer Fig. 6-4(b): Surface to Apply Sealing Bond on the R-Axis Speed Reducer Apply sealing bond evenly to whole surface. Apply sealing bond evenly to whole surface. Flange Side Shaft Side HW1484673...

  • Page 70: Disassembly And Reassembly Of The B-Axis Speed Reducer

    HW1484673 Disassembly and Reassembly of the Speed Reducer Disassembly and Reassembly of the B-Axis Speed Reducer Disassembly and Reassembly of the B-Axis Speed Reducer • Refer to fig. 6-5(a) “Disassembly and Reassembly of the B-Axis Speed Reducer” .  Disassembly 1.
  • Page 71 HW1484673 Disassembly and Reassembly of the Speed Reducer Disassembly and Reassembly of the B-Axis Speed Reducer Table 6-5: B-Axis Speed Reducer Parts Checklist Item Qty. Note Speed reducer HW0387737-B Flange HW0314090-1 Hexagon socket head cap screw M8 Tightening torque 40 N•m (length: 18 mm) each Conical spring washer 2L-8...
  • Page 72 HW1484673 Disassembly and Reassembly of the Speed Reducer Disassembly and Reassembly of the B-Axis Speed Reducer Fig. 6-5(b): Adjustment of B-Axis Gear Part Shim Shim adjustment is required when replacing the B-axis speed reducer. Old speed reducer New speed reducer Procedure for shim selection 1.

  • Page 73: Disassembly And Reassembly Of The T-Axis Speed Reducer

    HW1484673 Disassembly and Reassembly of the Speed Reducer Disassembly and Reassembly of the T-Axis Speed Reducer Disassembly and Reassembly of the T-Axis Speed Reducer • Refer to fig. 6-6(a) “Disassembly and Reassembly of the T-Axis Speed Reducer” .  Disassembly 1.
  • Page 74 HW1484673 Disassembly and Reassembly of the Speed Reducer Disassembly and Reassembly of the T-Axis Speed Reducer If grease is filled before the sealing bond is solidified, it may NOTE cause grease to leak. After tightening the screws, leave it 30 minutes or more, and then fill with grease. 8.
  • Page 75 HW1484673 Disassembly and Reassembly of the Speed Reducer Disassembly and Reassembly of the T-Axis Speed Reducer Fig. 6-6(b): Adjustment of T-Axis Gear Part Shim Shim adjustment is required when replacing the T-axis speed reducer. Old speed reducer New speed reducer Procedure for shim selection 1.
  • Page 76 HW1484673 Disassembly and Reassembly of the Speed Reducer Disassembly and Reassembly of the T-Axis Speed Reducer Fig. 6-6(c): Surface to Apply Sealing Bond on the T-Axis Speed Reducer Apply sealing bond evenly Apply sealing bond here. Apply sealing bond evenly to whole surface.

  • Page 77: Disassembly And Reassembly Of The Wrist Unit

    HW1484673 Disassembly and Reassembly of the Wrist Unit Disassembly and Reassembly of the Wrist Unit • Refer to fig. 7-1 “Disassembly and Reassembly of the Wrist Unit” . Refer to chapter 2 “Notes for Maintenance” , chapter 3 NOTE “Home Position Return” , and chapter 4.2 “Removing, Applying, Assembling of Sealing Bond”...

  • Page 78: Cable Wiring

    HW1484673 Cable Wiring Disassembly and Reassembly of the Internal Wiring Harness Cable Wiring Disassembly and Reassembly of the Internal Wiring Harness Refer to chapter 2 “Notes for Maintenance” and chapter 3 NOTE “Home Position Return” .  Disassembly 1. Connector for the Internal User I/O Wiring Harness of the Casing 1.
  • Page 79 HW1484673 Cable Wiring Disassembly and Reassembly of the Internal Wiring Harness Fig. 8-1: Disassembly and Reassembly of the Internal Wiring Harness (Connector for the Internal User I/O Wiring Harness of the Casing) Internal user I/O wiring harness Air 1 (10 dia.) Air 2 (12 dia.) 2.
  • Page 80 HW1484673 Cable Wiring Disassembly and Reassembly of the Internal Wiring Harness Table 8-2: Internal Wiring Harness Parts Checklist (Casing) Item Qty. Note Internal wiring harness HW1173234- YR-1-06VX50-A00 Internal wiring harness HW1173234- YR-1-06VXL35-A00 Cross head APS bolt M4 (length: 8 mm) *trivalent chromate* Cover HW1200707-A Hexagon socket flat head screw M8 Tightening torque 24.5...
  • Page 81 HW1484673 Cable Wiring Disassembly and Reassembly of the Internal Wiring Harness 3. L-arm • Refer to table 8-3 “Internal Wiring Harness Parts Checklist (L-Arm)” and fig. 8-3 “Disassembly and Reassembly of the Internal Wiring Harness (L-Arm)” . 1. Cut off the cable ties 2.
  • Page 82 HW1484673 Cable Wiring Disassembly and Reassembly of the Internal Wiring Harness 7. Turn the connector on the cable side of the power connector for the S- and L-axis motor, and then disconnect the power cable. If the connector does not turn, remove the connector by holding the connector on the cable side with a pair of plastic pliers etc.
  • Page 83 HW1484673 Cable Wiring Disassembly and Reassembly of the Internal Wiring Harness 5. Connector base 1. Unscrew the cross head APS bolts which are fixing the connector base, and then pull the connector base a little bit and disconnect the tube which is connected to the back side of the grease inlet. Be careful not to leak grease from the tube.
  • Page 84 HW1484673 Cable Wiring Disassembly and Reassembly of the Internal Wiring Harness Fig. 8-5: Disassembly and Reassembly of the Internal Wiring Harness (Connector Base) [LAMP] Section A-A Moly White RE No.00 Grease AIR1 AIR2 Internal user I/O wiring 1BC connector harness HW1484673 84/109...
  • Page 85 HW1484673 Cable Wiring Disassembly and Reassembly of the Internal Wiring Harness  Reassembly 1. Connector base Refer to fig. 8-5 “Disassembly and Reassembly of the Internal Wiring Harness (Connector Base)” and table 8-5 “Internal Wiring Harness Parts Checklist (Connector Base)” . 1.
  • Page 86 HW1484673 Cable Wiring Disassembly and Reassembly of the Internal Wiring Harness 6. Insert the power connector to the S-, and L-axis motor by aligning the key position, and then turn the coupling nut on the cable side until it makes a clicking sound. Confirm that the arrow marks on the connector on the motor side and the connector on the wiring harness side match.

  • Page 87: Battery Pack Replacement

    HW1484673 Battery Pack Replacement Battery Pack Replacement Three battery packs are installed to the position as shown in fig. 9-1 “Location of the Battery and Multi-port Connector” with the multi-port connectors. If the battery alarm appears on the programming pendant, replace the battery pack by following one of the procedures described as follows.
  • Page 88 HW1484673 Battery Pack Replacement  Normal (The power supply of the YRC1000 can be turned ON) Fig. 9-2: Battery connection (the power supply of the YRC1000 can be turned ON) Old battery pack Multi-port connector Connector New battery pack (HW1483880-A) 1.
  • Page 89 HW1484673 Battery Pack Replacement  When the Power Supply of the YRC1000 Cannot Be Turned ON Fig. 9-3: Battery Connection (the power supply of the YRC1000 cannot be turned ON) Old battery pack Multi-port connector Connector or “Y” Lead wires for battery replacement New battery pack (HW1471281-A) (HW1483880-A)
  • Page 90 HW1484673 Battery Pack Replacement 10. After placing the connector and the lead wires around the connector into the protective tube, fix the opening of the protective tube by using the cable tie T18L-HSW. 11. Fix the new battery pack and the protective tube in which the connector is placed at step 10 by using the cable tie T18L-HSW.

  • Page 91: Parts List

    HW1484673 Parts List 10.1 S-Axis Unit 10 Parts List 10.1 S-Axis Unit Fig. 10-1: S-Axis Unit 1035 1013 1036 1014 1010 1002 1011 1036 1009 1021 1007 1022 1005 1008 1003 1001 1004 1012 HW1484673 91/109 10-1...
  • Page 92 HW1484673 Parts List 10.1 S-Axis Unit Table 10-1: S-Axis Unit DWG No. Name Pcs. 1001 HW1382898-A Speed reducer 1002 SGM7G-30APK-YR1* Motor 1003 HW9404486-1 Shaft 1004 HW0400405-3 Stopper 1005 6310 Bearing 1007 M8X45 (TRIVALENT Hexagon socket head cap CHROMATE) screw 1008 2H-8 (TRIVALENT Conical spring washer CHROMATE)

  • Page 93: L-Axis Unit (Yr-1-06Vx50-A00)

    HW1484673 Parts List 10.2 L-Axis Unit (YR-1-06VX50-A00) 10.2 L-Axis Unit (YR-1-06VX50-A00) Fig. 10-2: L-Axis Unit (YR-1-06VX50-A00) 2021 2022 2001 2027 2024 2023 2018 2027 2025 2019 2010 2025 2027 2011 2020 2012 2014 2013 2026 2015 2016 1009 2005 2004 2026 2003 2009...
  • Page 94 HW1484673 Parts List 10.2 L-Axis Unit (YR-1-06VX50-A00) Table 10-2: L-Axis Unit (YR-1-06VX50-A00) DWG No. Name Pcs. 2001 SGM7G-37APK-YR1* Motor 2002 HW0102425-1 L-arm 2003 M12X55 Hexagon socket head cap screw 2004 SW-2H-12 Conical knurled washer 2005 HW9381465-B Speed reducer 2006 M10X40 Hexagon socket head cap screw 2007...

  • Page 95: L-Axis Unit (Yr-1-06Vxl35-A00)

    HW1484673 Parts List 10.3 L-Axis Unit (YR-1-06VXL35-A00) 10.3 L-Axis Unit (YR-1-06VXL35-A00) Fig. 10-3: L-Axis Unit (YR-1-06VXL35-A00) 2021 2022 2001 2027 2024 2023 2018 2027 2025 3019 3010 2025 2027 3020 3013 3011 3015 3014 3026 3016 1009 3005 3004 3026 3003 3009 3008...
  • Page 96 HW1484673 Parts List 10.3 L-Axis Unit (YR-1-06VXL35-A00) Table 10-3: L-Axis Unit (YR-1-06VXL35-A00) DWG No. Name Pcs. 3001 SGM7G-37APK-YR1* Motor 3002 HW0102644-1 L-arm 3003 M12X55 Hexagon socket head cap screw 3004 SW-2H-12 Conical knurled washer 3005 HW9381465-A Speed reducer 3006 M10X40 Hexagon socket head cap screw 3007...

  • Page 97: U-Axis Unit

    HW1484673 Parts List 10.4 U-Axis Unit 10.4 U-Axis Unit Fig. 10-4: U-Axis Unit 5017 5007 5027 5028 2002 5015 5014 5002 5004 5003 5022 5013 5012 5026 5024 5025 5023 5001 5019 5005 5020 5011 5016 5006 5021 5018 5008 5009 5010 HW1484673...
  • Page 98 HW1484673 Parts List 10.4 U-Axis Unit Table 10-4: U-Axis Unit DWG No. Name Pcs. 5001 SGM7G-13APK-YR1* Motor 5002 HW0413914-1 Stopper 5003 M6X55 Hexagon socket head cap screw 5004 2L-6 Conical spring washer 5005 M8X55 (TRIVALENT Hexagon socket head CHROMATE) cap screw 5006 2H-8 (TRIVALENT Conical spring washer...

  • Page 99: R-, B-, T-Axis Unit (Yr-1-06Vx50-A00)

    HW1484673 Parts List 10.5 R-, B-, T-Axis Unit (YR-1-06VX50-A00) 10.5 R-, B-, T-Axis Unit (YR-1-06VX50-A00) Fig. 10-5: R-, B-, T-Axis Unit (YR-1-06VX50-A00) 7018 7006 7051 7020 7024 7016 7045 7019 7025 7001 7050 7033 7044 7032 7029 7031 7028 7013 7037 7037 7007...
  • Page 100 HW1484673 Parts List 10.5 R-, B-, T-Axis Unit (YR-1-06VX50-A00) Table 10-5: R-, B-, T-Axis Unit (YR-1-06VX50-A00) (Sheet 1 of 2) DWG No. Name Pcs. 7001 HW0387754-A Speed reducer 7002 SGM7G-09APK-YR1* Motor 7003 AC1306-G00X6 Oil seal 7004 TC20367 *FKM* Oil seal 7005 ISTW-17 Retaining ring...
  • Page 101 HW1484673 Parts List 10.5 R-, B-, T-Axis Unit (YR-1-06VX50-A00) Table 10-5: R-, B-, T-Axis Unit (YR-1-06VX50-A00) (Sheet 2 of 2) DWG No. Name Pcs. 7040 M6X25 Hexagon socket head cap screw 7041 2L-6 Conical spring washer 7042 M6X50 Hexagon socket head cap screw 7043 2L-6...

  • Page 102: R-, B-, T-Axis Unit (Yr-1-06Vxl35-A00)

    HW1484673 Parts List 10.6 R-, B-, T-Axis Unit (YR-1-06VXL35-A00) 10.6 R-, B-, T-Axis Unit (YR-1-06VXL35-A00) Fig. 10-6: R-, B-, T-Axis Unit (YR-1-06VXL35-A00) 8006 8020 8056 8024 8045 8016 8019 8055 8052 8054 8032 8031 8053 8025 8051 8033 8050 8001 8044 8037 8028...
  • Page 103 HW1484673 Parts List 10.6 R-, B-, T-Axis Unit (YR-1-06VXL35-A00) Table 10-6: R-, B-, T-Axis Unit (YR-1-06VXL35-A00) (Sheet 1 of 2) DWG No. Name Pcs. 8001 HW0387754-A Speed reducer 8002 SGM7G-09APK-YR1* Motor 8003 AC1306-G00X6 Oil seal 8004 TC20367 *FKM* Oil seal 8005 ISTW-17 Retaining ring...
  • Page 104 HW1484673 Parts List 10.6 R-, B-, T-Axis Unit (YR-1-06VXL35-A00) Table 10-6: R-, B-, T-Axis Unit (YR-1-06VXL35-A00) (Sheet 2 of 2) DWG No. Name Pcs. 8039 2L-6 Conical spring washer 8040 M6X25 Hexagon socket head cap screw 8041 2L-6 Conical spring washer 8042 M6X50...

  • Page 105: Wrist Unit

    HW1484673 Parts List 10.7 Wrist Unit 10.7 Wrist Unit Fig. 10-7: Wrist Unit 10115 10058 10015 10093 10094 10016 10095 10096 10005 10114 10115 10113 10060 10040 10039 10039 10005 10055 10013 10014 10039 10008 10057 10033 10007 10022 10039 10053 10047 10091...
  • Page 106 HW1484673 Parts List 10.7 Wrist Unit Table 10-7: Wrist Unit (Sheet 1 of 3) DWG No. Name Pcs. 10001 HW0387737-B Speed reducer 10002 HW0389043-A Speed reducer 10003 HW9405880-1 B cover 10004 HW9405445-1 B nut 10005 HW9405881-1 B nut 10006 HW9405882-1 B nut 10007 O-ring...
  • Page 107 HW1484673 Parts List 10.7 Wrist Unit Table 10-7: Wrist Unit (Sheet 2 of 3) DWG No. Name Pcs. 10056 HW0102233-1 U-arm 10057 HW0102491-1 Wrist 10058 HW0201226-1 Cover 10059 HW0414884-1 Cover 10060 HW0412694-* Shim 10068 HW0412683-* Shim 10075 HW0412695-* Shim 10082 HW0412696-* Shim 10090...
  • Page 108 HW1484673 Parts List 10.7 Wrist Unit Table 10-7: Wrist Unit (Sheet 3 of 3) DWG No. Name Pcs. 10116 2L-6 Conical spring washer 10117 M4X12 Hexagon socket head cap screw 10118 2L-4 Conical spring washer 5017 HW0102239-2 Casing HW1484673 108/109 10-18...
  • Page 109 MAINTENANCE MANUAL HEAD OFFICE 2-1 Kurosakishiroishi, Yahatanishi-ku, Kitakyushu 806-0004, Japan Phone +81-93-645-7703 Fax +81-93-645-7802 YASKAWA America Inc. (Motoman Robotics Division) 100 Automation Way, Miamisburg, OH 45342, U.S.A. Phone +1-937-847-6200 Fax +1-937-847-6277 YASKAWA Europe GmbH Robotics Divsion ) Yaskawastrasse 1, 85391 Allershausen, Germany...

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