Yaskawa Motoman GP215 Maintenance Manual

MOTOMAN-GP215,GP250/SP235,GP280
MAINTENANCE MANUAL
TYPE:
YR-1-06VX215-A00
(MOTOMAN-GP215 STANDARD SPECIFICATION)
YR-1-06VX215-C00
(MOTOMAN-GP215 DRIP-PROOF SPECIFICATION)
YR-1-06VX250-A00
(MOTOMAN-GP250/SP235 STANDARD SPECIFICATION)
YR-1-06VX250-C00
YR-1-06VX280-A00
(MOTOMAN-GP280 STANDARD SPECIFICATION)
YR-1-06VX280-C00
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-GP215, GP250, GP280 INSTRUCTIONS
MOTOMAN-GP215, GP250, GP280 SUPPLEMENTAL INSTRUCTIONS
MOTOMAN-SP235 INSTRUCTIONS
YRC1000 INSTRUCTIONS
YRC1000 OPERATOR’S MANUAL (GENERAL) (SUBJECT SPECIFIC)
YRC1000 MAINTENANCE MANUAL
YRC1000 ALARM CODES (MAJOR ALARMS) (MINOR ALARMS)
184036-1CD MANUAL NO.

2
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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......................................... 3-2
3.2.2 Using Keys............................................................................................................ 3-2
3.2.3 Using Encoder Backup Error Recovery Function ................................................. 3-2
3.2.4 Robot Calibration (MOTOCALV EG) .................................................................... 3-2
3.2.5 Table of Suitable Methods for Home Position Return........................................... 3-2
3.3 Methods for Home Position Return.................................................................................... 3-3
3.3.1 Using a Teaching Point for Setting the Home Position......................................... 3-3
3.3.1.1 Preparation .............................................................................................. 3-3
3.3.1.2 Replacement of Motor or Speed Reducer ............................................... 3-3
3.3.1.3 Home Position Adjustment ...................................................................... 3-4
3.3.2 Using Keys............................................................................................................ 3-5
3.3.3 Using Encoder Backup Error Recovery Function ............................................... 3-10
3.3.4 Robot Calibration (MOTOCALV EG) .................................................................. 3-10
4 L-Axis Fixing Jig .............................................................................................................................. 4-1
4.1 Fixing Jig............................................................................................................................ 4-1
4.1.1 Recommended Installation Posture of the Specified Fixing Jig............................ 4-2
4.1.2 Range of L-Arm Postures to Avoid ....................................................................... 4-3
4.2 Installation and Removal of the L-axis Fixing Jig............................................................... 4-4
4.3 Mechanism......................................................................................................................... 4-8
5 Notes on Grease Replenishment/Exchange Procedures................................................................ 5-1
5.1 Grease Exchange Procedures for Each Axis Speed Reducer........................................... 5-1
5.1.1 Notes on Grease Exchange Procedures .............................................................. 5-1
5.1.2 Grease Exchange Procedure ............................................................................... 5-3
5.1.3 Grease Replenishment for Gas Balancer Link Part.............................................. 5-8
5.2 Removing, Applying, Assembling of Sealing Bond ............................................................ 5-9
5.2.1 Removing Sealing Bond from Sealing Surface and Cleaning .............................. 5-9
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Contents
5.2.2 Applying Sealing Bond to Sealing Surface ......................................................... 5-10
5.2.3 Assembling After Applying Sealing Bond ........................................................... 5-11
6 Disassembly and Reassembly of the Motors.................................................................................. 6-1
6.1 Disassembly and Reassembly of the S-Axis Motor ........................................................... 6-2
6.2 Disassembly and Reassembly of the L-Axis Motor ........................................................... 6-6
6.3 Disassembly and Reassembly of U-Axis Motor............................................................... 6-10
6.4 Disassembly and Reassembly of the R-, B-, T-Axis Motors ............................................ 6-14
7 Disassembly and Reassembly of the Speed Reducers .................................................................. 7-1
7.1 Disassembly and Reassembly of S-Axis Speed Reducer ................................................. 7-1
7.2 Disassembly and Reassembly of L-Axis Speed Reducer.................................................. 7-5
7.3 Disassembly and Reassembly of U-Axis Speed Reducer ............................................... 7-10
7.4 Disassembly and Reassembly of R-Axis Speed Reducer ............................................... 7-14
7.5 Disassembly and Reassembly of B-Axis Speed Reducer ............................................... 7-17
7.5.1 YR-1-06VX215-A00, -C00, YR-1-06VX250-A00, -C00 ...................................... 7-17
7.5.2 YR-1-06VX280-A00, -C00 .................................................................................. 7-20
7.6 Disassembly and Reassembly of T-Axis Speed Reducer ............................................... 7-25
8 Disassembly and Reassembly of Wrist Unit ................................................................................... 8-1
9 Cable Wiring ................................................................................................................................... 9-1
9.1 Disassembly and Reassembly of Internal Wiring Harness ................................................ 9-1
10 Disassembly and Reassembly of Balancer Unit ......................................................................... 10-1
10.1 Notes when Disassembling and Reassembling the Balancer Unit ................................ 10-1
10.2 Disassembly and Reassembly of Balancer Unit ............................................................ 10-2
10.3 Unit Assembly................................................................................................................ 10-8
10.3.1 Balancer Unit Assembly ................................................................................... 10-8
10.3.2 Shaft Assembly (Knuckle Part)......................................................................... 10-9
10.3.3 Shaft Assembly (Support Part 1) .................................................................... 10-10
10.3.4 Shaft Assembly (Support Part 2) .................................................................... 10-10
10.3.5 Unit Assembly Parts Checklist........................................................................ 10-11
11 Battery Pack Replacement ......................................................................................................... 11-1
11.1 Battery Pack Replacement ............................................................................................ 11-1
12 Parts List ..................................................................................................................................... 12-1
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Contents
12.1 S-Axis Unit ..................................................................................................................... 12-1
12.2 L-Axis Unit...................................................................................................................... 12-6
12.3 U-, R-, B-, T-Axis Unit .................................................................................................... 12-9
12.4 U-arm unit .................................................................................................................... 12-16
12.5 Wrist unit ...................................................................................................................... 12-21
12.6 Balancer Unit ............................................................................................................... 12-27
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1 Introduction
1 Introduction
DANGER
• This maintenance manual is intended to describe safety measures,
necessary items on maintenance and inspection, and maintenance
procedures for proper maintenance and inspection of the
mechanical part of this manipulator. Be sure to read and
understand this instruction manual thoroughly before installing and
operating the manipulator. Any matter not described in this manual
must be regarded as “prohibited” or “improper”.
• General information related to safety are described in “Chapter 1.
Safety” of the YRC1000 INSTRUCTIONS. To ensure correct and
safe operation, carefully read “Chapter 1. Safety” of the YRC1000
INSTRUCTIONS.
CAUTION
• In some drawings in this manual, protective covers or shields are
removed to show details. Make sure that all the covers or shields
are installed in place before operating this product. The drawings
and photos in this manual are representative examples and
differences may exist between them and the delivered product.
• YASKAWA is not responsible for incidents arising from unauthorized
modification of its products. Unauthorized modification voids the
product warranty.
NOTICE
• 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.
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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”, or “NOTICE”.
Indicates an imminently hazardous

DANGER situation which, if not avoided, will
result in death or serious injury.
Safety Signs identified by the signal
word DANGER should be used
sparingly and only for those
situations presenting the most
serious hazards.
Indicates a potentially hazardous

WARNING situation which, if not avoided, will
result in death or serious injury.
Hazards identified by the signal
word WARNING present a lesser
degree of risk of injury or death than
those identified by the signal word
DANGER.
Indicates a hazardous situation,

CAUTION which if not avoided, could result in
minor or moderate injury. It may
also be used without the safety alert
symbol as an alternative to
“NOTICE”.
NOTICE is the preferred signal word

NOTICE to address practices not related to
personal injury. The safety alert
symbol should not be used with this
signal word. As an alternative to
“NOTICE”, the word “CAUTION”
without the safety alert symbol may
be used to indicate a message not
related to personal injury.
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
• 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.
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.
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1 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.
– Disconnect the safety plug of the safety fence.
(when in the play mode or in the remote mode)
If operation of the manipulator cannot be stopped in an emergency,
personal injury and/or equipment damage may result.
Fig. : Emergency Stop Button
• Before releasing the emergency stop, make sure to remove the

obstacle or error caused the emergency stop, if any, and then turn
the servo power ON.
Failure to observe this instruction may cause unintended movement of
the manipulator, which may result in personal injury.
Fig. : Release of Emergency Stop
TURN
• Observe the following precautions when performing a teaching

operation within the manipulator's operating range:
– Be sure to perform lockout by putting a lockout device on the
safety fence when going into the area enclosed by the safety
fence. In addition, the operator of the teaching operation must
display the sign that the operation is being performed so that no
other person closes the safety fence.
– View the manipulator from the front whenever possible.
– Always follow the predetermined operating procedure.
– Always keep in mind emergency response measures against the
manipulator’s unexpected movement toward a person.
– Ensure a safe place to retreat in case of emergency.
Failure to observe this instruction may cause improper or unintended
movement of the manipulator, which may result in personal injury.
• Confirm that no person is present in the manipulator's operating
range and that the operator is in a safe location before:
– Turning ON the YRC1000 power
– Moving the manipulator by using the programming pendant
– Running the system in the check mode
– Performing automatic operations
Personal injury may result if a person enters the manipulator's
operating range during operation. Immediately press an emergency
stop button whenever there is a problem. The emergency stop buttons
are located on the front panel of the YRC1000 and on the right of the
programming pendant.
• Read and understand the Explanation of the Warning Labels before
operating the manipulator.
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1 Introduction
WARNING
• Perform the following inspection procedures prior to conducting
manipulator teaching. If there is any problem, immediately take
necessary steps to solve it, such as maintenance and repair.
– Check for a problem in manipulator movement.
– Check for damage to insulation and sheathing of external wires.
• Always return the programming pendant to the hook on the
YRC1000 cabinet after use.
If the programming pendant is left unattended on the manipulator, on a
fixture, or on the floor, etc., the Enable Switch may be activated due to
surface irregularities of where it is left, and the servo power may be
turned ON. In addition, in case the operation of the manipulator starts,
the manipulator or the tool may hit the programming pendant left
unattended, which may result in personal injury and/or equipment
damage.
NOTICE
• When performing maintenance and inspection, make sure to
connect the battery unit before removing the encoder connector.
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.
In this manual, the equipment is designated as follows.
Equipment Manual Designation
YRC1000 controller YRC1000
YRC1000 programming pendant Programming pendant
Cable between the manipulator and the Manipulator cable
YRC1000
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.
Note: Taking the maintenance-relevant trainings offered by YASKAWA is
indispensable for replacing the L-axis of the balancer-equipped
manipulator.
Fig. 1-1(a): Warning Label Locations (YR-1-06VX215-A00, -C00, YR-1-
06VX250-A00, -C00)
Crush hazard label
NJ4036
NJ4176
Balancer disassembly prohibited label
Motor removing prohibited label
NJ4175
A
15
B
TYPE
DATE PAYLOAD
kg
SERIAL NO. MASS
kg
YASKAWA ELECTRIC CORPORATION
2-1 Kurosakishiroishi, Yahatanishi-ku,
Kitakyushu 806-0004 Japan
MADE IN JAPAN
NJ4030
Crush hazard label Nameplate

NJ4036
Collision hazard label

NJ4032

Motor removing
NJ4032
prohibited label
NJ4175
15
FB
A B
NJ4040
1BC
S1
Fall down hazard label
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1 Introduction
Fig. 1-1(b): Warning Label Locations (YR-1-06VX280-A00, -C00)
NJ4036
NJ4176
Crush hazard label
15 NJ4175
TYPE
DATE PAYLOAD
kg
SERIAL NO. MASS
kg
MADE IN JAPAN
NJ4133
Crush hazard label

NJ4036
Collision hazard label NJ4032
Nameplate

Motor removing
NJ4032
prohibited label
NJ4175
15
FB
A B
NJ4040
1BC Moly White

RE No.00
Grease
IN
S1
Nameplate
TYPE
DATE PAYLOAD
kg
SERIAL NO. MASS
kg
MADE IN JAPAN
NJ4030
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1 Introduction
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.
Description
Personal injury may result if a person enters the manipulator's operating
range during operation. Immediately press an emergency stop button
whenever there is a problem. Confirm that no person is present in the
manipulator's operating range and that the operator is in a safe location
before:
• Turning ON the YRC1000 power
• Moving the manipulator by using the programming pendant
• Running the system in the check mode
• Performing automatic operations
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1 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.
Description
Do not disassemble the balancer.
When disassembling the balancer, the internal energy is released and the
L-arm rotates.
Failure to observe this caution may result in injury or malfunction.
Description
Do not remove the motor without installing the jig for fixing the motor.
Failure to observe this safety precaution may result in injury from
unexpected turning of the manipulator’s arm.
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2 Notes for Maintenance

2.1 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. 2-1 “Details of Internal
Connections” and table 2-1 “Details of Internal Connections” .
Fig. 2-1: Details of Internal Connections
S-head Casing
8 9 8 8
16
14 15
10 12
11 13
7 7 7
1 2 3 4 5 6
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Table 2-1: Details of Internal Connections

No. Item Qty. Note
1 S-axis motor 1 Encoder cable: Not provided with
the motor
Power cable: Not provided with
the motor
2 L-axis motor 1 Encoder cable: Not provided with
the motor
the motor
3 U-axis motor 1 Encoder cable: Not provided with
the motor
the motor
4
2 R-axis motor 1 Encoder cable: Not provided with
the motor
the motor
5 B-axis motor 1 Encoder cable: Not provided with
the motor
the motor
6 T-axis motor 1 Encoder cable: Not provided with
the motor
the motor
7
2 Multi-port connector 3
HW1384619-A
8
2 Battery pack 3
HW1483880-A
9
2 Internal wiring HW1173141-A 1 YR-1-06VX280-A00
harness HW1173141-B 1 YR-1-06VX215-A00
YR-1-06VX250-A00
HW1173683-A 1 YR-1-06VX280-C00
HW1173683-B 1 YR-1-06VX215-C00
YR-1-06VX250-C00
10
2 S-axis encoder cable 1
HW1372910-C
11 L-axis encoder cable 1
HW1372910-D
12 U-axis encoder cable 1
HW1372597-K
13 R-axis encoder cable 1
HW1372597-L
14 B-axis encoder cable 1
HW1372597-M
15 T-axis encoder cable 1
HW1372597-N
16
2 Lead wire 1
HW1471359-A
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2.2 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” .)
A multi-port connector has four ports: two for the motor and the other two
for the internal wiring harness. (Refer to fig. 2-3 “Wiring Connection of
Multi-Port Connector” .)
When removing the multi-port connector for a battery replacement, etc.,
be careful not to remove the connector between the motor and the multi-
port connector. If the connector between the motor and the multi-port
connector is removed, the encoder absolute data will be lost.
Fig. 2-2: Multi-Port Connector

Port nameplate
Motor 1 Internal wiring harness “IN” or lead wire “Y”
Motor 2 Internal wiring harness “OUT” or lead wire “X”
Fig. 2-3: Wiring Connection of Multi-Port Connector
Motor
Battery pack
Internal wiring
harness
Multi-port connector
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Fig. 2-4: Locations of Battery Pack and Multi-Port Connector
Protective tube Battery pack for B-, T-axes

Cable tie
Battery for U-, R-axes
Protective tube
Cable tie
When the Cover is Removed

Cover
Fixing bolt for the cover

Cross head APS bolt M4
(length: 8 mm) (3 bolts)
*trivalent chromate*
Cable tie
OUT
IN
S
L
Cover
Battery pack
for S-, L-axes
Protective tube Fixing bolt for the cover
When the Cover is Removed Cross head APS bolt M4
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3 Home Position Return

3.1 Home Position Posture of Manipulator
Reset the home position of the manipulator if the home

NOTE 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.
Thus, by precisely resetting the home position, the JOB
used before resetting can be used without correction.
Perform home position return in one of the following cases:
• The motor or absolute encoder is replaced.
• Stored memory is cleared due to the run-out of the internal
battery.
• The home position is deviated by hitting the MOTOMAN
against a workpiece, etc.
• A main part such as a speed reducer is replaced or disas-
sembled and reassembled.
When performing home position return, be sure that no
external force is applied to the manipulator.
3.1 Home Position Posture of Manipulator

The home position of this manipulator is shown in fig. 3-1 “Home Position
Posture” . Each axis has a home position mark as a guide for the home
position. The home position mark of the U-axis is shown below as an
example.
Fig. 3-1: Home Position Posture
A
View A: Home position mark
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3.2 Types of Methods for Home Position Return
3.2 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. After the replacement of
the motor, etc., move the manipulator to the created position to adjust the
deviation.
3.2.2 Using Keys

As a preparation, on the home position label inside of the YRC1000, write
down the difference of the pulse numbers between the key position and
the factory-set home position of the manipulator. If the home position data
disappear, move the manipulator to the key position, and set the position
where the above difference of the pulse numbers is reflected as the home
position.
3.2.3 Using Encoder Backup Error Recovery Function

If the stored memory is cleared due to the run-out of the internal battery
and the “Encoder Backup Error” alarm occurs, run the “Backup Alarm
Restoration” software on the programming pendant.
This function cannot be used when the motor or absolute encoder is
replaced.
3.2.4 Robot Calibration (MOTOCALV EG)

If any method described above in chapter 3.2.1 to chapter 3.2.3 cannot
be performed, perform robot calibration to reset the home position of the
manipulator.
Perform teaching of the five-point-in-five-posture (25 points in total) by
using the manipulator, and adjust the home position and tool data of the
manipulator by using its position data.
3.2.5 Table of Suitable Methods for Home Position Return

Suitable methods to return the home position for each case are shown in
table 3-1 “Table of Suitable Methods for Home Position Return” .
Table 3-1: Table of Suitable Methods for Home Position Return
Case Replacement Run-out of Hitting Replacing
of motor or internal against a a main part
Method
encoder battery workpiece
Teaching point High N/A N/A High
Key Mid Mid N/A Mid
Encoder backup error N/A High N/A N/A
recovery function
Robot calibration Low Low Low Low
Accuracy of home position return is categorized as follows:

High, Mid, Low (possible to obtain a more accurate home
position, but the home position of all axes are changed),
N/A (not applicable)
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3.3 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. The standard position is used after the replacement.
Create the check-point by satisfying the following conditions. Also, create
the JOB so that the manipulator safely moves from the standby position,
etc. to the check-point. (The JOB created in this manner is hereinafter
called the check-JOB.)
• The position of the check-point must not be deviated by turning the
power ON or OFF, or lowering air pressure.
Do not create the check-point in the movable part of the tool (end-
effector) or the jigs (related unit including the rotary table). It is rec-
ommended to use a specific jig if necessary.
• Use a pointed object (stylus, etc.) to create the check-point so that
deviation is easily found.
Keep the distance between the check-point and the rotational center
of the axis under home position adjustment as far as possible.
• Consider the moving direction of the axis under home position
adjustment, and create the check-point where deviation can be eas-
ily found and the axis does not interfere with jigs, etc. even if it devi-
ates.
It is recommended to create the check-point for each axis

NOTE under normal operating conditions beforehand. To create
the check-point, each axis must operate normally. The
check-point cannot be created if the axis does not move
because of failure.
3.3.1.2 Replacement of Motor or Speed Reducer

Replace the motor or the speed reducer by referring to chapter 6
“Disassembly and Reassembly of the Motors” and chapter 7
“Disassembly and Reassembly of the Speed Reducers” .
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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” in “YRC1000 INSTRUCTIONS (RE-CTO-A221)”.
Move the axis to the check-point by the check-JOB. Ensure that the
manipulator does not interfere with jigs, etc. when moving the axis.
Correct the deviation from the check-point created before the replacement
by moving only the axis whose motor or speed reducer was replaced.
Display the position screen (COMMAND POSITION).
The following figure shows the values of the U-axis as an example.
By using the above values, calculate the amount of deviation. (Subtract

the CMD (command value) from the CURR (current value).)
U (-3067) - (-2989) = -78
Perform stepping back, etc. of the check JOB to move the axis to the
position where the axis does not interfere with jigs, etc. when it moves to
the home position. Ensure that the manipulator does not interfere with
jigs, etc. when moving the axis. Refer to the position screen, and move
the axis to the position where the pulse number is equal to the amount of
deviation.
The following figure shows an example.
At this position, perform home position calibration only for the axis whose
motor or speed reducer was replaced. For details, refer to chapter 8.1
“Home Position Calibration” in “YRC1000 INSTRUCTIONS (RE-CTO-
A221)”.
Move the axis again to the check-point by the check-JOB. Confirm that
the axis is at the check-point created before the replacement. (If it is
deviated, repeat the adjustment procedure.)
Check the manipulator operation by using the JOB used before the
replacement. If there is no problem, write down the modified home
position data (ABSO data) and the date on the label inside of the
YRC1000.
Move the axis to the modified home position and check the position of the
home position mark. If the home position mark is deviated, modify the
home position mark.
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3.3.2 Using Keys

The parts in table 3-2(a) “Parts List (YR-1-06VX215-A00, -C00, YR-1-
06VX250-A00, -C00)” and table 3-2(b) “Parts List (YR-1-06VX280-A00,
-C00)” are required. Prepare them beforehand.
Table 3-2(a): Parts List (YR-1-06VX215-A00, -C00, YR-1-06VX250-A00,

-C00)
Drawing No. Name Qty. Note
HW9405595-1 Pin 1 For S-, L-, U-, and
R-axes
HW9405595-2 Pin 1 For B-axis
HW9405626-2 Pin 1 For T-axis
HW1400814-1 Block 1 Plate for R-axis
HW1405948-6-10 Pin 2 For HW1400814-1
HW1400813-1 Block 1 Plate for R-axis
HW1405948-6-10 Pin 1 For HW1400813-1
HW1405948-6-15 Pin 1 For HW1400813-1
HW1406657-1 Plate 1 Plate for T-axis
HW1406684-1 Pin 2 For HW1406657-1
Table 3-2(b): Parts List (YR-1-06VX280-A00, -C00)

Drawing No. Name Qty. Note
HW9405595-1 Pin 1 For S-, L-, and U-
axes
HW9405626-1 Pin 1 For R- and B-axes
HW9405626-2 Pin 1 For T-axis
HW0303572-1 Plate 1 Plate for R-axis
HW1405948-6-20 Pin 2 For HW0303572-1
HW0403868-1 Plate 1 Plate for T-axis
HW1406684-1 Pin 2 For HW0403868-1
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1. S-Axis Positioning
As shown in fig. 3-2 “S-Axis Positioning” , insert the pin (HW9405595-
1) from the pin hole ( 6 dia. +0.012
0 ) on the S-head and perform positioning
by using the programming pendant so that the pin fits into the hole of
the base.
Fig. 3-2: S-Axis Positioning
+0.012
Pin hole (6 dia. 0 )
S-head
Pin (HW9405595-1)
Base
2. L-Axis Positioning
As shown in fig. 3-3 “L-Axis Positioning” , insert the pin (HW9405595-
0 ) on the S-head and perform positioning
the L-arm.
Fig. 3-3: L-Axis Positioning
L-arm
S-head
㻼㼕㼚㻌(HW9405595-1)
+0.012
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3. U-Axis Positioning
As shown in fig. 3-4 “U-Axis Positioning” , insert the pin (HW9405595-
0 ) on the casing and perform positioning
the L-arm.
Fig. 3-4: U-Axis Positioning
B
+0.012
Pin (HW9405595-1)
Casing
L-arm
4. R-Axis Positioning
• YR-1-06VX215-A00, -C00, YR-1-06VX250-A00, -C00
As shown in fig. 3-5(a) “R-Axis Positioning (YR-1-06VX215-A00,
-C00, YR-1-06VX250-A00, -C00)” , insert the pin (HW1408161-6-
15) and pin (HW1408161-6-10) into the wrist base, and then mount
the block (HW1400813-1).
Next, insert two pins (HW1408161-6-10) into the U-arm, and then
mount the block (HW1400814-1).
Insert the pin (HW9405595-1) from the hole ( 6 dia. +0.012
0 ) of the block
(HW1400814-1), and perform positioning by using the programming
pendant so that the pin fits into the hole of the block (HW1400813-1).
Fig. 3-5(a): R-Axis Positioning (YR-1-06VX215-A00, -C00, YR-1-
06VX250-A00, -C00)
Wrist base
U-arm
Pin (HW9405595-1) Pin (HW1408161-6-15)

Pin (HW1408161-6-10)
Pin (HW1408161-6-10) (2 pins)
Block (HW1400814-1) Block (HW1400813-1)
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• YR-1-06VX280-A00, -C00
As shown in fig. 3-5(b) “R-Axis Positioning (YR-1-06VX280-A00,
-C00)” , insert two pins (HW1405948-6-20) into the U-arm, and then
mount the plate (HW0303572-1).
Insert the pin (HW9405626-1) from the groove of the plate
(HW0303572-1), and perform positioning by using the programming
pendant so that the pin fits into the hole of the wrist base.
Fig. 3-5(b): R-Axis Positioning (YR-1-06VX280-A00, -C00)
U-arm
Pin (HW9405626-1) Wrist base
Pin (HW1405948-6-20) (2 pins)
Plate (HW0303572-1) +0.012

Groove for pin (6 0 )
5. B-Axis Positioning
• YR-1-06VX215-A00, -C00, YR-1-06VX250-A00, -C00
As shown in fig. 3-6(a) “B-Axis Positioning (YR-1-06VX215-A00,
-C00, YR-1-06VX250-A00, -C00)” , insert the pin (HW9405595-2)
from the pin hole ( 6 dia. +0.012
0 ) on the wrist cover and perform position-
ing by using the programming pendant so that the pin fits into the
hole of the wrist base.
Fig. 3-6(a): B-Axis Positioning (YR-1-06VX215-A00, -C00, YR-1-
06VX250-A00, -C00)
㼃㼞㼕㼟㼠
㻌Wrist base
Pin㻌(HW9405595-2)
+0.012
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• YR-1-06VX280-A00, -C00
As shown in fig. 3-6(b) “B-Axis Positioning (YR-1-06VX280-A00,
-C00)” , insert the pin (HW9405626-1) from the pin hole ( 6 dia. +0.012
0 )
on the wrist cover and perform positioning by using the programming
pendant so that the pin fits into the slot of the wrist base.
Fig. 3-6(b): B-Axis Positioning (YR-1-06VX280-A00, -C00)
Wrist base
Wrist
Pin (HW9405626-1)
+0.012
6. T-Axis Positioning
• YR-1-06VX215-A00, -C00, YR-1-06VX250-A00, -C00
As shown in fig. 3-7(a) “T-axis Positioning (YR-1-06VX215-A00,
-C00, YR-1-06VX250-A00, -C00)” , insert two pins (HW1406684-
1) into the flange, and then mount the plate (HW1406657-1).
Insert the pin (HW9405626-2) from the above mentioned mounted
plate (HW1406657-1), and perform positioning by using the pro-
gramming pendant so that the pin fits into the hole ( 6 dia. +0.012
0 ) of the
wrist.
Fig. 3-7(a): T-axis Positioning (YR-1-06VX215-A00, -C00, YR-1-06VX250-
A00, -C00)
Plate (HW1406657-1)
Pin (HW1406684-1) (2 pins)
Flange
+0.012
Wrist Pin hole (6 dia. 0 )
Shaft (HW9405626-2)
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• YR-1-06VX280-A00, -C00
As shown in fig. 3-7(b) “T-Axis Positioning (YR-1-06VX280-A00,
-C00)” , insert two pins (HW1406684-1) into the flange, and then
mount the plate (HW0403868-1).
Insert the pin (HW9405626-2) from the above mentioned mounted
plate (HW0403868-1), and perform positioning by using the pro-
gramming pendant so that the pin fits into the hole ( 6 dia. +0.012
0 ) of the
wrist.
Fig. 3-7(b): T-Axis Positioning (YR-1-06VX280-A00, -C00)
Plate (HW0403868-1)
Pin (HW1406684-1) (2 pins)
Flange
+0.012
Wrist
Pin (HW9405626-2)
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.
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4 L-Axis Fixing Jig

4.1 Fixing Jig
4 L-Axis Fixing Jig
DANGER
• The maintenance operation should be carried out by a specified
person.
• Execute disassembly and reassembly of the L-axis motor after
mounting the L-axis fixing jig on the balancer. After mounting the L-
axis fixing jig, be sure to confirm that the L-axis is firmly fixed by
releasing the L-axis motor brake.
Failure to observe this leads unexpected L-arm rotation at the
moment when the L-axis motor is removed and it may result in
damage to machinery or death or serious injury.
4.1 Fixing Jig

In this manipulator, the “Linkless mechanism with the balancer” is
adopted. Therefore, releasing L-axis holding power (for removing the L-
axis motor and releasing the brake, etc.) is seriously dangerous since it
will cause an L-arm rotation which is different from the conventional
model, depending on the edge load, the wrist load posture, the U-axis
posture, and the L-axis posture. (For outlined mechanism, refer to
chapter 4.3 “Mechanism” in this chapter.) When releasing the L-axis
holding power, be sure to hold the L-arm with the fixing jig specified in this
manual by following the procedure.
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4 L-Axis Fixing Jig
4.1 Fixing Jig
4.1.1 Recommended Installation Posture of the Specified Fixing Jig

When using this fixing jig, operating the manipulator in the posture shown
in fig. 4-1 “Recommended Installation Posture of the Specified Fixing Jig”
is recommended.
L-axis: -60° (-176,020 pulses)
Care must be taken so that the arm may not interfere with the peripheral
devices including the workpiece and hand, and the main unit of the
manipulator. Install the specified fixing jig to the section A shown in
fig. 4-1 (the rear of the balancer). Set the posture in which the specified
fixing jig is installed on section A.
Fig. 4-1: Recommended Installation Posture of the Specified Fixing Jig
Section A
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4 L-Axis Fixing Jig

4.1 Fixing Jig
4.1.2 Range of L-Arm Postures to Avoid

Avoid operating the manipulator in the posture shown in fig. 4-2 “Range of
L-Arm Postures to Avoid” as much as possible. The flange tip may move
several hundred millimeters. If there are objects in the surrounding area
that will interfere with this operation, operate the turning axis or other axes
and move the manipulator to a posture without interference.
L-axis: -15° to +15° (-44005 to +44005 pulses)
CAUTION
When the axis must be secured in the range shown in fig. 4-2 out of
necessity as the motor cannot drive the axis, move the arm gradually
by turning the brake ON and OFF at short intervals when releasing the
brake. Repeat this operation until the arm cannot move.
Failure to observe this instruction may result in the axis moving when
the brake is released.
Fig. 4-2: Range of L-Arm Postures to Avoid
-15 +15
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4 L-Axis Fixing Jig
4.2 Installation and Removal of the L-axis Fixing Jig
Refer to table 4-1 “Parts Check List of L-Axis Fixing Jig” , fig. 4-3 “Details
of Specified Jig Installation” , and fig. 4-4 “Details of Specified Jig
Removal” .
 Installation
1. Remove the rubber cap 1 and hexagon socket head cap screws 2 .
2. Insert the stud 3 from the thread part M36 into the hole at the rear of
the balancer, and then screw it into the rod 4 .
Tighten so there is no looseness between the stud 3 and the rod 4 .
3. Mount the nut 5 on the stud 3 . Screw the nut 5 onto the stud 3
until it makes contact with the rear of the balancer.
Tighten so there is no looseness between the end face of the nut 5
and the contact surface of the rear of the balancer.
4. Mount the shaft 6 , and then tighten the hexagon socket head cap
screws 7 with the tightening torque shown in table 4-1.
5. Confirm that the L-axis is firmly fixed by releasing the L-axis motor
brake. (Release the brake in short intervals and prepare for the impact
when the arm moves.)
 Removal
DANGER
• To remove the L-axis fixing jig, first confirm that the L-axis holding
power has been restored (that the brake of the L-axis motor has not
released).
moment when the L-axis fixing jig is removed and it may result in
damage to machinery, death, or serious injury.
1. Remove the shaft 6 and nut 5 attached to the stud 3 .

2. Mount the plate 8 to the stud 3 by using the hexagon socket head
cap screw 9 , and tighten it with the tightening torque shown in
table 4-1.
3. Mount the plate 10 to the case by using the hexagon socket head cap
screws 11 , and tighten them with the tightening torque shown in
table 4-1.
4. Tighten the bolts 12 until the nut 5 becomes loose.
If the nut is tight, mount the hexagon nuts 13 on the tip of the bolts 12 ,
and then screw in the bolts 12 so that they push the plate 10 until the
nut 5 can be moved by hand.
5. Remove the stud 3 from the rear of the balancer.
6. Remove the plate 8 , plate 10 , and bolts 12 mounted to the stud 3
and case.
7. Tighten the hexagon socket head cap screws 2 with the tightening
torque shown in table 4-1.
8. Mount the rubber cap 1 on the balancer.
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4 L-Axis Fixing Jig

Table 4-1: Parts Check List of L-Axis Fixing Jig

No. Name Qty. Note
1 Rubber cap 1
2 Hexagon socket head cap screw M8 3 Tightening torque: 24.5 N•m
(length: 16 mm) each
Conical spring washer 2L-8
3 Stud HW0400632-1 1
4 Rod 1
5 Nut HW9405581-1 1
6 Shaft HW9405579-1 1
8 Plate HW9402997-1 1
9 Hexagon socket head cap screw M16 1 Tightening torque: 206 N•m
Conical spring washer 2H-16
10 Plate HW9402998-1 1
12 Bolt HW1409003-1 2
13 Hexagon nut M12 4
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4 L-Axis Fixing Jig
Fig. 4-3: Details of Specified Jig Installation
Before installing the jig
7
5
3
M36XP2
M55XP2
6
4
Case
After installing the jig
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4 L-Axis Fixing Jig

Fig. 4-4: Details of Specified Jig Removal

7
5
3
M36XP2
M55XP2
6
4
Case
Before removing the jig
11
5
9
3
13
8
12
10
4
Case
When using the jig for removal
After removing the jig
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4 L-Axis Fixing Jig
4.3 Mechanism
4.3 Mechanism
• Refer to fig. 4-5 “The L-arm Rotation Direction” .
The L-arm rotational direction of when L-axis holding power is released
depends on the extent of the torque Tb generated by the balancer, and the
load torque TL generated around the L-axis.
When no load is applied to the edge, the torque Tb generated by the
balancer is always generated toward the direction which makes the L-arm
posture lean 40° forward from the vertical posture, and the extent of the
torque Tb varies depending on the L-axis angle. Also, the load torque TL
which is generated around the L-axis works around the center of the L-
axis rotation, and its direction and extent vary depending on the edge
load, posture of the wrist, the U-arm, and the L-arm.
When no load is applied to the edge, for the L-arm rotational direction, 3
patterns are assumed as described in fig. 4-5.
It is quite difficult to accurately compare the extent of the torque which
works around the L-axis and the extent of the torque which is generated
by the balancer on the actual work site, and also, the rotational direction
cannot be identified in this unit. Therefore, handling this unit in the same
way as other manipulators is seriously dangerous, as the L-arm may
rotate in an unexpected direction.
Fig. 4-5: The L-arm Rotation Direction
 60
55 
 to
45
75
Posture in which L-arm moves Posture in which Posture in which

in the clockwise direction L-arm doesn’t move L-arm moves in
the counterclockwise
direction
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5 Notes on Grease Replenishment/Exchange Procedures

5.1 Grease Exchange Procedures for Each Axis Speed Reducer
5.1.1 Notes on Grease Exchange Procedures

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

NOTE 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 or it may result in a failure.
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 the
grease injection rate to 7 g/s or less. (Air supply
pressure to the grease pump: 0.3 MPa or less (rough stan-
dard))
• 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.
• 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/exchanging 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.
• After mounting a speed reducer or a motor, wait for 30
minutes or more and then inject grease.
If grease is filled before the sealing bond is solidified, it
may cause grease to leak.
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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 the operation.
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5.1.2 Grease Exchange Procedure

Fig. 5-1: Grease Inlets and Exhaust Ports for Each Axis
Grease inlet of S-axis
(Hexagon socket head plug PT1/4)
S-axis speed
reducer
Grease exhaust port of S-axis

Grease exhaust port of L-axis

L-axis speed reducer
Grease inlet of L-axis

R-, B-, and T-axis gear in the casing

Grease exhaust port
Grease exhaust port of U-axis (Hexagon socket head plug PT1/8)
U-axis speed reducer
M6
A
R-, B-, and T-axis gear M6
in the casing
Grease inlet
Grease inlet of U-axis
R-axis speed reducer B-axis speed reducer
T-axis speed reducer
Grease inlet of R-axis

(Hexagon socket head plug PT1/8) Grease inlet of B- and T-axes
Grease exhaust port of R- and B-axes
Grease exhaust port of T-axis
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1. Before injecting grease, the posture of the manipulator must be set as

indicated in table 5-1 “Recommended Posture for Grease Injection” .
If it is difficult to make the recommended posture because of the
external cabling or etc., adjust the posture as much as possible to set
the position of the grease inlet face the lower part and the position of
exhaust port face the upper part. If the exhaust port faces the lower
part, grease may not be exchanged properly.
Table 5-1: Recommended Posture for Grease Injection
Axis to inject Posture
S-axis L-axis U-axis R-axis B-axis T-axis
S-axis Any Any Any Any Any Any
L-axis Any 0° Any Any Any Any
U-axis Any 0° * 0° * Any Any Any
R-axis
B-axis Any 0° * 0° * 0° 0° 0°
T-axis
* If the recommended posture cannot be made, make the U-arm horizontal to the
ground.
2. Unscrew the hexagon socket head plugs from the grease inlet and
grease exhaust port.
3. Install a grease zerk 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: Molywhite RE No.00 (-A00)
RV grease LB00 (-C00)
– 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 5-2: Amount of Grease
Axis to exchange grease Amount of grease
S-axis Approx. 6800 g (GP215, GP250/SP235)
Approx. 6900 g (GP280)
L-axis Approx. 1500 g
U-axis Approx. 1650 g
R-, B-, and T-axis gear in the casing Approx. 1740 g
R-axis Approx. 1780 g
B-, and T-axes Approx. 1130 g
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5. Injection stop:
– <When replacing the speed reducer>
Stop injecting grease when grease can be seen from the exhaust
port.
– <When exchanging grease>
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.
And then, skip the steps 6 and 7, and proceed to the step 8.
6. Operate each axis about 5 times in the teach mode as shown in
table 5-3 “Teaching Operation for Each Axis” .
Table 5-3: Teaching Operation for Each Axis
Axis to replenish Angle for teaching Speed for teaching
grease operation operation
S-axis S-axis ±45°
L-axis L-axis ±45°
U-axis U-axis ±45°
User-specified
In the casing R-axis ±90°
R-, B-, and T-axis gear B-axis ±45°
R-, B-, and T-axes T-axis ±90°
7. Inject grease again, and when grease comes out from the exhaust
port, grease injection is completed.
8. Discharge the specified amount of grease from the grease inlet or
grease exhaust port. (Refer to table 5-4 “Amount of Grease
Discharged from Each Axis” .) In order to discharge the specified
amount of grease, receive the discharged grease into 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 5-3.
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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 5-3
“Teaching Operation for Each Axis” .
Table 5-4: Amount of Grease Discharged from Each Axis

Axis to exchange grease Amount of exhausted grease
[g] [cc]
S-axis 0 [unnecessary] 0 [unnecessary]
L-axis 60±10 70±10
U-axis 80±10 90±10
R-, B-, and T-axis gear 90±10 100±15
in the casing
R-, and B-axes 90±10 100±15
T-axis 55±5 65±10
9. For the axis where grease is exchanged, perform a playback operation

indicated in table 5-5 “Running- In Operation for Each Axis” to run-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, and then attach it to the grease inlet. Tighten the plug
with the tightening torque shown in table 5-6 “Plug Type and
Tightening Torque for Each Axis” . 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. 5-2 “Grease
Receiving Bag (Example)” , and then perform the running-in operation.
Table 5-5: Running- In Operation for Each Axis
Axis to exchange grease Running-in operation
Operation Operation speed Timer after each Operating time
angle operation
S-axis S-axis ±45° MOVJ VJ=50.00 1.0 s 15 minutes
L-axis L-axis ±45° MOVJ VJ=50.00 1.0 s 15 minutes
U-axis U-axis ±45° MOVJ VJ=50.00 1.0 s 15 minutes
In the casing R-axis ±90°

R-, B-, and T-axis gear B-axis ±45° MOVJ VJ=50.00 1.0 s 15 minutes
R-, B-, and T-axes T-axis ±90°
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Table 5-6: 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
S-axis PT1/4 12 N•m (1.2 kgf•m)
PT3/8 23 N•m (2.34 kgf•m)
L-axis
U-axis
In the casing
PT1/8 4.9 N•m (0.5 kgf•m)
R-, B-, and T-axis gear PT1/8 4.9 N•m (0.5 kgf•m)
R-, and B-axes
T-axis
Fig. 5-2: Grease Receiving Bag (Example)
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
10. 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 exhaust port,
and then tighten the plug with the tightening toque shown in table 5-6
“Plug Type and Tightening Torque for Each Axis” .
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5.1.3 Grease Replenishment for Gas Balancer Link Part
Fig. 5-3: Gas Balancer Link Part
Link 2 grease exhaust port

(Hexagon socket head plug PT1/8) Link 3 grease exhaust port
Link 3 grease inlet

Link 1 grease exhaust port (Hexagon socket head plug PT1/8)
Link 2 grease inlet
Link 1 grease inlet
(Hexagon socket head
plug PT1/8)
1. Remove the plugs from the grease inlet and from the air exhaust port
of the link 1 and 2 . (Refer to fig. 5-3 “Gas Balancer Link Part” .)
2. Inject grease through the grease inlet of the link 1 and 2 using a
grease gun.
– Grease type: Alvania EP Grease 2
– Amount of grease: to the link 1 : 4.35 g (5 cc)
(8.7 g (10 cc) for 1st supply)
to the link 2 : 4.35 g (5 cc)
(8.7 g (10 cc) for 1st supply)
NOTE Grease will not flow out of the air bleed port.
Be careful not to inject too much grease.
3. Reinstall the plug to the air bleed port of the link 1 , 2 , and 3 .
Before installing the plug, clean and degrease the thread part of the
plug. Wrap the seal tape TB4501 around the thread part, and then
tighten the plug with a tightening torque of 4.9 N•m (0.5 kgf•m).
4. Reinstall the plug to the grease inlet of the link 1 , 2 , and 3 .
Before installing the plug, clean and degrease the thread part of the
plug. Wrap the seal tape TB4501 around the thread part, and then
tighten the plug with a tightening torque of 4.9 N•m (0.5 kgf•m).
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5.2 Removing, Applying, Assembling of Sealing Bond
5.2.1 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.
2. In order to remove dust, dirt, foreign objects, and oil, wipe whole
surface of the speed reducer or motor for replacement by using a
waste cloth. (Refer to fig. 5-4 “Wiping Whole Surface of Speed
Reducer” .)
If not wiping whole surface of the speed reducer, the rust preventive oil
adhered to the speed reducer gradually flows out to the outside of the
manipulator, and a phenomenon considered as oil leakage occurs
(mis-recognition as oil leakage).
3. Saturate a clean cloth with the degreasing and cleaning agent, and
sufficiently degrease the sealing surface of the manipulator side and
the sealing surface of the speed reducer or the motor to be replaced.
Do not pour the degreasing and cleaning agent directly to

NOTE the sealing surface. When the agent remains inside and at
the concave part of the speed reducer, the sealing bond
would not be solidified and this may cause grease leakage.
Fig. 5-4: Wiping Whole Surface of Speed Reducer
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5.2.2 Applying Sealing Bond to Sealing Surface

1. Check that the degreasing and cleaning agent of the sealing surface is
dried. (Refer to fig. 5-5 “Checking the Dryness” .)
If not dried, wipe the agent with a new cloth. (Refer to fig. 5-6 “Wiping
the Agent” .) For the part where wiping cannot be performed such as
the concave part, use air to blow off.
2. Apply ThreeBond 1206C to the sealing surface.
The points to apply sealing bond depend on the axes.

NOTE When applying sealing bond, make sure to refer to
chapter 6 “Disassembly and Reassembly of the Motors”
and chapter 7 “Disassembly and Reassembly of the Speed
Reducers” of each axis.
Fig. 5-5: Checking the Dryness
Fig. 5-6: Wiping the Agent
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5.2.3 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.
• Align the screw hole positions etc. before applying the sealing bond,
and then contact the surfaces. Without this procedure, unevenness
of the sealing bond on the sealing surface may decline the sealing
efficiency. And it may cause grease leakage.
• The rust preventive oil is applied inside of the speed reducer. Imme-
diately perform assembling so that the rust preventive oil does not
flow out to the sealing surface.
2. After assembling, fix them with screws as soon as possible. For
tightening the screws, tighten them by using the tightening torque
indicated in chapter 6 “Disassembly and Reassembly of the Motors”
and chapter 7 “Disassembly and Reassembly of the Speed Reducers”
.
3. By using a waste cloth, wipe the exceeded sealing bond after
assembling. (Refer to fig. 5-7 “Wiping Excessive Sealing Bond”.)
If grease is filled before the sealing bond is solidified, it may

NOTE cause the grease leakage. After tightening the screws,
leave it 30 minutes or more, and then fill it with grease.
Fig. 5-7: Wiping Excessive Sealing Bond (Following Photos are Typical
Example)
Before removing After removing
Excessive sealing bond
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6 Disassembly and Reassembly of the Motors
WARNING
Because the motor is removed, the manipulator cannot keep its posture
during the replacement of the motor or speed reducer. When replacing
the motor or speed reducer, hold the manipulator arm by using a
hanging tool (e.g., chain block). Failure to observe this caution may
cause a hazardous condition. Replace the motor or speed reducer with
due care.
The U-axis is shown below as an example. Refer to fig. 6-1

“Replacement (Example)” .
Fig. 6-1: Replacement (Example)
Chain block
Hanging tool
Refer to chapter 2 “Notes for Maintenance” , chapter 3

“Home Position Return” , chapter 5 “Notes on Grease
Replenishment/Exchange Procedures” , and chapter 6
NOTE
“Disassembly and Reassembly of the Motors” .
Remove old sealing from each part before starting reas-
sembling.
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6.1 Disassembly and Reassembly of the S-Axis Motor
• Refer to fig. 6-2(a) “Disassembly and Reassembly of the S-Axis

Motor” .
 Disassembly
1. Turn OFF the power supply of the YRC1000.
2. Remove the encoder connector of the S-axis motor 1 (fixing bolt:
pan-head screw M2), and then disconnect the encoder cable.
3. Turn the connector on the cable side of the power connector for the S-
axis motor 1 , 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.
4. Unscrew the hexagon socket head cap screws 2 , and insert stud
bolts M6 (length: 50 mm or more) into the tapped hole M6 (4 places)
on the motor flange face. Screw the stud bolts so that the clearance
between the motor and the contact surface is 30 mm or more, roughly.
5. Mount eyebolts (2 bolts) on the thread parts M8 of the motor, and then
remove the S-axis motor 1 from the S-head (spacer 5 ) vertically by
using the eyebolts.
6. Unscrew the hexagon socket head cap screw 6 , and then remove
the gear 13 , fly wheel 7 , and key 4 .
For removing/applying of sealing bond and assembling after

NOTE applying sealing bond, refer to chapter 5.2 “Removing,
Applying, Assembling of Sealing Bond” .
 Reassembly
1. Mount the key 4 on the S-axis motor 1 . (The key 4 is provided
with the S-axis motor 1 .)
2. Apply ThreeBond 1206C to the contact surface of the S-axis motor
1 , gear 3 , and fly wheel 7 , and then mount the gear 3 and fly
wheel 7 on the S-axis motor 1 .
For the place to apply sealing bond, refer to fig. 6-2(b) “Surface to
Apply Sealing Bond on the S-Axis Motor” , fig. 6-2(c) “Surface to
Apply Sealing Bond on the S-Axis Gear” , and fig. 6-2(d) “Surface to
Apply Sealing Bond on the S-Axis Flywheel” .
3. Apply LOCTITE 243 to the thread part of the hexagon socket head cap
screw 6 , and then tighten it with the tightening torque shown in
table 6-1(a) “S-Axis Motor Parts Checklist (YR-1-06VX215-A00, -C00,
YR-1-06VX250-A00, -C00)” and table 6-1(b) “S-Axis Motor Parts
Checklist (YR-1-06VX280-A00, -C00)” .
4. Apply ThreeBond 1206C to the contact surface (2 places) of the S-axis
motor 1 and the S-head (spacer 5 ), and then mount the S-axis
motor 1 on the S-head (spacer 5 ).
For the place to apply sealing bond, refer to fig. 6-2(e) “Surface to
Apply Sealing Bond on the S-Axis Spacer” .
torque shown in table 6-1(a) and table 6-1(b).
6. Connect the encoder cable to the S-axis motor 1 , and then tighten
the connector fixing bolt (pan-head screw M2) with a tightening torque
of 0.2 N•m. (The connector fixing bolt is provided with the connector.)
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7. Insert the power connector to the S-axis motor 1 by aligning the key
position as shown in fig. 6-2(f) “Motor Power Cable” , and turn the
coupling nut of the connector 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.
8. Replenish grease from the grease inlet. (Refer to chapter 5 “Notes on
Grease Replenishment/Exchange Procedures” )
9. Turn ON the power supply of the YRC1000.
Table 6-1(a): S-Axis Motor Parts Checklist

(YR-1-06VX215-A00, -C00, YR-1-06VX250-A00, -C00)
No. Item Qty. Note
1 S-axis motor 1 SGM7G-44APK-YR1*
2 Hexagon socket head cap screw 3 Tightening torque 84.0 N•m
M12 (length: 60 mm) *trivalent each
chromate*
3 Gear HW0314016-1 1
4 Key 1 Provided with the motor
5 Spacer HW0404753-1 1
6 Hexagon socket head cap screw M8 1 Tightening torque 40.0 N•m
7 Fly wheel HW0404752-1 1
Table 6-1(b): S-Axis Motor Parts Checklist (YR-1-06VX280-A00, -C00)

No. Item Qty. Note
M12 (length: 60 mm) *trivalent chro- each
mate*
Conical spring washer 2H-12 *triva-
lent chromate*
3 Gear HW0314016-1 1
5 Spacer HW0404753-1 1
6 Hexagon socket head cap screw M8 1 Tightening torque 40.0 N•m
7 Fly wheel HW0404752-1 1
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Fig. 6-2(a): Disassembly and Reassembly of the S-Axis Motor

Tapped hole for motor and spacer
(2 places) (diagonal)
Tapped hole for eyebolt
Tapped hole for spacer

15
1 View A-A
Apply sealing
2
bond here.
A A
7
4
3
S-head
Fig. 6-2(b): Surface to Apply Sealing Bond on the S-Axis Motor

Apply sealing bond evenly to
whole surface.
Apply sealing
bond here.
Apply sealing
bond here.
Fig. 6-2(c): Surface to Apply Sealing Bond on the S-Axis Gear

Apply sealing whole surface.
bond here.
Apply sealing
bond here.
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Fig. 6-2(d): Surface to Apply Sealing Bond on the S-Axis Flywheel

Apply sealing bond evenly to Apply sealing bond evenly to
whole surface. whole surface.
Apply sealing Apply sealing

bond here. bond here.
Fig. 6-2(e): Surface to Apply Sealing Bond on the S-Axis Spacer

whole surface.
Apply sealing
bond here.
Fig. 6-2(f): Motor Power Cable

Main key
Coupling nut
Alignment mark
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6.2 Disassembly and Reassembly of the L-Axis Motor
DANGER
• Execute disassembly and reassembly of the L-axis motor after
mounting the L-axis fixing jig on the balancer.
Also, be sure to confirm that the L-axis is firmly fixed by releasing
the L-axis motor brake.
moment when the L-axis motor is removed and it may result in
damage to machinery or death or serious injury.
• For fixing the balancer, refer to chapter 4 “L-Axis Fixing Jig” .
• Refer to fig. 6-3(a) “Disassembly and Reassembly of the L-Axis

Motor” .
 Disassembly
1. Mount the fixing jig of the L-axis, and fix the L-arm so that it does not
rotate by using the fixing jig. (chapter 4 “L-Axis Fixing Jig” )
2. Discharge the grease.
3. Remove the encoder connector of the L-axis motor 1 (fixing bolt:
4. Turn the connector on the cable side of the power connector for the L-
5. Mount the brake releasing devices, and release the brake.
6. Unscrew the hexagon socket head cap screws 2 and plug 9 , and
insert the stud bolts M6 (length: 30 mm or more) into the tapped hole
M6 (4 places) on the motor flange face. Screw the stud bolt so that the
clearance between the motor and the contact surface is 5 mm or more,
roughly.
CAUTION
When removing the motor from the L-arm, a lot of grease comes out
from the outlet of the motor.
Make sure to protect peripheral equipment in advance.
7. Remove the L-axis motor 1 horizontally from the S-head. Be careful

not to damage the oil seal in the S-head at this time.
8. Unscrew the bolt 7 , and then remove the shaft 3 , key 4 , gear 5 ,
and shaft 6 .
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 Reassembly

1. Mount the key 4 on the L-axis motor 1 . (The key 4 is provided

with the L-axis motor 1 .)
2. Apply ThreeBond 1206C to the contact surface of the L-axis motor 1
and the shaft 3 , and then mount the shaft 3 and shaft 6 on the L-
axis motor 1 .
3. Apply LOCTITE 243 to the thread part of the bolt 7 on which the gear
5 and retaining ring 8 are mounted, and then tighten it with the
tightening torque shown in table 6-2(a) “L-Axis Motor Parts Checklist
(YR-1-06VX215-A00, -C00, YR-1-06VX250-A00, -C00)” and
table 6-2(b) “L-Axis Motor Parts Checklist (YR-1-06VX280-A00,
-C00)” .
Note: Be careful with the orientation of the washer 7 .
4. Apply ThreeBond 1206C to the contact surface of the L-axis motor 1
and the S-head, and then mount the L-axis motor 1 on the S-head
while being careful not to damage the oil seal in the S-head.
For the place to apply sealing bond, refer to fig. 6-3(b) “Surface to
Apply Sealing Bond on the L-axis Motor” .
5. Apply ThreeBond 1206C to the hexagon socket head cap screws 2 .
Tighten the screws with the tightening torque shown in table 6-2(a)
and table 6-2(b).
6. Connect the encoder cable to the L-axis motor 1 , and then tighten
7. Insert the power connector to the L-axis motor 1 by aligning the key
position as shown in fig. 6-3(c) “Motor Power Cable” , 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.
8. Replenish grease from the grease inlet.
(Refer to chapter 5 “Notes on Grease Replenishment/Exchange
Procedures” .)
9. Disassemble the L-axis fixing jig. (chapter 4 “L-Axis Fixing Jig” )
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Table 6-2(a): L-Axis Motor Parts Checklist

(YR-1-06VX215-A00, -C00, YR-1-06VX250-A00, -C00)
No. Item Qty. Note
1 L-axis motor 1 SGM7G-44APK-YR1*
mate*
lent chromate*
3 Shaft HW9482306-E 1
5 Gear HW0301778-1 1
6 Shaft HW9481343-A 1
7 Bolt HW0481082-A 1 Tightening torque 40.0 N•m
Washer HW0408806-1 each
8 Retaining ring ISTW-10 1
9 Hexagon socket head plug PT3/8 1 Tightening torque 23.0 N•m
*stainless*
Table 6-2(b): L-Axis Motor Parts Checklist (YR-1-06VX280-A00, -C00)

No. Item Qty. Note
mate*
lent chromate*
3 Shaft HW9482306-E 1
5 Gear HW0301778-1 1
6 Shaft HW9481343-A 1
9 Hexagon socket head plug PT3/8 1 Tightening torque 23.0 N•m
*stainless*
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Fig. 6-3(a): Disassembly and Reassembly of the L-Axis Motor
5 6 3 4
8 9
2
ＵＴＴＡＨ－Ｂ２０ＲＪ
ＡＢＳ．ＥＮＣＯＤＥＲ
Apply sealing
bond here.
S-head
7
Fig. 6-3(b): Surface to Apply Sealing Bond on the L-axis Motor

Apply sealing bond evenly Surface to apply
to whole surface. sealing bond 2
Apply sealing
bond evenly to
whole surface.
Surface to apply
sealing bond 1
Fig. 6-3(c): Motor Power Cable

Main key
Coupling nut
Alignment mark
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6.3 Disassembly and Reassembly of U-Axis Motor

• Refer to fig. 6-4(a) “Disassembly and Reassembly of the U-Axis
Motor” .
 Disassembly
1. Support the U-arm with the chain block, etc.
2. Turn OFF the power supply of the YRC1000, and then discharge the
grease.
3. Remove the encoder connector of the U-axis motor 1 (fixing bolt:
4. Turn the connector on the cable side of the power connector for the U-
5. Release the brake.
6. Unscrew the hexagon socket head cap screws 2 , and insert stud
bolts M6 (length: 30 mm or more) into the tapped hole M6 (4 places)
on the motor flange face. Screw the stud bolts so that the clearance
between the contact surface and the motor is 5 mm or more.
7. Remove the U-axis motor 1 horizontally from the casing. At this
time, be careful not to damage the oil seal in the casing.
CAUTION
When removing the motor from the casing, a lot of grease comes out
from the outlet of the motor.
Make sure to protect peripheral equipment in advance.
8. Unscrew the bolt 8 , and then remove the shaft 3 , gear 4 , shaft
5 , and key 6 .
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 Reassembly

1. Mount the key 6 on the U-axis motor 1 . (The key 6 is provided

with the U-axis motor 1 .)
2. Apply ThreeBond 1206C to the contact surface of the U-axis motor 1
and the shaft 3 , and then mount the shaft 3 and shaft 5 on the U-
axis motor 1 .
3. Apply LOCTITE 243 to the thread part of the bolt 8 on which the gear
4 and retaining ring 7 are mounted, and then tighten it with the
tightening torque shown in table 6-3(a) “U-Axis Motor Parts Checklist
table 6-3(b) “U-Axis Motor Parts Checklist (YR-1-06VX280-A00,
-C00)” .
Note: Be careful with the orientation of the washer 8 .
4. Apply ThreeBond 1206C to the contact surface of the U-axis motor 1
and the casing, and then mount the U-axis motor 1 on the casing
while being careful not to damage the oil seal in the casing.
6. Connect the encoder cable to the U-axis motor 1 , and then tighten
7. Insert the power connector to the U-axis motor 1 by aligning the key
position as shown in fig. 6-4(c) “Motor Power Cable” , and 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.
10. Remove the chain block.
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Table 6-3(a): U-Axis Motor Parts Checklist

(YR-1-06VX215-A00, -C00, YR-1-06VX250-A00, -C00)
No. Item Qty. Note
1 U-axis motor 1 SGM7G-44APK-YR1*
chromate*
3 Shaft HW9482306-E 1
4 Gear HW0315871-1 1
5 Shaft HW9481343-A 1
Table 6-3(b): U-Axis Motor Parts Checklist (YR-1-06VX280-A00, -C00)

No. Item Qty. Note
chromate*
3 Shaft HW9482306-E 1
4 Gear HW0315955-1 1
5 Shaft HW9481343-A 1
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Fig. 6-4(a): Disassembly and Reassembly of the U-Axis Motor
Casing
3 8
Apply sealing bond here.
L-arm
㻭
1 2 6 5 4
Fig. 6-4(b): Surface to Apply Sealing Bond on the U-axis Motor

Surface to apply Apply sealing bond evenly to
sealing bond 2 whole surface.
Apply sealing bond

evenly to whole surface.
Surface to apply
sealing bond 1
Fig. 6-4(c): Motor Power Cable

Main key
Coupling nut
Alignment mark
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6.4 Disassembly and Reassembly of the R-, B-, T-Axis Motors
• Make the U-arm point downwards as much as possible

at disassembly or reassembly of the R-, B-, T-axis
motor.
If the U-arm points upwards when removing the motor, a
NOTE lot of grease comes out, which makes disassembly or
reassembly difficult.
• Support the wrist part with a base, etc., before removing
the R-, B-, T-axis motor. Otherwise, the wrist part may
rotate unexpectedly.
• Refer to fig. 6-5(a) “Disassembly and Reassembly of the R-, B-, T-

Axis Motors” .
 Disassembly
2. Remove the encoder connector of the R-, B-, and T-axis motor 1
(fixing bolt: pan-head screw M2), and then disconnect the encoder
cable. Turn the connector on the cable side of the power connector for
the R-, B-, and T-axis motor 1 to the cable side connector, 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.
3. Before removing the R-, B-, and T-axis motor 1 , support the U-arm
and the wrist with the chain block, etc., to prevent the U-arm from
rotating and the wrist from falling.
4. Release the brake.
5. Unscrew the hexagon socket head cap screws 2 , and insert the stud
bolts M4 (length: 40 mm or more for R-axis and 20 mm or more for B-
and T-axes) into the tapped hole M4 (2 places) on the motor-flange
face. Screw the stud bolt into the tapped hole so that the clearance
between the motor and the contact surface is roughly 20 mm or more
for the R-axis and 6 mm or more for the B- and T-axes.
6. For the R-axis
Unscrew the hexagon socket head cap screw 5 , and then remove
the key 3 , gear unit ( 4 , 8 , and inner ring of bearing 9 ), and
plate 10 from the motor 1 . (It is not necessary to remove retaining
ring 7 .)
For the B-axis
the key 3 , gear 4 , and plate 10 from the motor 1 .
For the T-axis
the key 13 , gear 4 , plate 10 , and plate 11 from the motor 1 .
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 Reassembly

1. Apply ThreeBond 1206C to the contact surface of both sides of the

plate 10 .
For the place to apply sealing bond, refer to "Surface to apply sealing
bond 1" in fig. 6-5(b) “Surface to Apply Sealing Bond on the R-, B-,
and T-Axis Motors” .
2. Mount the plate on the R-, B-, and T-axis motor 1 . Mount the bigger
side of the internal chamfer of the plate 10 on the root side of the
motor axis.
3. Mount the key 3 on the R-, B-, and T-axis motor 1 .
4. For the R-axis

Mount the gear unit ( 4 , 7 , 8 , and inner ring of bearing 9 ) to the
motor 1 . Apply LOCTITE 243 to the thread part of the bolt, and then
tighten it with the tightening torque shown in table 6-4 “R-, B-, and T-
Axis Motor Parts Checklist” .
For the B-axis
Mount the gear 4 on the motor 1 . Apply LOCTITE 243 to the
thread part of the hexagon socket head cap screw 5 , and then
tighten it with the tightening torque shown in table 6-4.
For the T-axis
Mount the gear 4 and plate 11 on the motor 1 . Apply LOCTITE
243 to the thread part of the hexagon socket head cap screw 5 , and
then tighten it with the tightening torque shown in table 6-4.
5. Apply ThreeBond 1206C to the contact surface of the R-, B-, and T-
axis motor 1 and the casing 6 , and then mount R-, B-, and T-axis
motor 1 on the casing 6 .
6. Apply ThreeBond 1206C to the thread part of the hexagon socket

head cap screws 2 , and then tighten them with the tightening torque
shown in table 6-4.
7. Connect the encoder cable to the R-, B-, and T-axis motor 1 , and
then tighten the connector fixing bolt (pan-head screw M2) with a
tightening torque of 0.2 N•m.
(The connector fixing bolt is provided with the connector.)
8. Insert the power connector to the R-, B-, and T-axis motor 1 by
aligning the key position as shown in fig. 6-5(d) “Motor Power Cable” ,
and turn the coupling nut of the connector 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.

(Refer to chapter 5 “Notes on Grease Replenishment/Exchange
Procedures” .)
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Table 6-4: R-, B-, and T-Axis Motor Parts Checklist

No. Item Qty. Note
1 R-, B-, and T-axis motor 1×3 SGM7G-13APK-YR1*
each
2 Hexagon socket head cap screw M8 4×3 Tightening torque 24.5
(length: 25 mm) *trivalent chromate* each N•m
3 Key 1×3 Provided with the motor
each
4 R-axis gear HW0306788-1 1
B-axis gear HW0306797-1 1
T-axis gear HW0306795-1 1
5 Hexagon socket head cap screw M6 1 each Tightening torque 16.5

(length: 60 mm) N•m
Conical spring washer 2L-6 (For R-axis only)
Hexagon socket head cap screw M6 1×2 Tightening torque 16.5
(length: 25 mm) each N•m
Conical spring washer 2L-6 (For B- and T-axes)
6 Casing HW0100239-4 1
7 Retaining ring ISTW-30 1 (For R-axis only)
8 Collar HW0402544-1 1 (For R-axis only)
9 Bearing TAFI405520 1 (For R-axis only)
10 Plate HW0401506-1 1×3 (For R-, B-, and T-axes)
each
11 Plate HW0401507-1 1 (For T-axis only)
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Fig. 6-5(a): Disassembly and Reassembly of the R-, B-, T-Axis Motors
Apply sealing
bond here. 10 3
4 5
4
R-axis B-axis
10
2 9 8 7 5
T-axis
4 11 5
R-axis 1
㻭㻮㻿㻚䚷㻱㻺㻯㻻㻰㻱㻾
㼁㼀㼀㻭㻴䠉㻮㻞㻜㻾㻶
1 T-axis
B-axis 1
A
A
View A
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Fig. 6-5(b): Surface to Apply Sealing Bond on the R-, B-, and T-Axis
Motors
Apply sealing bond evenly
to whole surface.
Surface to apply
sealing bond 2
Surface to apply
sealing bond 1
Fig. 6-5(c): Removing the Key and Gear
1 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 gear and the motor.
2 Put the flat head screw driver into a space between the gear and
the motor, and tilt it in the direction of the arrow to remove the gear.
Fig. 6-5(d): Motor Power Cable

Main key
Coupling nut
Alignment mark
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7 Disassembly and Reassembly of the Speed Reducers
7.1 Disassembly and Reassembly of S-Axis Speed Reducer

• Refer to fig. 7-1(a) “Disassembly and Reassembly of the S-Axis
Speed Reducer” .
Refer to chapter 3 “Home Position Return” , chapter 5

“Notes on Grease Replenishment/Exchange Procedures” ,
and chapter 5.2 “Removing, Applying, Assembling of Seal-
NOTE
ing Bond” .
Remove old sealing from each part before starting reas-
sembling.
 Disassembly
2. Disconnect the internal wiring harness of only the rotating part of the
S-axis. (Refer to chapter 9 “Cable Wiring” .)
3. Remove the S-axis motor 7 . (Refer to chapter 6.1 “Disassembly and
Reassembly of the S-Axis Motor” .)
bolt M10 (length: 50 mm or more) into the tapped hole M10 (2 places)
on the S-head. Screw the stud bolt into the tapped hole until clearance
is made between the contact surface of the S-head and the speed
reducer 1 .
5. Lift up the upper part of the manipulator including the S-head, and put
it down next to the base. Be sure not to lose the pin 5 .
on the speed reducer 1 . Screw the stud bolt into the tapped hole
until the clearance is made between the contact surface of the base
and the speed reducer 1 .
7. Mount the eyebolts diagonally on the tapped hole M16 (2 places) on
the speed reducer 1 . Remove the speed reducer 1 vertically by
using the eyebolts. At this time, remove the O-ring 4 .
8. Remove the pins 3 from the speed reducer 1 .
9. Remove the old sealing bond on the S-head and base.
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 Reassembly

1. Apply ThreeBond 1206C to the contact surface of the base and the
speed reducer 1 . For the place to apply sealing bond, refer to "Base
side" in fig. 7-1(b) “Surface to Apply Sealing Bond on the S-Axis
Speed Reducer” .
2. Mount the O-ring 4 on the speed reducer 1 , and mount the pins 3
on the base.
While aligning the position of the pin hole on the speed reducer 1 ,
mount the unit (including the speed reducer 1 and the O-ring 4 ) on
the base. Be careful that the O-ring 4 does not get caught between
the speed reducer 1 and the base.
torque shown in table 7-1(a) “S-Axis Speed Reducer Parts Checklist
table 7-1(b) “S-Axis Speed Reducer Parts Checklist (YR-1-06VX280-
A00, -C00)” .
4. Apply ThreeBond 1206C to the contact surface of the speed reducer

1 and the S-head. For the place to apply sealing bond, refer to “S-
head side” in fig. 7-1(b).
5. Mount the S-head on the speed reducer 1 . For mounting, fit the
position of the pin hole on speed reducer 1 and the pin hole on the
S-head (refer to cross section A-A) and mount the pin 5 . Mount the
S-head on the speed reducer 1 .
7. Assemble the S-axis motor 7 , and mount the S-axis motor 7 on the
S-head.
(Refer to chapter 6.1 “Disassembly and Reassembly of the S-Axis
Motor” .)
(When replacing the speed reducer, replace the input gear 8 , too.)
8. Mount the internal wiring harness. (Refer to chapter 9 “Cable Wiring” .)
9. Remove the hexagon socket head plugs from the grease inlet and the
grease exhaust port, and then replenish grease from the grease inlet.
Mount the hexagon socket head plugs on the grease inlet and the
grease exhaust port after the replenishment of grease. (Refer to
chapter 5.1.2 “Grease Exchange Procedure” (S-axis).)

cause grease to leak.
NOTE
After tightening the screws, leave it 30 minutes or more, and
then fill with grease.
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Table 7-1(a): S-Axis Speed Reducer Parts Checklist

(YR-1-06VX215-A00, -C00, YR-1-06VX250-A00, -C00)
No. Item Qty. Note
1 Speed reducer HW0390045-A 1
2 Hexagon socket head cap screw M12 16 Tightening torque 142
Conical knurled washer SW-2H-12
3 Pin HW1405948-12-40 2
4 O-ring G415 1
5 Pin HW1405948-12-30 1
8 Input gear HW0314016-1 1
Table 7-1(b): S-Axis Speed Reducer Parts Checklist (YR-1-06VX280-A00,

-C00)
No. Item Qty. Note
3 Pin HW1405948-12-40 2
4 O-ring G415 1
5 Pin HW1405948-12-30 1
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Fig. 7-1(a): Disassembly and Reassembly of the S-Axis Speed Reducer
M12
M12
M12
View A-A
15
8 6
S-head
2
3
1
Base
Fig. 7-1(b): Surface to Apply Sealing Bond on the S-Axis Speed Reducer
Apply sealing bond evenly to Apply sealing bond evenly to

whole surface. whole surface.
S-head Side Base Side
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7.2 Disassembly and Reassembly of L-Axis Speed Reducer
NOTE Refer to chapter 10 “Disassembly and Reassembly of Bal-

ancer Unit” .
DANGER
When removing the balancer, confirm that the L-arm is firmly fixed with
the chain block, etc.
Failure to observe this caution may cause a hazardous condition due to
rotating the L-arm.
• Refer to fig. 7-2(a) “Disassembly and Reassembly of the L-Axis

Speed Reducer” .
 Disassembly
2. Support and fix the L-arm and the upper part of the manipulator to
keep the L-arm from falling off or rotating.
3. Remove the balancer 7 . (Refer to chapter 10 “Disassembly and
Reassembly of Balancer Unit” .)
4. Remove the L-axis motor 8 . (Refer to chapter 6.2 “Disassembly and
Reassembly of the L-Axis Motor” .)
5. Unscrew the hexagon socket head cap screws 4 and 5 , and insert
the stud bolt M10 (length: 40 mm or more) into the tapped hole M10 (2
places) on the L-arm 6 . Screw the stud bolt into the tapped hole until
clearance is made between the contact surface of the L-arm 6 and
the speed reducer 1 .
6. Remove the L-arm 6 from the speed reducer 1 .
bolt M8 (length: 35 mm or more) into the tapped hole M8 (2 places) on
the speed reducer 1 . Screw the stud bolt into the tapped hole until
the clearance is made between the contact surface of the S-head and
the speed reducer 1 . Remove the speed reducer 1 horizontally by
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 Reassembly

1. Mount the O-ring 3 on the speed reducer 1 .

2. Apply ThreeBond1206C to the contact surface of the S-head and the
speed reducer 1 . For the place to apply sealing bond, refer to “S-
head side” in fig. 7-2(b) “Surface to Apply Sealing Bond on the L-Axis
Speed Reducer” .
3. Mount the speed reducer 1 on the S-head, and then tighten the
hexagon socket head cap screws 2 with the tightening torque shown
in table 7-2(a) “L-Axis Speed Reducer Parts Checklist (YR-1-
06VX215-A00, -C00, YR-1-06VX250-A00, -C00)” and table 7-2(b) “L-
Axis Speed Reducer Parts Checklist (YR-1-06VX280-A00, -C00)” .
4. Apply ThreeBond1206C to the contact surface of the speed reducer
1 and the L-arm 6 .
For the place to apply sealing bond, refer to “L-arm side” in fig. 7-2(b).
5. Mount the L-arm 6 on the speed reducer 1 . Tighten the hexagon
socket head cap screws 4 and 5 with the tightening torque shown
in table 7-2(a) and table 7-2(b).
6. Assemble the L-axis motor 8 , and mount the L-axis motor on the S-
head. (Refer to chapter 6.2 “Disassembly and Reassembly of the L-
Axis Motor” .)
7. Mount the balancer 7 . (Refer to chapter 10 “Disassembly and
Reassembly of Balancer Unit” .)
Tighten the hexagon socket head plugs on the grease inlet and the
chapter 5.1.2 “Grease Exchange Procedure” (L-axis).)

NOTE
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Table 7-2(a): L-Axis Speed Reducer Parts Checklist

(YR-1-06VX215-A00, -C00, YR-1-06VX250-A00, -C00)
No. Item Qty. Note
1 Speed reducer HW0390225-B 1
2 Hexagon socket head cap screw 24 Tightening torque 142 N•m
M12 (length: 60 mm) each
3 O-ring G300 1
6 L-arm 1
7 Balancer unit 1
Table 7-2(b): L-Axis Speed Reducer Parts Checklist (YR-1-06VX280-A00,

-C00)
No. Item Qty. Note
3 O-ring G300 1
6 L-arm 1
7 Balancer unit 1
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Fig. 7-2(a): Disassembly and Reassembly of the L-Axis Speed Reducer

6
1
7
8
Apply sealing
bond here.
S-head 9 3
7-8 HW1484416 72/152

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Fig. 7-2(b): Surface to Apply Sealing Bond on the L-Axis Speed Reducer
ThreeBond 1206C
L-axis speed reducer
Border line for

applying sealing bond
Edge surface of
sealing bond
contacting part
L-arm Side S-head Side
ThreeBond 1206C
Apply sealing bond evenly from the edge surface
of sealing bond contacting part to the border line
for applying sealing bond without any break.
Apply sealing bond in the bead shape.
1
3
Bead Cross-section
(Indicated in the figure, the bead height must be

1 mm, and the width 3 mm.)
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7.3 Disassembly and Reassembly of U-Axis Speed Reducer
• Refer to fig. 7-3(a) “Disassembly and Reassembly of the U-Axis

Speed Reducer” .
 Disassembly
2. In order to prevent the U-arm unit from falling, support the U-arm unit
4 by using a chain block, etc., before removing the U-axis motor 6 .
3. Remove the U-axis motor 6 , and then remove the input gear 8 .
(Refer to chapter 6.3 “Disassembly and Reassembly of U-Axis Motor” .)
on the L-arm. Screw the stud bolt into the tapped hole until clearance
is made between the contact surface of the L-arm and the spacer 3 .
5. Remove the spacer 3 from the speed reducer 1 .
until the clearance is made between the contact surface of the casing
and the speed reducer 1 .
the speed reducer 1 . Remove the speed reducer 1 horizontally by
 Reassembly

1. Mount the O-ring 5 on the speed reducer 1 , and then mount the
speed reducer 1 on the U-arm unit 4 .
torque shown in table 7-3(a) “U-Axis Speed Reducer Parts Checklist
table 7-3(b) “U-Axis Speed Reducer Parts Checklist (YR-1-06VX280-
A00, -C00)” . When mounting, be careful that the O-ring 5 does not
get caught between the speed reducer 1 and the U-arm unit 4 .
1 and the spacer 3 . For the place to apply sealing bond, refer to
“Spacer side” in fig. 7-3(b) “Surface to Apply Sealing Bond on the U-
Axis Speed Reducer” .
4. Apply ThreeBond 1206C between the spacer 3 and the L-arm on the
side of the manipulator.
For the place to apply sealing bond to the L-arm, refer to fig. 7-3(c)
“Surface to Apply Sealing Bond Between U-axis Speed Reducer and
L-arm” .
Mount the U-arm unit 4 and spacer 3 on the L-arm, and then
tighten the hexagon socket head cap screws 2 with the tightening
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5. Mount the U-axis motor 6 . (Refer to chapter 6.3 “Disassembly and

Reassembly of U-Axis Motor” .)
chapter 5.1.2 “Grease Exchange Procedure” (U-axis).)

NOTE
Table 7-3(a): U-Axis Speed Reducer Parts Checklist

(YR-1-06VX215-A00, -C00, YR-1-06VX250-A00, -C00)
No. Item Qty. Note
3 Spacer HW0301779-1 1
4 U-arm unit 1
5 O-ring G280 1
Table 7-3(b): U-Axis Speed Reducer Parts Checklist (YR-1-06VX280-A00,

-C00)
No. Item Qty. Note
1 Speed reducer HW0388210-C 1
3 Spacer HW0301779-1 1
4 U-arm unit 1
5 O-ring G280 1
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Fig. 7-3(a): Disassembly and Reassembly of the U-Axis Speed Reducer

2 2 8 L-arm 2 3
Apply sealing
bond here.
7 1
Casing
Fig. 7-3(b): Surface to Apply Sealing Bond on the U-Axis Speed Reducer
Especially for the part A, apply sealing bond evenly without any break.
Part A whole surface.
Spacer Side
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Fig. 7-3(c): Surface to Apply Sealing Bond Between U-axis Speed

Reducer and L-arm
Apply sealing bond evenly to whole surface.
Apply sealing
bond here.
Spacer L-arm Side of the Spacer
L-arm
Apply sealing bond in the bead shape.
1
3
Bead Cross-section
(Indicated in the figure, the bead height
must be 1 mm, and the width 3 mm.)
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7.4 Disassembly and Reassembly of R-Axis Speed Reducer

• Refer to fig. 7-4(a) “Disassembly and Reassembly of the R-Axis
Speed Reducer” .
 Disassembly
2. Remove the wrist unit 4 from the speed reducer 1 . (Refer to
chapter 8 “Disassembly and Reassembly of Wrist Unit” .)
until the clearance is made between the contact surface of the U-arm
5 and the speed reducer 1 .
4. Remove the speed reducer 1 from the U-arm 5 .
 Reassembly

1. Apply ThreeBond 1206C to the contact surface of the U-arm 5 and

the speed reducer 1 . For the place to apply sealing bond, refer to
“U-arm side” in fig. 7-4(b) “Surface to Apply Sealing Bond on the R-
Axis Speed Reducer” .
2. Mount the U-arm 5 on the speed reducer 1 , and then tighten the
in table 7-4(a) “R-Axis Speed Reducer Parts Checklist (YR-1-
06VX215-A00, -C00, YR-1-06VX250-A00, -C00)” and table 7-4(b) “R-
Axis Speed Reducer Parts Checklist (YR-1-06VX280-A00, -C00)” .
3. Apply ThreeBond 1206C to the contact surface of the wrist unit 4
and the speed reducer 1 . For the place to apply sealing bond, refer
to “Wrist base side” in fig. 7-4(b).
4. Mount the O-ring 6 on the wrist unit 4 , and then mount the wrist
unit 4 on the speed reducer 1 .
Refer to chapter 8 “Disassembly and Reassembly of Wrist Unit” . Be
careful that the O-ring 6 does not get caught between the speed
reducer 1 and the wrist unit 4 .
chapter 5.1.2 “Grease Exchange Procedure” (R-axis).)

NOTE
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Table 7-4(a): R-Axis Speed Reducer Parts Checklist (YR-1-06VX215-A00,

-C00, YR-1-06VX250-A00, -C00)
No. Item Qty. Note
2 Hexagon socket head cap screw M10 16 Tightening torque 82 N•m
4 Wrist unit HW1173014-A 1
5 U-arm 1
6 O-ring G140 1
Table 7-4(b): R-Axis Speed Reducer Parts Checklist (YR-1-06VX280-A00,

-C00)
No. Item Qty. Note
4 Wrist unit HW1172979-A 1
5 U-arm 1
6 O-ring G140 1
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Fig. 7-4(a): Disassembly and Reassembly of the R-Axis Speed Reducer
A
5 1 2
6
4
View A-A
A
Fig. 7-4(b): Surface to Apply Sealing Bond on the R-Axis Speed Reducer
Apply sealing bond evenly to Apply sealing bond evenly
whole surface. to whole surface.
U-arm Side Wrist Unit Side
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7.5 Disassembly and Reassembly of B-Axis Speed Reducer
7.5.1 YR-1-06VX215-A00, -C00, YR-1-06VX250-A00, -C00
• Refer to fig. 7-5(a) “Disassembly and Reassembly of the B-Axis

Speed Reducer” .
 Disassembly
2. Unscrew the hexagon socket head cap screws 3 , and then remove
the cover 2 .
3. In order to prevent the B-axis from rotating, fixing the B-axis is

necessary before removing the speed reducer 1 .
4. Unscrew the hexagon socket head cap screws 4 and 6 , and insert
the stud bolt M10 (length: 25 mm or more) into the tapped hole M10 (2
places) on the speed reducer 1 . Screw the stud bolt into the tapped
hole until clearance is made between the contact surface of the wrist
10 and the speed reducer 1 .
5. Remove the speed reducer 1 , shim 8 , gear 9 , bearing 11 , and

O-ring 5 altogether from the wrist 10 .
6. Unscrew the hexagon socket head cap screws 7 , and remove the
shim 8 , gear 9 , and bearing 11 from the speed reducer 1 .
(When removing the gear 9 , use the tapped holes.)
 Reassembly

1. Adjust the shim before mounting the gear 9 .
2. Mount the bearing 11 , shim 8 , and gear 9 on the speed reducer

1 , and then tighten the hexagon socket head cap screws 7 with the
tightening torque shown in table 7-5 “B-Axis Speed Reducer Parts
Checklist (YR-1-06VX215-A00, -C00, YR-1-06VX250-A00, -C00)” .

1 and the wrist 10 . For the place to apply sealing bond, refer to
“Wrist base side” in fig. 7-5(b) “Surface to Apply Sealing Bond on the
B-Axis Speed Reducer” .
4. Tighten the hexagon socket head cap screws 4 and 6 with the
tightening torque shown in table 7-5.
5. Mount the O-ring 5 and cover 2 on the speed reducer 1 , and

then tighten the hexagon socket head cap screws 3 with the
chapter 5.1.2 “Grease Exchange Procedure” (B-axis).)
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NOTE
Table 7-5: B-Axis Speed Reducer Parts Checklist

(YR-1-06VX215-A00, -C00, YR-1-06VX250-A00, -C00)
No. Item Qty. Note
2 Cover HW0315877-1 1
5 O-ring G195 1
8 Shim HW0402205
9 Gear HW0306792-1 1
10 Wrist HW0102836-1 1
11 Bearing 6009 1
Retaining ring C-type STW-45 each
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Fig. 7-5(a): Disassembly and Reassembly of the B-Axis Speed Reducer

7 6
10
HR32004XJ
HR32004XJ
11
4 8 2 1 5 3
11 8 7 9 6
0.5 (shim)
22 ±0.1
*21.5
Shim adjustment:
When installing the gear 9 , measure the space
indicated with “*” mark, and select a shim to meet
the dimensions in this figure.
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Fig. 7-5(b): Surface to Apply Sealing Bond on the B-Axis Speed Reducer
Apply sealing bond evenly
to whole surface.
Wrist Base Side
7.5.2 YR-1-06VX280-A00, -C00
• Refer to fig. 7-6(a) “Disassembly and Reassembly of the B-Axis

Speed Reducer” .
 Disassembly
the cover 2 .
3. In order to prevent the B-axis from rotating, fixing the B-axis is

necessary before removing the speed reducer 1 .
4. Unscrew the hexagon socket head cap screws 4 , 5 , and 6 , and

insert the stud bolts M6 (length: 35 mm or more) into the tapped hole
M6 (4 places) on the speed reducer 1 . Screw the stud bolt into the
tapped holes until the clearance is made between the contact surface
of the wrist 10 and the speed reducer 1 .
5. Remove the speed reducer 1 , shim 8 , gear 9 , bearing 11 , and

O-ring 12 altogether from the wrist 10 .
shim 8 , gear 9 , bearing 11 , and O-ring 12 from the speed reducer
1 . (When removing the gear 9 , use the tapped holes.)
 Reassembly

2. Mount the bearing 11 , shim 8 , and gear 9 on the speed reducer

1 , and then tighten the hexagon socket head cap screws 7 with the
tightening torque shown in table 7-6 “B-Axis Speed Reducer Parts
Checklist (YR-1-06VX280-A00, -C00)” .
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1 and the wrist 10 , and then tighten the hexagon socket head cap
screws 4 , 5 , and 6 with the tightening torque shown in table 7-6
“B-Axis Speed Reducer Parts Checklist (YR-1-06VX280-A00, -C00)” .
For the place to apply sealing bond, refer to “Wrist base side” in
fig. 7-6(c) “Surface to Apply Sealing Bond on the B-Axis Speed
Reducer” .
Note: Apply ThreeBond 1206C to the thread part of the hexagon
socket head cap screws 4 .
4. Mount the O-ring 12 on the speed reducer 1 .
5. Mount the cover 2 on the wrist 10 .
chapter 5.1.2 “Grease Exchange Procedure” (B-axis).)

NOTE
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Table 7-6: B-Axis Speed Reducer Parts Checklist (YR-1-06VX280-A00,

-C00)
No. Item Qty. Note
1 Speed reducer 1
HW9381453-B (-A00)
HW9381453-G (-C00)
2 Cover HW9302370-1 1
3 Hexagon socket head cap screw M6 6 Tightening torque 13.75
8 Shim HW0402205
9 Gear HW0306792-1 1
10 Wrist HW0100243-1 1
11 Bearing 6009 1
Retaining ring C-type STW-45 each
12 O-ring G220 1
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Fig. 7-6(a): Disassembly and Reassembly of the B-Axis Speed Reducer

6 7 5
HR32004XJ
HR32004XJ
1
11
12 4 8 2 1 3 10
Fig. 7-6(b): Disassembly and Reassembly of B-Axis Speed Reducer

(Shim Adjustment)
0.5 (shim)
22 ±0.1
7 5
*21.5
11
9 8
Shim adjustment:
When installing the gear 9 , measure the space
indicated with “*” mark, and select a shim to meet
the dimensions in this figure.
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Fig. 7-6(c): Surface to Apply Sealing Bond on the B-Axis Speed Reducer
Apply sealing bond evenly to whole surface.
Apply sealing
Apply sealing bond evenly to bond here.
whole surface.
Wrist Base Side Cover
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7.6 Disassembly and Reassembly of T-Axis Speed Reducer
• Refer to fig. 7-7(a) “Assembling View of T-axis (Disassembly and

Reassembly of Speed Reducer)” .
 Disassembly
the flange 3 and spacer 10 .
bolt M6 (length: 35 mm or more) into the tapped hole M6 (2 places) on
the speed reducer 1 . Screw the stud bolt into the tapped hole until
the clearance is made between the contact surface of the wrist 9 and
4. Remove the speed reducer 1 , gear 5 , shim 6 , bearing 8 , and
retaining ring 9 altogether from the wrist 9 .
the gear 5 , shim 6 , bearing 8 , and retaining ring 9 from the
speed reducer 1 .
6. Remove the O-ring 11 from the speed reducer 1 .
 Reassembly


2. Mount the gear 5 , shim 6 , bearing 8 , retaining ring 9 , and O-
ring 11 on the speed reducer 1 . Tighten the hexagon socket head
cap screws 7 with the tightening torque shown in table 7-7(a) “T-
Axis Speed Reducer Parts Checklist (YR-1-06VX215-A00, -C00, YR-
1-06VX250-A00, -C00)” and table 7-7(b) “T-Axis Speed Reducer
Parts Checklist (YR-1-06VX280-A00, -C00)” .
3. Apply ThreeBond 1206C between the speed reducer 1 and the wrist
12 . For the place to apply sealing bond, refer to "Wrist side of the
speed reducer" in fig. 7-7(b) “Surface to Apply Sealing Bond on the T-
axis Speed Reducer (T-axis Speed Reducer_Spacer)” .
4. Make sure that the speed reducer is mounted in the correct direction
by referring to fig. 7-7(a) “Assembling View of T-axis (Disassembly
and Reassembly of Speed Reducer)” and mount the speed reducer
1 on the wrist 12 . Tighten the hexagon socket head cap screws 4
with the tightening torque shown in table 7-7(a) and table 7-7(b).
5. Apply ThreeBond1206C to the contact surface of the speed reducer
1 and the spacer 10 , and the contact surface of the spacer 10 and
the flange 3 . For the place to apply sealing bond, refer to "Spacer
side" in fig. 7-7(b) and fig. 7-7(c) “Surface to Apply Sealing Bond on
the T-axis Speed Reducer (Spacer_Flange)” .
6. Mount the spacer 10 and flange 3 on the speed reducer 1 . Mount
the spacer 10 by aligning it with the grease hole on the flange 3 .
7. Mount the spacer 10 , flange 3 , and speed reducer 1 by using the
hexagon socket head cap screws 2 , tighten them with the tightening
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chapter 5.1.2 “Grease Exchange Procedure” (T-axis).)

NOTE
Table 7-7(a): T-Axis Speed Reducer Parts Checklist

(YR-1-06VX215-A00, -C00, YR-1-06VX250-A00, -C00)
No. Item Qty. Note
1 Speed reducer HW0380794-A (-A00) 1
HW0380794-F (-C00)
(length: 20 mm) *FA coat* each N•m
Conical spring washer 2L-8 *FA coat*
3 Flange HW0302422-2 1
5 Gear HW0306790-1 1
6 Shim HW0402206
8 Bearing 6006 1
9 Retaining ring STW-30 1
10 Spacer HW0301782-1 1
11 O-ring ARP568-263 1
12 Wrist HW0102836-1 1
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Table 7-7(b): T-Axis Speed Reducer Parts Checklist (YR-1-06VX280-A00,

-C00)
No. Item Qty. Note
1 Speed reducer HW0380794-A (-A00) 1
HW0380794-F (-C00)
(length: 20 mm) *FA coat* each N•m
Conical spring washer 2L-8 *FA coat*
3 Flange HW0302422-2 (-A00) 1
HW0302422-3 (-C00)
5 Gear HW0306790-1 1
6 Shim HW0402206
8 Bearing 6006 1
9 Retaining ring STW-30 1
10 Spacer HW0301782-1 1
11 O-ring ARP568-263 1
12 Wrist HW0100243-1 1
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Fig. 7-7(a): Assembling View of T-axis (Disassembly and Reassembly of

Speed Reducer)
11 9 1 4 10
12
HR32004XJ
3
HR32004XJ
1 (shim)
52.5±0.1
6 8 9
Shim adjustment:
When installing the gear 5 , select a shim to
meet the dimensions as shown in this figure.
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Fig. 7-7(b): Surface to Apply Sealing Bond on the T-axis Speed Reducer
(T-axis Speed Reducer_Spacer)
Apply sealing bond evenly to whole surface. Apply sealing bond evenly
to whole surface.
Wrist Side of the Speed Reducer Spacer Side

Fig. 7-7(c): Surface to Apply Sealing Bond on the T-axis Speed Reducer
(Spacer_Flange)
whole surface.
Apply sealing
bond here.
Spacer Flange Side of the Spacer
Flange
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HW1484416
8 Disassembly and Reassembly of Wrist Unit
• Refer to fig. 8-1 “Disassembly and Reassembly of Wrist Unit” .
Refer to chapter 2 “Notes for Maintenance” and chapter 3

“Home Position Return” .
NOTE
Remove old sealing from each part before starting assem-
bling.
 Disassembly
1. Make the wrist a 90° angle to the U-arm (refer to fig. 8-1 “Disassembly
and Reassembly of Wrist Unit” ), and then, turn OFF the power supply
of the YRC1000.
2. Unscrew the GT-SA bolts 6 , and then remove the cover 5 .
3. Unscrew the magic screws 7 and remove the B nut 8 .
4. Remove the gear 9 . (Be sure not to lose the shim 10 ).
wrist unit 1 from the speed reducer 4 by using the tapped holes on
the wrist base 2 .
 Reassembly
1. Apply sealing bond ThreeBond 1206C to the contact surface of the
wrist unit 1 and the speed reducer 4 , and then mount the wrist unit
1 on the speed reducer 4 . At this time, mount the wrist unit 1 on
the speed reducer 4 with the gear 9 not mounted to the wrist unit
1 .
torque shown in table 8-1 “Wrist Unit Parts Checklist (YR-1-06VX215-
A00, -C00, YR-1-06VX250-A00, -C00)” and table 8-2 “Wrist Unit
Parts Checklist (YR-1-06VX280-A00, -C00)” .
3. Mount the retaining ring 12 and bearing 11 on the gear 9 .
4. Mount the gear 9 and shim 10 on the wrist unit 1 .
5. Measure the backlash in the gear 9 and adjust the shim. Use a
small micrometer and determine the number of shims so that the
backlash is 0.05 mm to 0.1 mm in the gear pitch diameter.
6. Tighten the B nut 8 with the tightening torque shown in table 8-1 and
table 8-2.
7. Apply LOCTITE 243 to the thread part of the magic screws 7 , and
then tighten them with the tightening torque shown in table 8-1 and
table 8-2.
8. Apply ThreeBond 1206C to the mounting surface of the cover 5 .

Mount the cover 5 by using the GT-SA bolts 6 , and tighten them
with the tightening torque shown in table 8-1 and table 8-2.
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Table 8-1: Wrist Unit Parts Checklist

(YR-1-06VX215-A00, -C00, YR-1-06VX250-A00, -C00)
No. Item Qty. Note
1 Wrist unit HW1173014-A (-A00) 1
HW1173014-B (-C00)
2 Wrist base 1
5 Cover HW0409072-1 1
6 GT-SA bolt M4 (length: 12 mm) 4 Tightening torque 4.8 N•m
7 Magic screw M5 (length: 7 mm) 2 Tightening torque 4 N•m
8 B nut HW0411721-1 1 Tightening torque 12.4
N•m
9 Gear HW0309518-1 1
10 Shim HW0410868-1 to 4
11 Bearing 6007 1
Note: Ready a small micrometer for adjusting the shims.
Table 8-2: Wrist Unit Parts Checklist (YR-1-06VX280-A00, -C00)

No. Item Qty. Note
1 Wrist unit HW1172979-A (-A00) 1
HW1172979-B (-C00)
2 Wrist base 1
5 Cover HW0409072-1 1
6 GT-SA bolt M4 (length: 12 mm) 4 Tightening torque 4.8 N•m
7 Magic screw M5 (length: 7 mm) 2 Tightening torque 4 N•m
8 B nut HW0411721-1 1 Tightening torque 12.4
N•m
9 Gear HW0309518-1 1
10 Shim HW0410868-1 to 4
11 Bearing 6007 1
Note: Ready a small micrometer for adjusting the shims.
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Fig. 8-1: Disassembly and Reassembly of Wrist Unit

2
1
11 9
10
12
4 3
9
U-arm
Wrist
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HW1484416
9 Cable Wiring
9.1 Disassembly and Reassembly of Internal Wiring Harness
9 Cable Wiring
NOTE Refer to chapter 2 “Notes for Maintenance” and chapter 3

“Home Position Return” .
 Disassembly
1. Connectors for Internal User I/O Wiring Harness of the
Casing
• Refer to table 9-1 “Internal Wiring Harness Parts Checklist (Connec-
tors for Internal User I/O Wiring Harness)” and fig. 9-1 “Disassem-
bly and Reassembly of Internal Wiring Harness (Connectors for
Internal User I/O Wiring Harness)” .
2. Unscrew the hexagon socket head cap screws 2 which are mounted
on the side of the casing, and then remove the cover 1 .
3. Unscrew the pan-head sems screws 3 which are mounted on the
cover 1 , and remove the connector.
4. Remove the air line connected to the back of the union 4 from the
cover.
Table 9-1: Internal Wiring Harness Parts Checklist

(Connectors for Internal User I/O Wiring Harness)
No. Item Qty. Note
1 Cover HW0405047-1 (-A00) 1
HW1409749-A (-C00)
3 Pan-head sems screw M4 2 (-A00)
(length: 16 mm) *stainless* each
Nut M4 *stainless*
Pan-head sems screw M4 2 (-C00)
(length: 10 mm) *stainless*
4 Union KQ2E12-03A 2
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9 Cable Wiring
Fig. 9-1: Disassembly and Reassembly of Internal Wiring Harness

(Connectors for Internal User I/O Wiring Harness)
Air line (Blue)
Air line (Black)
1
2
For the internal user
A
3
I/O wiring harness
B
4
Connector for the internal
user I/O wiring harness
Position of the main key
Details of the Connector for

the Internal User I/O Wiring Harness
2. Casing
• Refer to table 9-2 “Internal Wiring Harness Parts Checklist (Casing)”
and fig. 9-2 “Disassembly and Reassembly of the Internal Wiring
Harness (Casing)” .
1. Unscrew the cross head APS bolts 2 and remove the cover 3 .
2. Remove the “IN” connector of the internal wiring harness 1 from the
“IN” port of the multi-port connector on the motor side in the casing.
3. Cut off cable ties 4 , 5 , and 6 .
4. Turn the connector on the cable side of the power connector for the U-,
R-, B-, and T-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.
5. Unscrew the hexagon socket head cap screws 7 and then remove
internal wiring harness 1 together with the support.
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9 Cable Wiring
Table 9-2: Internal Wiring Harness Parts Checklist (Casing)

No. Item Qty. Note
1 Internal wiring HW1173141-A 1 YR-1-06VX280-A00
harness HW1173141-B 1 YR-1-06VX215-A00
YR-1-06VX250-A00
HW1173683-A 1 YR-1-06VX280-C00
HW1173683-B 1 YR-1-06VX215-C00
YR-1-06VX250-C00
2 Cross head APS bolt M4 (length: 8 3
mm) *trivalent chromate*
3 Cover HW1307162-1 1
4 Cable tie T18L-HSW 1
5 Cable tie T50R-HSW 6
6 Cable tie T120R-HSW 2 pcs
(2 places)
7 Hexagon socket head cap screw 3 each Tightening torque 10 N•m
M6 (length: 16 mm) *trivalent
chromate*
Washer M6 *stainless*
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9 Cable Wiring
Fig. 9-2: Disassembly and Reassembly of the Internal Wiring Harness

(Casing)
6 2 6
7
3
1
Support
Casing
IN (Internal wiring harness)

(Internal
wiring harness) (Internal wiring
4 harness)
A
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9 Cable Wiring
3. L-Arm
• Refer to table 9-3 “Internal Wiring Harness Parts Checklist (L-Arm)”
and fig. 9-3 “Disassembly and Reassembly of the Internal Wiring
Harness (L-Arm)” .
1. Unscrew the hexagon socket head cap screws 2 and remove the
plate 1 .
2. Unscrew the hexagon socket head cap screws 4 and then remove
the saddles 3 .
3. Cut off cable ties 5 .
Table 9-3: Internal Wiring Harness Parts Checklist (L-Arm)

No. Item Qty. Note
1 Plate HW0403915-1 1
2 Hexagon socket head cap screw 2 each Tightening torque 6 N•m
M5 (length: 12 mm) *trivalent
chromate*
3 Saddle CD36 2
4 Hexagon socket head cap screw 2 screws Tightening torque 10 N•m
M6 (length: 16 mm) *trivalent (2 places)
chromate*

(L-Arm)
3
2
1
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9 Cable Wiring
4. S-Head
• Refer to table 9-4 “Internal Wiring Harness Parts Checklist (S-
Head)” and fig. 9-4 “Disassembly and Reassembly of the Internal
Wiring Harness (S-Head)” .
2. Unscrew the hexagon socket head cap screws 2 and remove the
plate 1 .
3. Unscrew the cross head APS bolts 4 and remove the cover 3 .
5. Remove the “IN” and “OUT” connectors of the internal wiring harness
from the “IN” and “OUT” ports of the multi-port connector in the S-
head.
6. Cut off the cable ties 7 .
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.
Table 9-4: Internal Wiring Harness Parts Checklist (S-Head)

No. Item Qty. Note
1 Plate HW0403915-1 1
(length: 12 mm) *trivalent chromate* each
Conical spring washer 2H-5 *trivalent
chromate*
3 Cover HW1408867-1 1
mm) *trivalent chromate*
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9 Cable Wiring

(S-Head)
(Internal wiring harness)
6
1
2
6
6
(Internal wiring 7
harness)
5
3 4
OUT
IN
S
L
IN
(Internal wiring
harness)
OUT
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9 Cable Wiring
5. Connector Base
tor Base)” and fig. 9-5 “Disassembly and Reassembly of the Internal
Wiring Harness (Connector Base)” .
1. Unscrew the cross head APS bolts 1 which are fixing the connector
base. 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.
2. Pull out the connector base further, and unscrew the cross head APS
bolts 2 which are mounted on the connector base. Remove the
ground lead wire.
3. Cut off the cable tie 3 .
4. Remove the air line connected to the back of the union from the
connector base.
5. Unscrew the pan-head sems screws 4 which are mounted on the

connector base, and then remove the gasket 5 and connector of the
internal user I/O wiring harness.
6. Remove the connectors (5 places), except for CN4, connected to the

back side of the 1BC connector. The 1BC connectors are 1, 2, 3, 4, 5
and 6 from the top to the bottom.
7. Cut off the cable tie 6 and disconnect the tube 7 .
the saddle 9 and saddle 10 .
9. Cut off the connector sticking out from the connector base box, and
then pull out the internal wiring harness from the top of the S-head.
Table 9-5: Internal Wiring Harness Parts Checklist (Connector Base)

No. Item Qty. Note
mm) *stainless*
mm) *stainless*
4 Pan-head sems screw M4 (length: 16 2 (-A00)
mm) *stainless* each
Nut M4 *stainless*
Pan-head sems screw M4 (length: 8 2 (-C00)
mm) *stainless*
5 Gasket HW9481087-E 1 (-A00 only)
7 Tube HW9406005-A 1
9 Saddle CD-51 1
10 Saddle CD-42 1
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9 Cable Wiring

(Connector Base)
Union
(Air line (Black))
1
Union Union
(Air line (Blue)) FB
(Grease inlet)
A B
1BC
S1
S-axis grease hose
1BC connector Connector base

Connector for
(White marking)
internal user I/O wiring harness Connector joint part A
7 (Coming from the board for
9 8 the encoder power box)
10 Tube for replenishment:
Connector joint part B
Connect to the union
(For LAMP)
(KQ2L10-01S)
2
3 Board for the encoder power box
6
Position of the main key Position of the main key

4
4
5
Details of the Connector for the Internal Details of the Connector for the Internal
User I/O Wiring Harness (-A00) User I/O Wiring Harness㻌(-C00)
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9 Cable Wiring
 Reassembly
1. Connector Base
tor Base)” and fig. 9-5 “Disassembly and Reassembly of the Internal
Wiring Harness (Connector Base)” .
1. Put the internal wiring harness through the manipulator from the top
part of the S-head.
2. Connect the connector of the connector base box.
3. Connect [LAMP] and [External axis] sticking out from the connector
which are inserted into 4CN of the 1BC connector with the connector
sticking out from the internal wiring harness.
4. Mount the internal wiring harness on the connector base by using the
saddle 9 and saddle 10 , and tighten the hexagon socket head cap
screws 8 with the tightening torque shown in table 9-5. It must be
fixed in position with the white mark on the internal wiring harness
facing directly upward.
5. Mount the connector for the internal user I/O wiring harness together
with the gasket 5 on the connector base unit, and then tighten it with
pan-head sems screws 4 .
6. Connect the 1BC connector.
7. Connect the air line to the union.
8. Mount the ground lead wires (3 wires) by using the cross head APS
bolts 2 .
9. Cover the connectors with tube 7 , and then tie the openings of the
tube 7 by using the cable ties 6 .
10. Connect the grease hose to the back side of the connector base unit.
11. Mount the cross head APS bolts 1 , and then mount the connector
base on the manipulator.
2. S-Head
• Refer to fig. 9-4 “Disassembly and Reassembly of the Internal Wir-
ing Harness (S-Head)” and table 9-4 “Internal Wiring Harness Parts
Checklist (S-Head)” .
1. Mount the internal wiring harness on the plate 1 by using the
hexagon socket head cap screws 2 , and tighten them with the
tightening torque shown in table 9-4. Fix the white-marked part of the
internal wiring harness by using the cable ties 6 .
2. Connect the “IN” port and the “OUT” port of the multi-port connector of
the S-head to the “IN” connector and the “OUT” connector of the
internal wiring harness respectively.
3. Fix together the “IN” and “OUT” lead wires of the internal wiring
harness and the lead for the encoder of the S- and L-axis by using the
cable tie 7 .
4. Mount the cover 3 by using the hexagon socket head cap screws
4 , and tighten them with the tightening torque shown in table 9-4.
5. 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.
6. Fix the internal wiring harness around the S-head with the cable ties
5 .
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9 Cable Wiring
3. L-Arm
ing Harness (L-Arm)” and table 9-3 “Internal Wiring Harness Parts
Checklist (L-Arm)” .
1. Set the Velcro part of the shield tubing (zipper type) alongside the L-
arm.
2. Mount the hexagon socket head cap screws 4 on the saddle 3 with
the tightening torque shown in table 9-3, and then fix the internal wiring
harness. (2 places)
When fixing the internal wiring harness, position it so that the white
marking is on the opposite side of the saddle 3 .
3. Mount the hexagon socket head cap screws 2 on the plate 1 with
the tightening torque shown in table 9-3, and then fix the internal wiring
harness.
4. Casing
ing Harness (Casing)” and table 9-2 “Internal Wiring Harness Parts
Checklist (Casing)” .
1. Put the internal wiring harness 1 through the inside of the casing.
2. Mount the support by using the hexagon socket head cap screws 7 ,
and tighten them with the tightening torque shown in table 9-2.
3. Connect the “IN” port of the multi-port connector on the R-, B-, and T-
axis motor side of the casing to the “IN” connector of the internal wiring
harness.
4. Fix the lead wire (6 wires) sticking out from the multi-port connector of
the casing by using the cable tie 4 .
5. Mount the cover 3 by using the cross head APS bolts 2 .
6. Insert the power connector to the U-, R-, B-, and 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.
7. Fix the internal wiring harness by using the cable ties 5 .
5. Connectors for Internal User I/O Wiring Harness of the

Casing
tors for Internal User I/O Wiring Harness)” and fig. 9-1 “Disassem-
bly and Reassembly of Internal Wiring Harness (Connectors for
1. Mount the connector for the internal user I/O wiring harness on the
cover 1 by using the pan-head sems screws 3 .
Mount the connector with the key position as indicated in the detailed
figure of the connector for the internal user I/O wiring harness in
fig. 9-1.
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HW1484416
9 Cable Wiring
2. Connect the air line to the union from the back of the cover.
3. Mount the cover 1 on the side face of the casing by using the cross
head APS bolts 2 , and tighten them with the tightening torque shown
in table 9-1 “Internal Wiring Harness Parts Checklist (Connectors for
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HW1484416
10 Disassembly and Reassembly of Balancer Unit
10.1 Notes when Disassembling and Reassembling the Balancer Unit
10.1 Notes when Disassembling and Reassembling the

Balancer Unit
Carefully read and observe the precautions below when disassembling

and reassembling the balancer unit.
NOTICE
• Do not damage the rod part of the balancer unit.
• Do not apply any horizontal forces to the rod part.
• When lifting the balancer unit, do not attach lifting jigs to the rod part
and/or clevis.
• Do not use the balancer unit with foreign substances at the rod part
or the entry of the rod to the cylinder.
Failure to observe this may damage the sealing inside the balancer
unit, and this may cause the grease leakage or abnormal noise.
DANGER
• Be sure to mount the spring fixing bolts when removing the balancer
unit from the manipulator. If the balancer is removed without the
spring fixing bolts, the rod will rapidly shrink which may result in
injury or accident.
• Before removing the balancer unit from the manipulator, confirm
that the L-axis motor brake is appropriately functioning and L-axis is
firmly secured with a chain block, etc., to prevent it from rotating.
Failure to observe this instruction may rotate the L-axis and cause a
hazardous condition.
• Before unscrewing the spring fixing bolts, confirm that the L-axis
motor brake is appropriately functioning.
Fig. 10-1: Notes when Disassembling and Reassembling the Balancer

Unit
Spring fixing bolt
Clevis
Rod
Although the balancer unit position would not deviate when

NOTE disassembled and reassembled, refer to chapter 3 “Home
Position Return” before replacement just in case.
10-1 HW1484416 109/152

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10.2 Disassembly and Reassembly of Balancer Unit

• Refer to fig. 10-2 “Spring Fixing Bolts Mounted” and fig. 10-3 “Bal-
ancer Installation Diagram” .
 Disassembly
Although the balancer unit position would not deviate when

NOTE disassembled and reassembled, refer to chapter 3 “Home
Position Return” before replacement just in case.
1. Make the L-arm of the manipulator vertical to the ground.

2. Remove the hexagon socket head cap screws 5 and mount 3 spring
fixing bolts M8 or M10 instead. Push up 3 points evenly about 5 mm of
the flange which is located inside of the balancer unit assembly 1 so
that the spring force is not applied to the rod of the balancer unit
assembly.
Fig. 10-2: Spring Fixing Bolts Mounted
Balancer unit assembly
Rod (spring force applied) Flange
Spring fixing bolt

Spring pressure Spring pressure
direction direction
Rod
(free from spring force)
Spring pressure Spring pressure

direction Space (approx. 5 mm)
direction
Spring
3. Remove the hexagon socket head cap screws 6 .
4. Mount fully threaded screws M12 for removal on the shaft assembly
(knuckle part) 2 , then remove the shaft assembly (knuckle part) 2 .
DANGER
• Be sure to mount the spring fixing bolts when removing the balancer
unit from the manipulator. If the balancer is removed without the
spring fixing bolts, the rod will rapidly shrink which may result in
injury or accident.
• Before removing the balancer unit from the manipulator, confirm
that the L-axis motor brake is appropriately functioning and L-axis is
firmly secured with a chain block, etc., to prevent it from rotating.
5. In order to prevent the balancer unit assembly 1 from falling, support

it by using a chain block, etc.
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HW1484416
6. Remove the hexagon socket head cap screws 7 and mount 2 fully
threaded screws M8 for removal on the B-cover 8 . Then remove the
B-cover 8 and shim 9 .
7. Only when replacing the balancer unit: remove the O-ring 10 .
threaded screws M6 for removal on the shaft assembly (support part
1) 3 . Then remove the shaft assembly (support part 1) 3 and the
outer ring of the tapered roller bearing 12 .
threaded screws M8 for removal on the B-cover 14 . Then remove the
B-cover 14 .
10. Only when replacing the balancer unit: remove the O-ring 15 .
threaded screws M6 for removal on the shaft assembly (support part
2) 4 . Then remove the shaft assembly (support part 2) 4 and the
outer ring of the tapered roller bearing 17 .
12. Put the balancer unit assembly 1 down next to the manipulator.
13. Only when replacing the balancer unit: unscrew the spring fixing bolts
mounted on the rear of the balancer unit assembly 1 .
14. Only when replacing the balancer unit: remove the oil seals 18 and 19
from the S-head.
 Reassembly
NOTE Refer to chapter 5.2 “Removing, Applying, Assembling of

Sealing Bond” .
1. Only when replacing the balancer unit: assemble the unit assembly.
Refer to chapter 10.3 “Unit Assembly” .
2. Remove the old sealing bond adhering on the S-head, the B-cover 8
and 14 .
3. Only when replacing the balancer unit: mount the oil seals 18 and 19
on the S-head. (Apply Alvania EP Grease 2 on the lip parts of the oil
seals.)
4. Lift up the balancer unit assembly 1 , then put it down on its mounting
position.
shaft assembly (support part 2) 4 and the balancer unit 1 .
6. Mount the shaft assembly (support part 2) 4 on the balancer unit
assembly 1 .
7. Apply sealing bond ThreeBond 1206C on the thread parts of the
hexagon socket head cap screws 16 and tighten them with the
tightening torque shown in table 10-1 “Balancer Unit Parts Checklist” .
8. Insert the outer ring of the tapered roller bearing 17 on the S-head.
9. Only when replacing the balancer unit: mount the O-ring 15 on the B-
cover 14 .
10. Mount the B-cover 14 on the S-head. (Be careful that the O-ring does
not get caught between the parts.)
10-3 HW1484416 111/152

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torque shown in table 10-1 “Balancer Unit Parts Checklist” .
shaft assembly (support part 1) 3 and the balancer unit assembly 1 .
13. Mount the shaft assembly (support part 1) 3 on the balancer unit
assembly 1 .
14. Apply sealing bond ThreeBond 1206C on the thread parts of the
hexagon socket head cap screws 11 , and tighten them with the
15. Insert the outer ring of the tapered roller bearing 12 into the S-head.
16. Only when replacing the balancer unit: mount the O-ring 10 on the B-
cover 8 .
17. Only when replacing the balancer unit: mount the B-cover 8 on the S-
head. (Be careful that the O-ring does not get caught between the
parts.)
18. Only when replacing the balancer unit: tighten the hexagon socket
head cap screws 7 with the light tightening torque shown in
table 10-1. Proceed to Step 21.
19. Mount the B-cover 8 and shim 9 on the S-head. (Be careful that the
O-ring does not get caught between the parts.)
21. Push the flange inside the balancer evenly with the spring fixing bolts
(or hexagon socket head cap screws 20 ) to free the rod in the balancer
unit assembly 1 .
22. Only when replacing the balancer unit: if the thread length with the
hexagon socket head cap screws 20 is short, use 3 fully threaded
spring fixing bolts M8 or M10 instead.
23. Align the center of the hole in the L-arm and the center of the hole in
the balancer unit assembly 1 . Pass the shaft assembly (knuckle part)
2 through the L-arm and balancer unit assembly 1 .
25. Unscrew the spring fixing bolts (or hexagon socket head cap screws
20 ), and replace them with the hexagon socket head cap screws 5 .
DANGER
• Before unscrewing the spring fixing bolts, confirm that the L-axis
motor brake is appropriately functioning.
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27. Remove the chain block, etc., that is supporting the balancer unit
assembly 1 .
When not replacing the balancer unit: the reassembly work is finished.
Only when replacing the balancer unit: perform the following work.
28. Measure the space between the B-cover 8 and S-head at the
positions (a) and (b).
29. If there is not enough space (50 micrometer or less), tighten the
in table 10-1 “Balancer Unit Parts Checklist” .
30. If there is enough space, remove the B-cover 8 and the hexagon
socket head cap screws 7 , and insert the shim 9 , whose thickness
is about the average of the space at the (a) and (b).
Select shims from the table below.
Drawing No. Thickness of shim
HW9405195-1 0.05 mm
HW9405195-2 0.1 mm
HW9405195-3 0.3 mm
HW9405195-4 0.4 mm
HW9405195-5 0.5 mm
HW9405195-6 0.6 mm
HW9405195-7 0.7 mm
31. Mount the B-cover 8 on the S-head. (Be careful that the O-ring does
not get caught between the parts.)
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Table 10-1: Balancer Unit Parts Checklist

No. Item Qty. Note
1 Balancer unit assembly 1
Balancer unit 1
HW0171165-G
Oil seal VB60787 1
Needle bearing NA6912 1 Outer ring
Retaining ring AR85 1
Oil seal VB75956 1
2 Shaft assembly (knuckle part) 1
Shaft HW9302054-1 1
Needle bearing NA6912 1 Inner ring of the needle bearing
in the balancer unit assembly 1
Retaining ring WR60 1
3 Shaft assembly (support part 1) 1
Shaft HW9405055-1 1
Tapered roller bearing 1 Inner ring
HR32916J
4 Shaft assembly (support part 2) 1
Shaft HW9405055-1 1
Tapered roller bearing 1 Inner ring
HR32916J
5 Hexagon socket head cap 3 Tightening torque 24.5 N•m
screw M8 (length: 16 mm) each
7 Hexagon socket head cap 8 Light tightening torque 9.8 N•m
screw M8 (length: 20 mm) each Tightening torque 24.5 N•m
8 B-cover HW9405699-1 1
9 Shim HW9405195
10 O-ring S105 1
12 Tapered roller bearing 1 Outer ring of the tapered roller
HR32916J bearing in the shaft assembly
(support part 1) 3
14 B-cover HW9405699-1 1
15 O-ring S105 1
17 Tapered roller bearing 1 Outer ring of the tapered roller
HR32916J bearing in the shaft assembly
(support part 2) 4
18 Oil seal KE901107 1
19 Oil seal KE901107 1
20 Hexagon socket head cap 3 Provided with the balancer unit
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Fig. 10-3: Balancer Installation Diagram
(b)
7 11 8
A
10 (a)
6 2
9 View A
12 18
3
17
4 19 5 20
L-arm
Flange
S-head 1
13 15
16 14
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HW1484416

10.3 Unit Assembly
10.3 Unit Assembly
10.3.1 Balancer Unit Assembly

1. Insert the oil seal 2 into the clevis of the balancer unit to the correct
direction.
2. Apply Alvania EP Grease 2 on the lip part of the oil seal 2 .
Clevis
2
Apply Alvania EP Grease 2
3. Inject Alvania EP Grease 2 into the outer ring of the needle bearing 3 ,
and insert it into the clevis of the balancer unit so that the grease inlet
for the needle bearing is positioned at “*” in the figure below.
4. Mount the retaining ring 4 .
45
Clevis
4
3 (Outer ring)
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HW1484416
10.3 Unit Assembly
5. Insert the oil seal 5 into the clevis of the balancer unit to the correct
direction.
6. Apply Alvania EP Grease 2 on the lip part of the oil seal 5 .
Apply Alvania EP Grease 2
Clevis
10.3.2 Shaft Assembly (Knuckle Part)

1. Insert the inner ring of the needle bearing 3 into the shaft 6 .
2. Mount the retaining ring 7 .
6
3 (Inner ring)
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HW1484416

10.3 Unit Assembly
10.3.3 Shaft Assembly (Support Part 1)

1. Inject Alvania EP Grease 2 on the tapered roller bearing 8 .
2. Insert the inner rings of the tapered roller bearing 8 into the shaft 9 .
8 (Inner ring)
10.3.4 Shaft Assembly (Support Part 2)

1. Inject Alvania EP Grease 2 on the tapered roller bearing 10
8 .
2. Insert the inner rings of the tapered roller bearing 10

8 into the shaft 11
8 .
10 (Inner ring)
11
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HW1484416
10.3 Unit Assembly
10.3.5 Unit Assembly Parts Checklist
Table 10-2: Unit Assembly Parts Checklist

No. Item Qty. Note
1 Balancer unit HW0171165-G 1
2 Oil seal VB60787 1
3 Needle bearing NA6912 1 Outer ring/inner ring
4 Retaining ring AR85 1
5 Oil seal VB75956 1
6 Shaft HW9302054-1 1
7 Retaining ring WR60 1
8 Tapered roller bearing 1 Inner ring
HR32916J Outer ring is used in chapter 10.2
“Disassembly and Reassembly of
Balancer Unit” .
9 Shaft HW9405055-1 1
10 Tapered roller bearing 1 Inner ring
HR32916J Outer ring is used in chapter 10.2.
11 Shaft HW9405055-1 1
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HW1484416
11 Battery Pack Replacement

11.1 Battery Pack Replacement
Three battery packs are installed to the position as shown in fig. 11-1
“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.
Make sure to refer to chapter 2 “Notes for Maintenance” when replacing
the battery pack.
Fig. 11-1: Location of the Battery and Multi-port Connector

Battery pack for B-, T-axes
Protective tube
Cable tie
Battery for U-, R-axes
Protective tube
Cable tie
Cover
Fixing bolt for the cover

Cross head APS bolt M4
Cable tie
LOUT
SIN
Cover
Battery pack for

S-, L-axes
Protective tube Fixing bolt for the cover
When the Cover is Removed Cross head APS bolt M4
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 Normal (The power supply of the YRC1000 can be turned ON)
Fig. 11-2: Battery connection (the power supply of the YRC1000 can be
turned ON)
Old battery pack
Connector
New battery pack

(HW1483880-A)
1. Turn ON the power supply of the YRC1000 and turn OFF the servo
power.
DANGER
• Make sure to perform the battery replacement with the emergency
stop button being pressed.
Failure to observe this instruction may cause improper movement of
the manipulator which may result in personal injury and/or equipment
damage.
2. Loosen the cover mounting bolts and remove the cover.
3. The old battery pack is fixed by using the cable tie. Cut the cable tie
(1 place) to remove the old battery pack from the protective tube.
4. The connector is in the protective tube. Cut the cable ties (2 places)
fixing the protective tube, and take out the connector.
5. Remove the old battery pack from the multi-port connector and mount
the new battery pack.
6. Fix the new battery pack by using the cable tie T50R-HSW.
7. 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.
8. Fix the new battery pack and the protective tube in which the
connector is placed at step 7 by using the cable tie T18L-HSW.
9. Tighten the cover mounting bolts to reinstall the cover.
NOTE When reinstalling the cover, be careful not to get caught the
cable.
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HW1484416

 When the Power Supply of the YRC1000 Cannot Be Turned ON
Fig. 11-3: Battery Connection (the power supply of the YRC1000 cannot
be turned ON)
Old battery pack
Connector
IN
or “Y”
Lead wires for battery replacement

New battery pack
(HW1471281-A)
(HW1483880-A)
Battery pack for back-up

(HW1483880-A)
1. Prepare lead wires for battery replacement and a battery pack for
backup. (Apart from the new battery pack for replacement, prepare a
battery pack for backup)
2. Loosen the cover mounting bolts and remove the cover.
3. Remove the connector from the “IN” or “Y” port of the multi-port
connector.
Connect the lead wires for battery replacement to the “IN” or “Y” port of
the multi-port connector.
4. Connect the battery pack for backup to the lead wires for battery
replacement.
Before removing the old battery pack, make sure to connect

NOTE the battery pack for backup to prevent the encoder absolute
data from disappearing.
5. The old battery pack is fixed by using the cable tie. Cut the cable tie
(1 place) to remove the old battery pack from the protective tube.
6. The connector is in the protective tube. Cut the cable ties (2 places)
fixing the protective tube, and take out the connector.
7. Remove the old battery pack from the multi-port connector and mount
the new battery pack.
8. Remove the lead wires for battery replacement and the battery pack
for backup from the multi-port connector, connect the connector which
has been removed at step 3 of this procedure to the “IN” or “Y” port
again.
If the battery pack for backup remains connected,

an electric current flows from the new battery to the backup
NOTE battery and which may result in the voltage drop in the new
battery. Remove the battery pack for backup immediately
after connecting the new battery.
9. Fix the new battery pack by using the cable tie T50R-HSW.
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HW1484416
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.
12. Tighten the cover mounting bolts to reinstall the cover.
NOTE When reinstalling the cover, be careful not to get caught the
cable.
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HW1484416
12 Parts List
12.1 S-Axis Unit
12 Parts List
12.1 S-Axis Unit

Fig. 12-1: S-Axis Unit
1029
1030
1002
1039
1040
1004
1005
1015
1003
1025 1006
1026
1032
1001 1031
1037
1038
1016
1020
1027 1021 1008

1028
1014
1033
1009
1034
1023 1012
1024 1035
1042 1036
1017
1013 1010
1041 1022
1011
1007
1019
1018
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12 Parts List
12.1 S-Axis Unit
Table 12-1(a): S-Axis Unit (YR-1-06VX215-A00, -C00, YR-1-06VX250-

A00, -C00) (Sheet 1 of 2)
No. DWG No. Name Pcs.
1001 HW0390045-A Speed reducer 1
1002 SGM7G-44APK-YR1* Motor 1
1003 TC12015014 (-A00) Oil seal 1
TC12015014*FKM*
(-C00)
1004 STW-50 Retaining ring 1
1005 6310 Bearing 1
1006 HW0314016-1 Gear 1
1007 HW0100193-2 Base 1
1008 HW0100471-1 (-A00) S-head 1
HW0100471-2 (-C00)
1009 HW0402102-1 Stopper 1
1010 HW0302424-2 Stopper 1
1011 HW0402104-1 Pin 1
1012 HW0306181-1 Pipe 1
1013 HW0403903-1 Plate 1
1014 HW9404486-1 Shaft 1
1015 HW1405948-12-30 Pin 1
1016 HW1405948-12-40 Pin 2
1017 HW1405947-6-20 Pin 2
1018 KQ2L10-01S Union 1
1019 NB-1075-1 Tube 1
1020 PT3/8 (STAINLESS) Hexagon socket head plug 1
1021 G415 O-ring 1
1022 G105 O-ring 1
1023 M6X16 (STAINLESS) Hexagon socket head cap screw 1
1024 2L-6 Conical spring washer 1
1025 M12X50 Hexagon socket head cap screw 16
1026 SW-2H-12 Conical knurled washer 16
1029 M12X60 (TRIVALENT Hexagon socket head cap screw 3
CHROMATE)
1030 2H-12 (TRIVALENT Conical spring washer 3
CHROMATE)
1035 M20X45 (12.9) Hexagon head screw 3
1036 M20 (STAINLESS) Washer 3
1038 GT-SH-16 Conical spring washer 12
1039 HW0404753-1 Spacer 1
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HW1484416
12 Parts List
12.1 S-Axis Unit
Table 12-1(a): S-Axis Unit (YR-1-06VX215-A00, -C00, YR-1-06VX250-

A00, -C00) (Sheet 2 of 2)
1040 HW0404752-1 Flywheel 1
1041 EZ5002A0 Cap 1
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HW1484416
12 Parts List
12.1 S-Axis Unit
Table 12-1(b): S-Axis Unit (YR-1-06VX280-A00, -C00) (Sheet 1 of 2)

1003 TC12015014 (-A00) Oil seal 1
TC12015014*FKM*
(-C00)
1005 6310 Bearing 1
1006 HW0314016-1 Gear 1
1007 HW0100193-2 Base 1
1008 HW0101612-1 (-A00) S-head 1
HW0101612-2 (-C00)
1009 HW0402102-1 Stopper 1
1010 HW0302424-2 Stopper 1
1011 HW0402104-1 Pin 1
1012 HW0306181-1 Pipe 1
1013 HW0403903-1 Plate 1
1014 HW9404486-1 Shaft 1
1015 HW1405948-12-30 Pin 1
1016 HW1405948-12-40 Pin 2
1017 HW1405947-6-20 Pin 2
1018 KQ2L10-01S Union 1
1019 NB-1075-1 Tube 1
1021 G415 O-ring 1
1022 G105 O-ring 1
CHROMATE)
CHROMATE)
1035 M20X45 (12.9) Hexagon head screw 3
1038 GT-SH-16 Conical spring washer 12
1039 HW0404753-1 Spacer 1
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12 Parts List
12.1 S-Axis Unit
Table 12-1(b): S-Axis Unit (YR-1-06VX280-A00, -C00) (Sheet 2 of 2)

1040 HW0404752-1 Flywheel 1
1041 EZ5002A0 Cap 1
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12 Parts List
12.2 L-Axis Unit
12.2 L-Axis Unit

Fig. 12-2: L-Axis Unit
2033
2034
2026
2012
2019
2005
2019 2018
2050
2017
2010 2031
2007
2032
2009
2020
2008
2019 2002
2017 1008
2005
2012 2009
2026
2018 2032 2003
2031
2007
2015
2019 2038
2008
2016
2004
2034
2033
2040
2039
2006
2011
2001
2036
2035
2019
2030
2029
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12 Parts List
12.2 L-Axis Unit
Table 12-2(a): L-Axis Unit (YR-1-06VX215-A00, -C00, YR-1-06VX250-

A00, -C00)
2001 HW0390225-B Speed reducer 1
2003 Y507212.5 Oil seal 1
2004 ISTW-10 Retaining ring 1
2005 HR32916J Bearing 2
2006 HW0100647-2 L-arm 1
2007 HW9482306-E Shaft 1
2008 HW0481082-A Bolt 1
2009 HW9405055-1 Shaft 2
2010 EZ0094-A0 (-A00 only) Air breezer 1
2011 G300 O-ring 1
2012 S105 O-ring 2
2014 CP-30-BC-12 Cap 6
2015 HW9481343-A Gear 1
2016 HW0301778-1 Gear 1
2017 KE901107 Oil seal 2
2018 HW9405699-1 B cover 2
2026 HW9405195-* Shim -
CHROMATE)
CHROMATE)
2030 2H-12 Conical spring washer 21
2049 HW0408806-1 Washer 1
2050 HW0171165-G Balancer 1
1008 HW0100471-1 (-A00) S-head 1
HW0100471-2 (-C00)
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HW1484416
12 Parts List
12.2 L-Axis Unit
Table 12-2(b): L-Axis Unit (YR-1-06VX280-A00, -C00)

2003 Y507212.5 Oil seal 1
2005 HR32916J Bearing 2
2006 HW0100647-2 L-arm 1
2007 HW9482306-E Shaft 1
2008 HW0481082-A Bolt 1
2009 HW9405055-1 Shaft 2
2010 EZ0094-A0 (-A00 only) Air breezer 1
2011 G300 O-ring 1
2012 S105 O-ring 2
2014 CP-30-BC-12 Cap 6
2015 HW9481343-A Gear 1
2016 HW0301778-1 Gear 1
2017 KE901107 Oil seal 2
2018 HW9405699-1 B cover 2
2026 HW9405195-* Shim -
CHROMATE)
CHROMATE)
2049 HW0408806-1 Washer 1
2050 HW0171165-G Balancer 1
1008 HW0101612-1 (-A00) S-head 1
HW0101612-2 (-C00)
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HW1484416
12 Parts List
12.3 U-, R-, B-, T-Axis Unit

Fig. 12-3: U-, R-, B-, T-Axis Unit
3016
3017
R-axis 3056
3004
3008 3049
3021
3055 3006 3047
3020 3045
3053
3044 3037
B-axis 3056 3007 3002 3046
3005 3048
3020
T-axis 3056 3018
3055
3009 3054
3021 3003
3010
3012 3053 3032 3030
3033 3031
3011 3011 3034
3021 3014
3055 3053 3035
3025
3020 3015
3010 3036
3001
3024
3022 3023
3028
3050
3038
3041
3040 4033
3039
3043
3042
3013
2006
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12 Parts List
Table 12-3(a): U-, R-, B-, T-Axis Unit (YR-1-06VX215-A00, -C00) (Sheet 1
of 2)
3001 GS210 O-ring 1
3002 HW0402391-1 Collar 1
3003 HW0402406-1 Collar 1
3004 HW0306788-1 Gear 1
3008 HW0402544-1 Collar 1
3009 HW0306797-1 Gear 1
3012 HW0306795-1 Gear 1
3015 HW0401507-1 Plate 1
CHROMATE)
CHROMATE)
3018 IRTW-55 Retaining ring 1
CHROMATE)
CHROMATE)
3022 HW0100239-4 Casing 1
3025 HW9405703-1 Flange 1
3028 HW1405947-8-20 Pin 1
3032 HW9482447-A Oil seal 1
3033 HW9405481-1 Collar 1
3039 HW0301779-1 Spacer 1
3044 HW0481083-A Bolt 1
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12 Parts List
Table 12-3(a): U-, R-, B-, T-Axis Unit (YR-1-06VX215-A00, -C00) (Sheet 2
of 2)
3045 HW0408806-1 Washer 1
3046 HW0315871-1 Gear 1
3047 HW9481343-A Shaft 1
3049 HW9482306-E Shaft 1
3050 G280 O-ring 1
3053 Y507212.5 Oil seal 3
3054 TAFI405520 Needle bearing 1
3055 HW0401506-1 Plate 3
2006 HW0100647-2 L-arm 1
5001 HW0102835-2 U-arm 1
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12 Parts List
Table 12-3(b): U-, R-, B-, T-Axis Unit (YR-1-06VX250-A00, -C00) (Sheet 1
of 2)
3001 GS210 O-ring 1
3002 HW0402391-1 Collar 1
3003 HW0402406-1 Collar 1
3004 HW0306788-1 Gear 1
3008 HW0402544-1 Collar 1
3009 HW0306797-1 Gear 1
3012 HW0306795-1 Gear 1
3015 HW0401507-1 Plate 1
CHROMATE)
CHROMATE)
CHROMATE)
CHROMATE)
3022 HW0100239-4 Casing 1
3025 HW9405703-1 Flange 1
3028 HW1405947-8-20 Pin 1
3032 HW9482447-A Oil seal 1
3033 HW9405481-1 Collar 1
3039 HW0301779-1 Spacer 1
3044 HW0481083-A Bolt 1
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HW1484416
12 Parts List
Table 12-3(b): U-, R-, B-, T-Axis Unit (YR-1-06VX250-A00, -C00) (Sheet 2
of 2)
3045 HW0408806-1 Washer 1
3046 HW0315871-1 Gear 1
3047 HW9481343-A Shaft 1
3049 HW9482306-E Shaft 1
3050 G280 O-ring 1
3053 Y507212.5 Oil seal 3
3055 HW0401506-1 Plate 3
2006 HW0100647-2 L-arm 1
5001 HW1100083-1 U-arm 1
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HW1484416
12 Parts List
Table 12-3(c): U-, R-, B-, T-Axis Unit (YR-1-06VX280-A00, -C00) (Sheet 1
of 2)
3001 GS210 O-ring 1
3002 HW0402391-1 Collar 1
3003 HW0402406-1 Collar 1
3004 HW0306788-1 Gear 1
3008 HW0402544-1 Collar 1
3009 HW0306797-1 Gear 1
3012 HW0306795-1 Gear 1
3015 HW0401507-1 Plate 1
CHROMATE)
CHROMATE)
CHROMATE)
CHROMATE)
3022 HW0100239-4 Casing 1
3025 HW9405703-1 Flange 1
3028 HW1405947-8-20 Pin 1
3032 HW9482447-A Oil seal 1
3033 HW9405481-1 Collar 1
3038 HW0388210-C Speed reducer 1
3039 HW0301779-1 Spacer 1
3044 HW0481083-A Bolt 1
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HW1484416
12 Parts List
Table 12-3(c): U-, R-, B-, T-Axis Unit (YR-1-06VX280-A00, -C00) (Sheet 2
of 2)
3045 HW0408806-1 Washer 1
3046 HW0315955-1 Gear 1
3047 HW9481343-A Shaft 1
3049 HW9482306-E Shaft 1
3050 G280 O-ring 1
3053 Y507212.5 Oil seal 3
3055 HW0401506-1 Plate 3
2006 HW0100647-2 L-arm 1
5033 HW0101553-1 U-arm 1
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HW1484416
12 Parts List
12.4 U-arm unit
12.4 U-arm unit

Fig. 12-4(a): U-arm unit (YR-1-06VX215-A00, -C00, YR-1-06VX250-A00,
-C00)
3022 5007
5001 5008
5003 5005
5002
5004
5015
5016
5006
5009
5010
5009
5014
5011
5017 5022
5023
5030
5029
5020 5018
5019
5028 5012
5031 5021 5013
5032 5024
5033
5025
5034 5026
5027
5035
5036
5038
5037
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HW1484416
12 Parts List
12.4 U-arm unit
Table 12-4(a): U-arm unit (YR-1-06VX215-A00, -C00)

5003 HW0401508-1 Plate 1
5004 HW0401505-1 B nut 1
5005 M4X6 Hexagon socket set screw 1
5006 HW0100173-2 Housing 1
5009 HR32006XJ Bearing 2
5010 HW0306796-1 Gear 1
5011 HW0312812-C Shaft 1
5012 6904 Bearing 1
5013 STW-20 Retaining ring C-type 1
5014 HW0306798-1 Gear 1
5017 HW0303938-C Shaft 1
5018 HW0301237-3 Shaft 1
5021 HW0306787-1 Gear 1
5025 HW0303939-C Shaft 1
5027 AC3842F1 Oil seal 1
5028 HW0315876-1 Shaft 1
5031 6812LLU Bearing 1
5032 WR60 Cir clip 1
5033 SC60789 *FKM* Oil seal 1
5034 HW0102835-2 U-arm 1
3022 HW0100239-4 Casing 1
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HW1484416
12 Parts List
12.4 U-arm unit
Table 12-4(b): U-arm unit (YR-1-06VX250-A00, -C00)

5003 HW0401508-1 Plate 1
5004 HW0401505-1 B nut 1
5006 HW0100173-2 Housing 1
5010 HW0306796-1 Gear 1
5011 HW0312812-B Shaft 1
5012 6904 Bearing 1
5014 HW0306798-1 Gear 1
5017 HW0303938-B Shaft 1
5018 HW0301237-3 Shaft 1
5021 HW0306787-1 Gear 1
5025 HW0303939-B Shaft 1
5028 HW0315876-1 Shaft 1
5033 SC60789 *FKM* Oil seal 1
5034 HW1100083-1 U-arm 1
3022 HW0100239-4 Casing 1
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HW1484416
12 Parts List
12.4 U-arm unit
Fig. 12-4(b): U-arm unit (YR-1-06VX280-A00, -C00)
3022 5007
5008
5005
5001
5002
5003
5004
5015
5016
5006
5009
5010
5009
5020
5014 5019
5022 5011
5023
5017
5030 5018
5012
5029
5013
5021
5028 5024
5031
5032 5025
5033
5034
5026
5035
5039 5027
5040 5038
5041
5036
5037
5043
5042 5039
5038
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HW1484416
12 Parts List
12.4 U-arm unit
Table 12-4(c): U-arm unit (YR-1-06VX280-A00, -C00)

5003 HW0401508-1 Plate 1
5004 HW0401505-1 B nut 1
5006 HW0100173-2 Housing 1
5010 HW0306796-1 Gear 1
5011 HW0312108-1 Shaft 1
5012 6904 Bearing 1
5014 HW0306798-1 Gear 1
5017 HW0301235-B Shaft 1
5018 HW0301237-1 Shaft 1
5021 HW0306787-1 Gear 1
5025 HW0301236-C Shaft 1
5028 HW0402202-1 Shaft 1
5032 HW0402204-1 Collar 1
5035 HW0101553-1 U-arm 1
5037 HW0302990-1 Washer 1
5041 HW1408161-6-15 Pin 1
5042 HW0408612-1 Block 1
5043 HW1408161-6-10 Pin 2
3022 HW0100239-4 Casing 1
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HW1484416
12 Parts List
12.5 Wrist unit
12.5 Wrist unit

Fig. 12-5(a): Wrist unit (YR-1-06VX215-A00, -C00, YR-1-06VX250-A00,
-C00)
5011
6002
6004
6007
6015 6006
6012 6014 6001 6008
6021 6003 6009
6013
6016 6020 6005 6010
6019 6054
6011 6053
6050 6055
6022 6051
6023 6045
6025 6028 6048
6017 6025 6047 6052
6018 6024 6046
6029 6045 6051
6045 6049
6026 6044 6057 6052
6027 6030 6045 6060
6056 6059
6058
6033
6034
6035 6061
6036 6064
6038 6037 6065 6067
6062 6066
6032
6031 6063 6068
6039
6040
6042 6071
6041 6072
6075
6070
6043
6069
6042 6074
6041 6073
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HW1484416
12 Parts List
12.5 Wrist unit
Table 12-5(a): Wrist unit (YR-1-06VX215-A00, -C00, YR-1-06VX250-A00,

-C00) (Sheet 1 of 2)
6001 HW0401510-1 B nut 1
6003 HW0401511-1 B holder 1
6004 M4X12 GT-SA bolt 4
6005 6908DB Bearing 1
6006 HW0401509-1 Housing 1
6008 HW0401516-* Shim -
6010 6909 Bearing 1
6011 HW0306791-1 Gear 1
6012 G-140 O-ring 1
6013 HW0102837-1 Wrist base 1
6016 EZ5036A0 Cap 2
6019 6911 Bearing 1
6020 HW0404270-1 Shim 1
6021 AE3290E3 (-A00) Oil seal 1
TC62809*FKM* (-C00)
6022 HW0411718-1 Collar 1
6023 HW0410868-* Shim -
6024 HW0309518-1 Gear 1
6026 6007 Bearing 1
6027 HW0411721-1 B nut 1
6028 M5X7 Magic screw 2
6029 HW0409072-1 Cover 1
6031 HW0102836-1 Wrist 1
6032 HW0306792-1 Gear 1
6035 HW0402205-* Shim -
6036 6009 Bearing 1
6039 G195 O-ring 1
6040 HW0315877-1 Cover 1
12-22 HW1484416 145/152

HW1484416
12 Parts List
12.5 Wrist unit
Table 12-5(a): Wrist unit (YR-1-06VX215-A00, -C00, YR-1-06VX250-A00,

-C00) (Sheet 2 of 2)
6044 HW0301223-1 Gear 1
6046 S60 O-ring 1
6047 HW9403622-* Shim -
6048 HW9403618-1 Housing 1
6050 HW0301224-1 Gear 1
6051 HW0401514-1 B nut 2
6053 HW0200615-1 Cover 1
6056 HW0306789-1 Gear 1
6057 HW9403621-* Shim -
6058 HW9403617-1 Housing 1
6060 HW0301225-1 Gear 1
6061 HW0306790-1 Gear 1
6064 HW0402206-* Shim -
6065 6006 Bearing 1
6067 ARP568-263 O-ring 1
6068 HW0380794-A (-A00) Speed reducer 1
HW0380794-F (-C00)
6071 HW0301782-1 Spacer 1
6072 HW0302422-2 (-A00) Flange 1
HW0302422-3 (-C00)
6073 M8X20 (FA COAT) Hexagon socket head cap screw 18
6074 2L-8 (FA COAT) Conical spring washer 18
5011 HW0312812-B Shaft 1
12-23 HW1484416 146/152

HW1484416
12 Parts List
12.5 Wrist unit
Fig. 12-5(b): Wrist unit (YR-1-06VX280-A00, -C00)
5011
6002
6004
6015 6007
6006
6014 6001
6012 6021 6008
6003 6009
6013 6016 6020 6005
6019 6010
6063
6011 6062
6054 6064
6022 6055
6023
6025 6049
6025 6052
6017 6028 6051
6029 6050 6055 6056
6018 6024 6032 6049
6026 6030 6049 6053
6033
6048 6058
6027 6061 6056
6049
6057 6060
6059
6035
6036
6037 6066
6040 6038 6068 6071
6039 6066 6069
6034 6070
6042 6031 6067 6072
6041
6075
6043 6076
6079
6044
6074
6073
6078
6077
6047
6046
6045
12-24 HW1484416 147/152

HW1484416
12 Parts List
12.5 Wrist unit
Table 12-5(b): Wrist unit (YR-1-06VX280-A00, -C00) (Sheet 1 of 2)

6001 HW0401510-1 B nut 1
6003 HW0401511-1 B holder 1
6005 6908DB Bearing 1
6006 HW0401509-1 Housing 1
6008 HW0401516-* Shim -
6010 6909 Bearing 1
6011 HW0306791-1 Gear 1
6012 G140 O-ring 1
6013 HW0100242-1 Wrist base 1
6016 EZ5036A0 Cap 2
6019 6911 Bearing 1
6020 HW0404270-1 Shim 1
6021 AE3290E3 (-A00) Oil seal 1
TC62809*FKM* (-C00)
6022 HW0411718-1 Collar 1
6023 HW0309518-1 Gear 1
6025 6007 Bearing 1
6026 HW0410868-* Shim -
6027 HW0411721-1 B nut 1
6029 HW0409072-1 Cover 1
6031 HW0100243-1 Wrist 1
6034 HW0306792-1 Gear 1
6037 HW0402205-* Shim -
6038 6009 Bearing 1
6040 HW9381453-B (-A00) Speed reducer 1
HW9381453-G (-C00)
12-25 HW1484416 148/152

HW1484416
12 Parts List
12.5 Wrist unit
Table 12-5(b): Wrist unit (YR-1-06VX280-A00, -C00) (Sheet 2 of 2)

6043 G220 O-ring 1
6044 HW9302370-1 Cover 1
6048 HW0301223-1 Gear 1
6050 HW9403622 Shim -
6051 S60 O-ring 1
6052 HW9403618-1 Housing 1
6054 HW0301224-1 Gear 1
6055 HW0401514-1 B nut 2
6057 HW0306789-1 Gear 1
6058 HW9403621 Shim -
6059 HW9403617-1 Housing 1
6061 HW0301225-1 Gear 1
6062 HW0200615-1 Cover 1
6064 PT1/8 (STAINLESS) Plug 1
6065 HW0306790-1 Gear 1
6068 HW0402206-* Shim -
6069 6006 Bearing 1
6071 ARP568-263 O-ring 1
6072 HW0380794-A (-A00) Speed reducer 1
HW0380794-F (-C00)
6075 HW0301782-1 Spacer 1
6076 HW0302422-2 (-A00) Flange 1
HW0302422-3 (-C00)
6077 M8X20 (FA COAT) Hexagon socket head cap screw 18
6078 2L-8 (FA COAT) Conical spring washer 18
5011 HW0312108-1 Shaft 1
12-26 HW1484416 149/152

HW1484416
12 Parts List
12.6 Balancer Unit
12.6 Balancer Unit

Fig. 12-6: Balancer Unit
7018
7004
7011
7007 7005
7001
7002
7006
7016 7017
7015
7012
7003
7008
7003
7012 7014
7010
7013
2006
7009
2046
2041
2045
2042 2044
2043
2048
2047
12-27 HW1484416 150/152

HW1484416
12 Parts List
12.6 Balancer Unit
Table 12-6: Balancer Unit

7001 HW0481740-A Coil spring 1
7003 SOB607440 OILES bearing 2
7004 HW0100477-1 Case 1
7005 HW0306033-1 Flange 1
7006 HW0200420-1 Flange 1
7007 HW0401112-1 Flange 1
7008 HW0303581-1 Rod 1
7009 HW9405057-1 Clevis 1
7010 FD3187A0 Dust seal 1
7011 EZ2228B0 Cap 1
2006 HW0100647-2 L-arm 1
2041 NA6912 Needle bearing 1
2042 HW9302054-1 Shaft 1
2043 AR-85 Cir clip 1
2045 VB75X95X6 Oil seal 1
2046 VB60X78X7 Oil seal 1
12-28 HW1484416 151/152

MOTOMAN-GP215,GP250/SP235,GP280
MAINTENANCE MANUAL
C 2018 YASKAWA ELECTRIC CORPORATION

Published by YASKAWA
July 2020 18-04
MANUAL NO.
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Yaskawa Motoman GP215 Maintenance Manual

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Yaskawa Motoman GP215 Maintenance Manual

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MOTOMAN-GP215,GP250/SP235,GP280

184036-1CD MANUAL NO.

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

3.2.2 Using Keys............................................................................................................ 3-2

3.2.3 Using Encoder Backup Error Recovery Function ................................................. 3-2

3.2.4 Robot Calibration (MOTOCALV EG) .................................................................... 3-2

3.2.5 Table of Suitable Methods for Home Position Return........................................... 3-2

3.3 Methods for Home Position Return.................................................................................... 3-3

3.3.2 Using Keys............................................................................................................ 3-5

3.3.3 Using Encoder Backup Error Recovery Function ............................................... 3-10

3.3.4 Robot Calibration (MOTOCALV EG) .................................................................. 3-10

4 L-Axis Fixing Jig .............................................................................................................................. 4-1

4.1 Fixing Jig............................................................................................................................ 4-1

4.1.1 Recommended Installation Posture of the Specified Fixing Jig............................ 4-2

4.1.2 Range of L-Arm Postures to Avoid ....................................................................... 4-3

4.2 Installation and Removal of the L-axis Fixing Jig............................................................... 4-4

4.3 Mechanism......................................................................................................................... 4-8

5 Notes on Grease Replenishment/Exchange Procedures................................................................ 5-1

5.1.1 Notes on Grease Exchange Procedures .............................................................. 5-1

5.1.2 Grease Exchange Procedure ............................................................................... 5-3

5.1.3 Grease Replenishment for Gas Balancer Link Part.............................................. 5-8

5.2 Removing, Applying, Assembling of Sealing Bond ............................................................ 5-9

5.2.2 Applying Sealing Bond to Sealing Surface ......................................................... 5-10

5.2.3 Assembling After Applying Sealing Bond ........................................................... 5-11

6 Disassembly and Reassembly of the Motors.................................................................................. 6-1

6.1 Disassembly and Reassembly of the S-Axis Motor ........................................................... 6-2

6.2 Disassembly and Reassembly of the L-Axis Motor ........................................................... 6-6

6.3 Disassembly and Reassembly of U-Axis Motor............................................................... 6-10

7 Disassembly and Reassembly of the Speed Reducers .................................................................. 7-1

7.1 Disassembly and Reassembly of S-Axis Speed Reducer ................................................. 7-1

7.2 Disassembly and Reassembly of L-Axis Speed Reducer.................................................. 7-5

7.3 Disassembly and Reassembly of U-Axis Speed Reducer ............................................... 7-10

7.4 Disassembly and Reassembly of R-Axis Speed Reducer ............................................... 7-14

7.5 Disassembly and Reassembly of B-Axis Speed Reducer ............................................... 7-17

7.5.1 YR-1-06VX215-A00, -C00, YR-1-06VX250-A00, -C00 ...................................... 7-17

7.5.2 YR-1-06VX280-A00, -C00 .................................................................................. 7-20

7.6 Disassembly and Reassembly of T-Axis Speed Reducer ............................................... 7-25

8 Disassembly and Reassembly of Wrist Unit ................................................................................... 8-1

9 Cable Wiring ................................................................................................................................... 9-1

9.1 Disassembly and Reassembly of Internal Wiring Harness ................................................ 9-1

10 Disassembly and Reassembly of Balancer Unit ......................................................................... 10-1

10.2 Disassembly and Reassembly of Balancer Unit ............................................................ 10-2

10.3 Unit Assembly................................................................................................................ 10-8

10.3.1 Balancer Unit Assembly ................................................................................... 10-8

10.3.2 Shaft Assembly (Knuckle Part)......................................................................... 10-9

10.3.3 Shaft Assembly (Support Part 1) .................................................................... 10-10

10.3.4 Shaft Assembly (Support Part 2) .................................................................... 10-10

10.3.5 Unit Assembly Parts Checklist........................................................................ 10-11

11 Battery Pack Replacement ......................................................................................................... 11-1

11.1 Battery Pack Replacement ............................................................................................ 11-1

12 Parts List ..................................................................................................................................... 12-1

iii HW1484416 3/152

12.1 S-Axis Unit ..................................................................................................................... 12-1

12.2 L-Axis Unit...................................................................................................................... 12-6