Service Manual

Robot manipulator

Model No. YA-1QMR4**00, YA-1RMR4**00

TAWERS types Model number

G2/GX/GXP controller types YA-1QMR41T00 YA-1QMR42T00
YA-1QMR41Y00 YA-1QMR42Y00
YA-1QMR41E00 YA-1QMR42E00
YA-1QMR41R00 YA-1QMR42R00
YA-1QMR41U00 YA-1QMR42U00
(TB -1400WG)

YA-1RMR41T00 YA-1RMR42T00
YA-1RMR41Y00 YA-1RMR42Y00
YA-1RMR41E00 YA-1RMR42E00
YA-1RMR41R00 YA-1RMR42R00
YA-1RMR41U00 YA-1RMR42U00
(TB -1400G2 / GX / GXP)

Before operating this product, please read the instructions carefully and save this manual for future use.

• First of all, please read “Safety precautions” or “Safety manual”.

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< Disclaimer >

We make every reasonable effort to present accurate information in this document, however, it is the respon-
sibility of the practitioner(s) of the maintenance or repair work to be executed in accordance with the contents
of this document. Therefore we assume no responsibility whatsoever for any damages resulting from the use
of this document.

● The description of this manual is based on the contents as of October, 2012.

● The contents of this manual are subject to change without further notice.
● We prohibit unannounced disclosure of information in this document to a third party and the use of infor-
mation in this document except for the maintenance or repair work of our products.
● All rights reserved.

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♦About model numbers

This service manual is for the following manipulator types

Manipulator code Controller type Remarks

YA-1QMR4*T00 Japanese market

YA-1QMR4*Y00 TAWERS Overseas markets

YA-1QMR4*E00 European (EU) markets

YA-1QMR4*R00 TB-1400WG US markets

YA-1QMR4*U00 US and Canadian markets

YA-1RMR4*T00 Japanese market

TA series
YA-1RMR4*Y00 (G2/GX/GXP) Overseas markets

YA-1RMR4*E00 EU markets
TB-1400G2
YA-1RMR4*R00 TB-1400GX US market
TB-1400GXP
YA-1RMR4*U00 US and Canadian markets

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♦Table of Contents
1. Safety.........................................................6 4.3.1 Replacing procedure ................................ 33
1.1 Prior to maintenance work............................... 6 4.3.2 Details of RT motor installation area ........ 34
1.2 Environmental preparation .............................. 6 4.4 UA axis motor replacement ........................... 35
1.3 Safe operation................................................... 6 4.4.1 Replacing procedure ................................ 35
1.4 At the end of maintenance work ..................... 6 4.4.2 Details of UA motor installation area........ 36
4.5 FA axis motor replacement............................ 37
4.5.1 Replacing procedure ................................ 37
2. Inner wiring ...............................................7 4.5.2 Details of FA motor installation area ........ 38
2.1 Harness wiring inside robot manipulator....... 7 4.6 RW axis motor replacement .......................... 39
2.2 Wiring between connecting connectors......... 8 4.6.1 Replacing procedure ................................ 39
2.3 Pin numbers and signal names of each connect- 4.6.2 Details of RW motor installation area....... 40
ing connector .................................................... 9 4.7 BW motor replacement .................................. 41
2.3.1 B-MOLEX connector (58719-0010).......... 10 4.7.1 Replacing procedure ................................ 41
2.3.2 A-MOLEX connector (58691-0010).......... 12 4.7.2 Details of BW motor installation area ....... 42
2.3.3 D-1, D-2. D-3, D-4. D-5 connectors: Resolver 4.8 TW motor replacement ................................... 43
I/F card (ZUEP5764*, ZUEP5764*A1) ........ 14 4.8.1 Replacing procedure ................................ 43
2.3.4 D-3, D-4 connector (Hirose: DF11-8DS-2C)15 4.8.2 Details of TW motor installation area ....... 44
2.3.5 E-1, E-2 connector (Nichiatsu: ELP-04NV, 4.9 Wire feed motor replacement (for TAWERS) 45
ELR04-NVF) ................................................ 15 4.9.1 Replacing procedure ................................ 45
2.3.6 E-3, E4 connector (Nichiatsu: SLP-04V, SLR- 4.9.2 Details of wire feeder installation area ..... 45
04VF)........................................................... 15 4.9.3 How to replace the wire feeder motor ...... 46
2.3.7 E-5, E6 connector (Nichiatsu: XAO-04V-1, 4.9.4 Details of wire feeder motor installation area
XARR-04VF) ............................................... 16 47
2.3.8 F-3, F-1 connector: Brake card (ZUEP5759*,
ZUEP5760*) ................................................ 16 5. Reduction gear replacement and grease in-
2.3.9 F-1, F-2 connector (Nichiatsu: XAP-02V-1,
XARR-02VF) ............................................... 17
jection ..........................................................51
2.3.10 F-4, F-5 connector (Nichiatsu: XAP-02V-1, 5.1 Cautions for reduction gear replacement..... 51
XARR-02VF) ............................................... 17 5.1.1 Points of grease injection to RV reduction gear
2.3.11 H-1, H-2 connector (Hirose: DF11-6DS-2C) at RV reduction gear replacement............... 51
17 5.1.2 Points of grease application to harmonic re-
2.3.12 J-3 connector (Nichiatsu: STO-01T-187N)18 duction gear at HDC replacement ............... 51
2.3.13 H-4, H-5 connector (Nichiatsu: XAP-02V-1, 5.1.3 Specific gravity for each grease ............... 52
XARR-02VF) ............................................... 18 5.2 Photos of grease applied surface ................. 53
2.3.14 J-1, J-2 connector (Hirose: DF11-6DS-2C) 5.2.1 RT, UA and FA axes: RV reduction gear . 53
18 5.2.2 RW axis: Harmonic reduction gear and RW
2.3.15 Feeder part: DDK connector (CM02-8DR5P) body gear..................................................... 53
19 5.2.3 BW axis .................................................... 54
2.3.16 OT connecting connector ....................... 20 5.2.4 TW axis .................................................... 54
2.3.17 Lamp harness connecting connector (UL 5.3 Resupply of grease for reduction gears and loca-
spec.)........................................................... 21 tion of grease supply/air relief ports ............. 55
5.3.1 TW, BW and RW axis ................. 55
5.3.2 FA, UA and RT axes ................. 56
3. Harness replacement .............................22
5.4 Standard clamp torque for each bolt at reduction
3.1 How to replace swiveling harness ................ 22 gear replacement ............................................ 57
3.1.1 Procedure................................................. 22 5.4.1 Bolts ......................................................... 57
3.2 How to replace wrist harness ........................ 24 5.4.2 Washers ................................................... 57
3.2.1 Procedure................................................. 24 5.5 RT axis RV reduction gear replacement ....... 58
3.3 How to replace TW harness........................... 28 5.5.1 Replacing procedure ................................ 58
3.3.1 Procedure................................................. 28 5.5.2 Details of RT axis RV reduction gear motor
mounted area .............................................. 59
4. Motor replacement .................................30 5.5.3 Details of RT axis RV reduction gear ....... 61
4.1 Location of motors and resolver card .......... 30 5.6 UA axis RV reduction gear replacement ...... 62
4.1.1 TAWERS type .......................................... 30 5.6.1 Replacing procedure ................................ 62
4.2 Cautions at motor replacement ..................... 31 5.6.2 Details of UA axis RV reduction gear motor
4.2.1 How to reset encoder after motor replacement mounted area .............................................. 63
31 5.6.3 Details of UA axis RV reduction gear....... 65
4.2.2 Standard clamp torque for each bolt at motor 5.7 FA axis RV reduction gear replacement ....... 66
replacement................................................. 32 5.7.1 Replacing procedure ................................ 66
4.2.3 Cautions ................................................... 32 5.7.2 Details of FA axis RV reduction gear motor
4.3 RT axis motor replacement............................ 33 mounted area .............................................. 67

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5.7.3 Details of FA axis RV reduction gear ....... 69 8. Brake release .......................94

5.8 RW axis harmonic reduction gear replacement 8.1 All axes brake release method (1) ................. 94
70 8.2 All axes brake release method (2) ................. 95
5.8.1 Replacing procedure ................................ 70
5.8.2 Details of RW axis harmonic reduction gear
motor mounted area .................................... 71 9. RT axis mechanical stopper replacement
5.8.3 Details of RW axis harmonic reduction gear72 96
5.9 BW axis harmonic reduction gear replacement 9.1 How to change the mechanical stopper ....... 96
74
5.9.1 Replacing procedure ................................ 74 10. Assembly drawings ............................. 97
5.9.2 Details of BW axis harmonic reduction gear
motor mounted area .................................... 76 10.1 RT and UA axes: parts layout ...................... 97
5.9.3 Details of BW axis harmonic reduction gear78 10.2 RT and UA axes: parts list............................ 99
5.9.4 Details of BW axis harmonic reduction gear 10.3 FA and RW axes: Parts layout ................... 102
motor mounted area .................................... 79 10.4 FA/RW-axis parts list ...................104
5.10 TW axis harmonic reduction gear replacement 10.5 BW and TW axes: parts layout: YA-1QMR41*00/
81 YA-1RMR41*00............................................... 108
5.10.1 Replacing procedure .............................. 81 10.6 BW/TW-axis parts list: YA-1QMR41*00/YA-
5.10.2 Details of TW axis harmonic reduction gear 1RMR41*00..............................110
motor mounted area .................................... 83 10.7 BW and TW axes: parts layout: YA-1QMR42*00/
5.10.3 Details of TW axis harmonic reduction gear YA-1RMR42*00............................................... 114
85 10.8 BW/TW-axis parts list: YA-1QMR42*00/YA-
5.10.4 Details of TW axis bearing mounted area86 1RMR42*00..............................116
10.9 Wire feeder................................................... 119
10.9.1 TAWERS specification (YA-1QMR41T00) .
6. Timing belt and pulley replacement..... 89 119
6.1 Replacement procedure: BW axis ................. 89 10.9.2 Details of feeder fixing bracket ............. 120
6.1.1 Timing belt ................................................ 89 10.10 Feed unit (ADU01489) ............................... 121
6.1.2 Pulley........................................................ 90 10.11 Motor unit (ADU01550) ............................. 123
10.12 Welding torch assembly drawing (YT-
7. Resolver battery replacement............... 91 CBT351): YA-1QMR41*00/YA-1RMR41*00 ... 125
10.13 Welding torch assembly drawing (YT-
7.1 Location of the resolver battery .................... 91
CCT351): YA-1QMR42*00/YA-1RMR42*00 ... 126
7.2 Resolver battery replacement........................ 92
10.14 Welding cable (AWC32776) ...................... 127
7.2.1 Replacing batteries on the manipulator side92
10.15 Limit SW (AEB31006)................................ 128
7.2.2 Replacing batteries on the controller side 93

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1. Safety
Read and follow the below instructions carefully and without fail

1.1 Prior to maintenance work

(1) The personnel in charge of maintenance work must (2) Make sure to read the safety precaution section in the
receive proper safety education and training. operating instructions of each of related units thor-
oughly and always be aware of safe operation to pre-
vent any possible accident.

1.2 Environmental preparation

(1) Keep other personnel away from the maintenance (3) Before starting the maintenance of pneumatic lines,
area by showing “On maintenance” plate or blocking confirm that the inner pressure has dropped to zero.
the area with protective chain.
(2) To avoid accidental switching the power ON, lock the
switchbox or attach the notice plate “On maintenance”
to it.

1.3 Safe operation

(1) Shut off all power to the robot and the system while (4) Use caution when handling any heat generating parts,
working on maintenance work unless absolutely nec- such as servo motors and regenerating resisters in the
essary. In case of working while power is on, keep the controller. If sufficient cooling time cannot be ensured
emergency stop switch pressed during maintenance for maintenance work, make sure to ware protective
work as much as possible. equipment such as heat-proof gloves.
(2) Before replacing parts, make sure to read related man- (5) Reassemble all parts removed for replacement (bolts
uals thoroughly and understand replacement proce- etc.) back in position. Any parts missing or remaining
dure. Replacing parts in improper way may not only after reassembling, check and redo the reassembling
damage the robot but also cause unexpected injury to process.
the operator. (6) Try to work in relatively dust-free condition when
(3) Never foot on or climb up any part of the robot. It may replacing parts to avoid any dust particles to enter
not only give bad affect on the robot motion or perfor- inside of the robot. Dust particles can cause electric
mance but also cause injury to the operation by slip- contact failure and may result in abnormal movement.
ping.

1.4 At the end of maintenance work

(1) Never neglect cleaning of the robot and the operating specified procedure. The check operation must be
area, such as wiping oily or watery part or removing all operated outside of the safety fence after confirming
scattered parts on the floor if any. that no personnel are present within the safety fenced
(2) Safety and performance check operation after parts space.
replacement must be executed in accordance with the

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2. Inner wiring
2.1 Harness wiring inside robot manipulator

④
TW harness Lamp harness Note 1)
(AWC42334) (AWC32837)

Wrist harness ( AWC12826) Swiveling harness

(AWC12818)

② RS relay harness
(AWC42292)

BK relay harness U (AWC42293)

BK relay harness R (AWC42315)

Note 1) For R and U types, servo ON indicator lamp is provided as standard.

For T, Y and E types, as the servo ON indicator lamp is available as an optional.

Grease application quantity

<Grease application is required for the following parts when a harness is replaced.>
1 RT axis rotation part 3-push SUMI grease splay 259664
2 UA axis rotation part Not required -
3 FA axis rotation part Not required -
4 RW axis rotation par 2-push SUMI grease splay 259664
5 BW axis rotation part 1g Albania S2 grease

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2.2 Wiring between connecting connectors

BK relay harness U

BK relay harness R

1
MOLEX connector
Note 2)

2
*1
*2

*3
*4
*5
Note 5)

RS relay harness *6

MOLEX connector *7

*8

*9

*10

*11

Note 3)
*12

Swiveling harness

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2.3 Pin numbers and signal names of each connecting connector

RS Resolver signal
M Motor power
BK Motor brake power
OT Overtravel signal
SH Safety holder signal
LMP Lamp power
FAN Fan power
GV1 Gas valve power
3 GV2 Gas valve (spare)
BAT Lithium battery
*1
*2
Note 4) Fan harness

*3
*4
*5
Note 7)

*6 Feeder

*7

*8

Note 3)
*9

*10

*11

4 5
Note 6)
Wrist harness TW harness
*12

Note 2) As for E and U types, ZUEP57600 can be used as brake card in place for ZUEP57590.
Note 3) As for U type, connect the limit switch to FAUA-OT.
Note 4) As for U type, use lamp harness.
Note 5) Connect it to the ground terminal (RT base part)
Note 6) Connect it to the ground terminal (BW base part)
Note 7) For details of the feeder part, please refer to the next section “Feeder: DDK connector”.

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2.3.1 B-MOLEX connector (58719-0010)

1) Pin numbers and signals
No. Pin No. Signal name Color
No. Pin No. Signal name Color
33 3-4 TW Phase A+ Purple
1 1-1 RT Phase A+ Blue
34 3-10 Phase A- White
2 1-7 Phase A- White
35 3-5 Phase B+ Pink
3 1-2 Phase B+ Gray
36 3-11 Phase B- White
4 1-8 Phase B- White
37 3-6 Phase S+ Orange
5 1-3 Phase S+ Yellow
38 3-12 Phase S- White
6 1-9 Phase S- White
39 4-4 VCC Red
7 1-4 UA Phase A+ Blue
40 4-10 GND Black
8 1-10 Phase A- White
41 4-6 PG-SLD Green/Yellow
9 1-5 Phase B+ Gray
42 5-2 Feeder - SLD Green/Yellow
10 1-11 Phase B- White
43 5-4 24V - SLD Green/Yellow
11 1-6 Phase S+ Yellow
44 4-1 OPT 1-1 (FD S2) Blue
12 1-12 Phase S- White
45 4-7 OPT 1-2 (FD S4) White
13 2-1 FA Phase A+ Purple
46 4-2 OPT 1-3 (FD S1) Gray
14 2-7 Phase A- White
47 4-8 OPT 1-4 (FD S3) White
15 2-2 Phase B+ Pink
48 4-3 OPT 1-5 (FD R1) Yellow
16 2-8 Phase B- White
49 4-9 OPT 1-6 (FD R2) White
17 2-3 Phase S+ Orange
50 5-7 OPT 2-1 (GV1+) Blue
18 2-9 Phase S- White
51 5-8 OPT 2-2 (GV1-) White
19* 4-5 BAT Red
52 5-9 OPT 2-3 (SH+) Gray
20* 4-11 BAT GND Black
53 5-10 OPT 2-4 (SH-) White
21 2-4 RW Phase A+ Blue
54 6-1 OPT 2-5 (GV2+) Yellow
22 2-10 Phase A- White
55 6-2 OPT 2-6 (GV2-) White
23 2-5 Phase B+ Gray
56 6-3 OPT 3-1 (Spare1+) Pink
24 2-11 Phase B- White
57 6-4 OPT 3-2 (Spare1-) Gray
25 2-6 Phase S+ Yellow
58 5-5 OT1+ Red
26 2-12 Phase S- White
59 5-6 OT1- Black
27 3-1 BW Phase A+ Blue
60 5-11 OT2+ Pink
28 3-7 Phase A- White
61 5-12 OT2- Gray
29 3-2 Phase B+ Gray
62 6-7 Connection C shield Green/Yellow
30 3-8 Phase B- White
31 3-3 Phase S+ Yellow * No.19 and No.20 are not used in G3 controllers.

32 3-9 Phase S- White

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2) Pins location

1-1 1-2 1-3 1-4 1-5

４１

1-7
1-6

Slot 1
1 - 12

Slot 2

Slot 3

Slot 4

Slot 5

6-6
Slot 6

6-1 6 - 12

6-7 6 - 11
6-8 6-9 6 - 10

Note
Layout of pins “-1” to “-12” of “Slot 2” to “Slot 5” are the same as that of “Slot 1” and “Slot 6”.

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2.3.2 A-MOLEX connector (58691-0010)

1) Pin numbers and signals
No. Pin No. Signal name Color
No. Pin No. Signal name Color
19 5-1 FD Phase U Red
1 1-1 RT Phase U Red
20 5-2 FD Phase V White
2 1-2 Phase V White
21 5-3 FD Phase W Black
3 1-3 Phase W Black
22 6-6 FB 1 Orange/Black
4 1-4 UA Phase U Red
23 (6-6) FB 2 Orange
5 1-5 Phase V White
24 4-6 E Green/Yellow
6 1-6 Phase W Black
25 4-3 Motor ground Green/Yellow
7 2-1 FA Phase U Red
26 4-1 BK+ Green/Yellow
8 2-2 Phase V White
27 4-2 BK - Orange
9 2-3 Phase W Black
28 4-4 BKR+ Black
10 2-4 RW Phase U Red
29 4-5 BKR - White
11 2-5 Phase V White
30 PE Mechanical ground Green/Yellow
12 2-6 Phase W Black
13 3-1 BW Phase U Red
14 3-2 Phase V White
15 3-3 Phase W Black
16 3-4 TW Phase U Red
17 3-5 Phase V White
18 3-6 Phase V Black

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2) Pins location

1-1 1-2 1-3

1-4
1-6

Slot 1

Slot 2
1-5

Slot 3

Slot 4
6-2

Slot 5

Slot 6 6-3

6-1
6-6

6-4 6-5

Note
Layout of pins “-1” to “-12” of “Slot 2” to “Slot 5” are the same as that of “Slot 1” and “Slot 6”.

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2.3.3 D-1, D-2. D-3, D-4. D-5 connectors: Resolver I/F card (ZUEP5764*, ZUEP5764*A1)
1) ZUEP5764*

D-3 connector (RS2/5, RS3/6)

D-1 Signal name (color) Pin No. Signal name (color)
NC 7 8 Shield Green/
Yellow

D-3 UA R1 Yellow 5 6 UA R2 White

UA S1 Gray 3 4 UA S3 White
UA S2 Blue 1 2 UA S4 White
D-5 D-4 The same for FA except signal name (switch from “UA” to “FA”)

D-4 connector (RS1/4)

Signal name (color) Pin No. Signal name (color)
D-1 connector (PG1) Shield Green/ 8 7 NC
Yellow
Signal name (color) Pin No. Signal name (color)
RT R2 White 6 5 RT R1 Yellow
FA Shield Green/ 23 24 UAFA Shield Green/
Yellow Yellow RT S3 White 4 3 RT S1 Gray
VCC 21 22 GND RT S4 White 2 1 RT S2 Blue
FA Phase S+ Orange 19 20 FA Phase S- White
FA Phase B+ Pink 17 18 FA Phase B- White D-5 connector (BAT1 to BAT6)
FA Phase A+ Purple 15 16 FA Phase A- White Pin No. Signal name (color)
UA Phase S+ Yellow 13 14 UA Phase S- White 1 BAT Red
UA Phase B+ Gray 11 12 UA Phase B- White 2 BAT GND Black
UA Phase A+ Blue 9 10 UA Phase A- White Battery connection
RA Phase S+ Yellow 7 8 RA Phase S- White
RA Phase B+ Gray 5 6 RA Phase B- White
RA Phase A+ Blue 3 4 RA Phase A- White
BAT Red 1 2 BATGND Black

2) ZUEP5764*A1
TW Phase B+ Pink 15 16 TW Phase B- White
TW Phase A+ While 13 14 TW Phase A- White
BW Phase S+ Yellow 11 12 BW Phase S- White
D-2
BW Phase B+ Gray 9 10 BW Phase B- White
BW Phase A+ Blue 7 8 BW Phase A- White
RW Phase S+ Yellow 5 6 RW Phase S- White
RW Phase B+ Gray 3 4 RW Phase B- White
D-3 RW Phase A+ Blue 1 2 RW Phase A- White

D-3 connector (RS1/4, RS2/5, RS3/6)

Signal name (color) Pin No. Signal name (color)
NC 7 8 Shield Green/
D-1 connector (PG1) Yellow
Signal name (color) Pin No. Signal name (color) RW R1 Yellow 5 6 RW R2 White
RW shield Yellow/ 21 22 BWTW shield Yellow/ RW S1 Gray 3 4 RW S3 White
Blue Blue RW S2 Blue 1 2 RW S4 White
VCC Red 19 20 GND Black The same for BW and TW except signal name (switch from “UA”
TW Phase S+ Orange 17 18 TW Phase S- White to “BW” or “TW” respectively.)

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2.3.4 D-3, D-4 connector (Hirose: DF11-8DS-2C)

• For resolver signal cable

D-3 D-4

D-3 connector (RT, UA, FA, RW, BW, TW, FD-RS) D-4 connector (RT, UA, FA, RW, BW, TW, FD-RS)
Signal name (color) Pin No. Signal name (color) Signal name (color) Pin No. Signal name (color)
NC 7 8 Shield Green/ NC 7 8 Shield Green/
Yellow Yellow
R1 Yellow 5 6 R2 White R1 Yellow 5 6 R2 White
S1 Gray 3 4 S3 White S1 Gray 3 4 S3 White
S2 Blue 1 2 S4 White S2 Blue 1 2 S4 White

2.3.5 E-1, E-2 connector (Nichiatsu: ELP-04NV, ELR04-NVF)

• For UA axis motor power cable

E-1 E-2

E-1 connector (UA-M) E-2 connector (UA-M)

Pin No. Signal name (color) Pin No. Signal name (color)
1 Phase U Red 1 Phase U Red
2 Phase V White 2 Phase V White
3 Phase W Black 3 Phase W Black
4 E Green/Yellow 4 E Green/Yellow

2.3.6 E-3, E4 connector (Nichiatsu: SLP-04V, SLR-04VF)

• For RT, FA, BW-axis motor power cable
Brake connector

E-3 E-4

E-3 connector (RT, FA, BW-M) E-4 connector (RT, FA, BW-M)
Pin No. Signal name (color) Pin No. Signal name (color)
1 Phase U Red 1 Phase U Red
2 Phase V White 2 Phase V White
3 Phase W Black 3 Phase W Black
4 E Green/Yellow 4 E Green/Yellow

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2.3.7 E-5, E6 connector (Nichiatsu: XAO-04V-1, XARR-04VF)

• For RW, TW-axis feeder motor power cable
Brake connector
Brake connector

E-5 E-6

E-5 connector (RW, TW-M) E-6 connector (RW, TW-M)

Pin No. Signal name (color) Pin No. Signal name (color)
1 Phase U Red 1 Phase U Red
2 Phase V White 2 Phase V White
3 Phase W Black 3 Phase W Black
4 E Green/Yellow 4 E Green/Yellow

2.3.8 F-3, F-1 connector: Brake card (ZUEP5759*, ZUEP5760*)

1) ZUEP5759* (Standard specification)

F-3 connector (BK-PWR)

F-3 Pin No. Signal name (color)
1 BK + Orange/Black
2 BK - Orange
3 BKR + Black
4 BKR - White
F-1

F-1 connector (RT, UA, FA, RW, BW, TW-BK)

Pin No. Signal name (color)
1 BK + Orange/Black (Black)
2 BK - Orange
* Color in bracket is for BK relay harness U, BK
relay harness R and fan harness.

2) ZUEP5760* (CE and UL specifications)

F-3 connector (RT, FA, BW-M)

F-3 Pin No. Signal name (color)

1 BK + Orange/Black
2 BK - Orange
3 BKR + Black
4 BKR - White

F-1
F-1 connector (RT, UA, FA, RW, BW, TW-BK)
Pin No. Signal name (color)
1 BK + Orange/Black (Black)
2 BK - Orange
* Color in bracket is for BK relay harness U, BK
relay harness R and fan harness.

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2.3.9 F-1, F-2 connector (Nichiatsu: XAP-02V-1, XARR-02VF)

• For RT, UA, FA, RW, WB and TW-axis motor brake
power cable

Orange tube

F-1 F-2

F-1 connector (RT, UA, FA, RW, BW, TW-BK) F-2 connector (RT, UA, FA, RW, BW, TW-BK)
Pin No. Signal name (color) Pin No. Signal name (color)
1 BK + Orange/Black (Black) 1 BK + Orange/Black (Black)
2 BK - Orange 2 BK - Orange
* Color in bracket is for BK relay harness U, BK * Color in bracket is for BK relay harness U, BK
relay harness R and fan harness. relay harness R and fan harness.

2.3.10 F-4, F-5 connector (Nichiatsu: XAP-02V-1, XARR-02VF)

• For FAN power cable

F-4 F-5

F4 connector (FAN) F-5 connector (FAN)

Pin No. Signal name (color) Pin No. Signal name (color)
1 BK + Orange/Black (Black) 1 BK + Orange/Black (Black)
2 BK - Orange 2 BK - Orange
* Color in bracket is for BK relay harness U, BK * Color in bracket is for BK relay harness U, BK
relay harness R and fan harness. relay harness R and fan harness.

2.3.11 H-1, H-2 connector (Hirose: DF11-6DS-2C)

• For gas valve power cable

H-1
H-2

H-1 connector (GV / UA, FA-OT) H-2 connector (GV / UA, FA-OT)
Signal name (color) Pin No. Signal name (color) Signal name (color) Pin No. Signal name (color)
GV/OT 1+ Red 1 2 GV/OT 1- Black GV/OT 1+ Red 1 2 GV/OT 1- Black
GV/OT 2+ Pink 3 4 GV/OT 2- Gray GV/OT 2+ Pink 3 4 GV/OT 2- Gray
NC 5 6 Shield Green/ NC 5 6 Shield Green/
Yellow Yellow

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2.3.12 J-3 connector (Nichiatsu: STO-01T-187N)

For gas valve power cable

J-3 connector (GV1, GV2)

Pin No. Signal name (color)
1 Gas valve 1+
2 Gas valve 1-

J-3

2.3.13 H-4, H-5 connector (Nichiatsu: XAP-02V-1, XARR-02VF)

For Gas valve power cable
Details of fuse harness part

Fuse

CL connector
Wrist harness

CL connector Fuse holder

H-4 H-5

H-4 connector (FB) H-5 connector (FB)

Pin Fuse side Pin Fuse side
No. Signal name (color) Signal name (color) No. Signal name (color) Signal name (color)
1 FD-FB 1 Orange/Black FD-FB1 Black 1 FD-FB1 Black FD-FB 1 Orange/Black
2 FD-FB 2 Orange FD-FB2 Black 2 NC NC

2.3.14 J-1, J-2 connector (Hirose: DF11-6DS-2C)

• For Gas valve power cable

H-1 H-2

J-1 connector (SH) J-2 connector (SH)

Signal name (color) Pin No. Signal name (color) Signal name (color) Pin No. Signal name (color)
GV/OT 1+ Red 1 2 Safety Black Safety Red 1 2 Safety Black
holder - holder + holder -
GV/OT 2+ Pink 3 4 Spare 1- Gray Spare 1+ Pink 3 4 Spare 1- Gray
NC 5 6 Shield Green/ NC 5 6 Shield Green/
Yellow Yellow

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2.3.15 Feeder part: DDK connector (CM02-8DR5P)

1) Details of the feeder part

DDK connector 3

SH + Red SH + Red SH + Red

SH - Black SH - Black SH - Black
Spare+ Orange Spare+ Orange Spare+ Orange
Spare- Gray Spare- White Spare- White
FD FB1 Black

Connector
Feeder cable harness

2) Details of DDK connector

Positioning pin
DDK connector CM02-8DR5P (D3): Signal connection
Pin No. Signal name Color
1 1 Safety holder + Red
2 Safety holder - Black
4
3 Spare 1+ Orange
4 Spare 1- White
2
5 FD FB1 Black

5
3

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2.3.16 OT connecting connector

1) Standard and CE specifications

Wrist harness
(To swiveling harness)

Swiveling harness OT1+ Red OT1- Black

OT2+ Orange OT2- Gray
(To Wrist harness) NC NC
Shield Gn/Yw Shield Gn/Yw

OT1- Black
OT2- Gray
NC
Shield Gn/Yw
OT1- Black OT1+ Red
OT1- Black OT2- Gray OT2+ Orange
OT2- Gray NC NC
NC Shield Gn/Yw Shield Gn/Yw
Shield Gn/Yw

Swiveling harness

(To MOLEX connector) OT1+ Red OT1+ Red

OT2+ Orange OT2+ Orange
NC NC
NC Shield Gn/Yw

2) UL (RIA) specifications

Wrist harness
(To swiveling harness)

OT1+ Red OT1- Black

Swiveling harness OT2+ Orange OT2- Gray
NC NC
(To Wrist harness) Shield Gn/Yw Shield Gn/Yw
OT1- Black OT1- Black OT1+ Red OT1+ Red
OT2- Gray OT2- Gray OT2+ Orange OT2+ Orange
NC NC NC NC
Shield Gn/Yw Shield Gn/Yw NC Shield Gn/Yw
OT1- Black
OT2- Gray
NC
Shield Gn/Yw
OT1- Black
OT2- Gray
NC
OT1+ Red OT1- Black
Shield Gn/Yw
OT2+ Orange OT2- Gray
NC NC
Shield Gn/Yw Shield Gn/Yw
Swiveling harness
OT1+ Red OT1+ Red
(To MOLEX connector) OT2+ Orange OT2+ Orange
NC NC
NC Shield Gn/Yw

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2.3.17 Lamp harness connecting connector (UL spec.)

Black Orange Black Orange

BK+ Or/Bk BK+ Black BK+ Or/Bk BK+ Black
BK- Orange BK- Orange CL connector BK- Orange BK- Orange
Black Black
Orange Orange
CL connector
Swirveling harness Lamp harness Fan harness

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3. Harness replacement
It is recommended to replace inner harness and apply grease every forth year (or 8000
hours)

3.1 How to replace swiveling harness

3.1.1 Procedure

(1) Remove the RT motor cover, RSIF mounting plate and

BKSW mounting plate. RT
BKSW motor cover
mounting plate

RSIF
mounting plate

(2) Disconnect the connectors of RT motor harness

(power cable, brake cable and resolver signal har-
ness), and then remove the swiveling harness fixing
bracket and RT axis motor.

RT motor

Resolver
IF card

(3) Disconnect all connectors connecting wrist harness

and swiveling harness inside the UA body (including
gas hose), and then cover the reduction gear part with
plastic sheet or the like to avoid dust.
Details of inside of UA body
< Note >
Remove the binding bands at the bottom of the wrist
harness inlet port tying the “Wrist H fitting bracket”
(and also crossed roller bearing.) Tie them with
two binding bands

Swiveling harness
Cover with plastic
(4) Disconnect the brake card connecting connector of the fixing bracket
sheet or the like
BKSW mounting plate. to avoid dust.

< Note >

The figure on the right shows the one of standard
specification. Details of inside of UA body
When installing the harness, connect the harness in
accordance with the connector number of the brake
card of CE spec., UL spec. as well as standard spec. UA body
respectively.
BKSW
mounting plate

When BKSW mounting plate is removed

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(5) Disconnect all connectors connecting to the controller

and remove the terminal plate from the RT base, and
then disconnect the OT harness (RT limit switch)
inside.

RT base

Terminal plate

RT-OT
harness connector

(6) Disconnect the swiveling harness and the terminal When the terminal plate is removed
plate as a set.

< Note >

Preparing a jig for harness wiring (see the figure on the
right) will allow you to install the harness easily. (Put
the connector part at the end of the harness in the Terminal plate
mesh tube part, and then use the wire part to pass the
harness through.
Wire part

Mesh tube part

Jig for harness wiring

(7) Re-assemble the unit in reverse order of the above
procedure.

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3.2 How to replace wrist harness

3.2.1 Procedure

(1) Remove the TWBW cover, RW cover, RW rear cover RW cover TWBW cover
and RW harness cover on the left as you face.

RW rear cover

RW harness cover

(2) Disconnect the connectors of BWTW motor harness

(power cable, brake cable and resolver signal harness)
behind the TW cover. Cable holder Disconnect connector

(3) Remove the cable holder and remove two saddles. Two saddles

When BWTW cover (left) is removed

Removed cable holder and saddles

(4) Remove the saddle behind the RW cover and remove
the BWTW harness from the BW body to the RW body.

< Note >

When installing the harness, lightly apply Albania
grease to the coated part of the harness between the Pull out the harness
from BW body
saddle of RW body and the saddle of the BW body.

Saddle

Details of inside of the RW body (behind the RW cover)

(5) Disconnect all the connectors of feeder motor harness

(power cable, brake cable and resolver signal harness)
behind the RW rear cover and gas hose. (Do not forget
to disconnect the grounding cable.)

Gas hose

Feeder motor
harness connector

Details of inside of the RW body (behind the RW rear cover)

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(6) Disconnect the connectors of RW motor harness

(power cable, brake cable and resolver signal harness) Motor harness connector
at the RW harness cover

When the RW motor harness cover is removed

(7) Remove the wrist harness mounting bracket from the

RW body, and pull out the wrist harness from RW Wrist harness
body. mounting bracket

< Note >

• Work with caution when pulling out the wrist harness. Wire part
The ends of the wrist harness have been wired toward
three directions; toward RW cover to BWTW cover,
toward RW rear, and toward RW harness cover direc-
tions.
• Preparing a jig for harness wiring (see the figure on the
Mesh tube part
right) will allow you to install the harness easily. (Put
the connector part at the end of the harness in the Jig for harness wiring
mesh tube part, and then use the wire part to pass the
harness through.

(8) Remove the UA arm cover. UA arm cover

Nylon clamp

(9) Remove the nylon clamp, fixing plate and saddle from UAFA-OT cable
behind the UA arm cover.

< Note >

Fixing plate
When reassembling after completion of harness
replacement, fix UAFA-OT cable carefully not to touch
the coil spring.

Saddle

When UA arm cover is removed

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(10) Remove the RT motor cover, RSIF mounting plate and

BKSW mounting plate.
RT
motor cover
BKSW
mounting plate
RSIF
mounting plate

(11) Disconnect the connectors of RT motor harness

(power cable, brake cable and resolver signal harness)
inside UA body. Remove the swiveling harness fitting
bracket and RT axis motor.
RT motor

Resolver IF card

Details of inside of UA body

(12) Disconnect all the connectors connecting the wrist har-
ness and swiveling harness inside the UA body
(including gas hose) and cover the reduction gear part
with plastic sheet to avoid dust.

< Note > Tie them with

Remove the binding bands at the bottom of the wrist two binding bands
harness inlet port tying the “Wrist H fitting bracket”
(and also crossed roller bearing.)
Cover with plastic
Swivel harness
fixing bracket sheet or the like
to avoid dust.

(13) Disconnect the brake card connecting connector of the

BKSW mounting plate. Details of inside of UA body

< Note >

The figure on the right shows the one of standard
specification.
When installing the harness, connect the harness in
accordance with the connector number of the brake
card of CE spec., UL spec. as well as standard spec.
respectively. UA body
BKSW
mounting plate

When BKSW mounting plate is removed

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(14) Straighten the wrist harness inside UA body so as to

pull it out smoothly.

Wrist harness

Swivel harness

Details of inside of UA body

(15) Remove the wrist harness mounting bracket from UA

body, and then pull out the wrist harness.

< Note >

When installing the harness, work with caution not to
twist the coil spring.
Wrist harness

Mounting bracket

(16) Pull out the wrist harness from UA arm.

< Note >

• When installing the harness, slide the sleeve boot (rub-
ber part) and fixing bracket to pass the fitting part of
the harness through UA arm. Wrist harness
• To slide them easily, hold clamping part of the binding
band to the coil spring.
UA arm

(17) After replacement, re-assemble the unit in reverse

order of the above procedure.

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3.3 How to replace TW harness

3.3.1 Procedure

(1) Remove the TWBW cover on the left as you face.

TWBW cover

(2) Disconnect connectors of TW harness (power cable,

brake cable and resolver signal harness), and remove
TW harness connector Nylon clamp
three nylon clamps.

< Note >

• Disconnect the screw inside the curl cable with caution
not to drop the screw inside the BW body.
• When installing the harness, lightly apply Albania
grease to the curled part of the TW harness.
TW harness

When BWTW cover (left) is removed

(3) Loosen the CP bolts 6-M4x12(CW) ☆, and remove

the TW gear cover, and then unscrew the CP bolts 4-
M5x40 (CW) ☆.
Nylon clamp
< Note >
• To remove the TW gear cover, use the cutout to pry
open with the flathead screwdriver.
• Prior to reassemble the TW gear cover, remove the old CP bolt 6-M4x12(CW) ☆
sealing agent (THREE BOND: 1211) and newly apply
it. Sealing agent
THREE BOND; 1211

(4) Loosen the CP bolts 2-M5x18(CW) ☆ and remove the

Cutout part
TW gear housing from TW body.
When TW gear cover is removed

CP bolt 4-M5x40(CW) ☆

CP bolt 2-M5x18 (CW) ☆

TW gear housing

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(5) Disconnect connectors of TW motor harness (power TW body TW motor

cable, brake cable and resolver signal harness).

TW gear
housing

TW motor
harness
connectors

When TW gear housing is removed

(6) Pull out TW harness from the Bearing fix side of BW

body.
BW body
< Note >
• When installing the harness, lightly apply Albania Bearing fix
grease to the curled part of TW harness.
• Preparing a jig for harness wiring (see the figure on the
right) will allow you to install the harness easily. (Put
the connector part at the end of the harness in the Wire part
mesh tube part, and then use the wire part to pass the
harness through.
TW harness

Mesh tube part

Jig for harness wiring

(7) After replacement, re-assemble the unit in reverse
order of the above procedure.

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4. Motor replacement
4.1 Location of motors and resolver card
4.1.1 TAWERS type

BW axis motor

FA axis motor

UA axis motor

TW axis motor RW axis motor

Feeder motor

Feeder part
(TAWERS spec.)

Resolver card
レゾルバカード

RT axis motor

Battery
(Lithium battery)

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4.2 Cautions at motor replacement

Under the main power off condition, when the resolver is Please note that it is necessary to perform “Encoder reset”
disconnected for motor replacement, the message “Sensor and then “Origin adjustment” after replacing the motor (if
cable disconnected. Check sensor cable. And reset the connector between the resolver R and D is discon-
encoder.” appears. nected.)

4.2.1 How to reset encoder after motor replacement

Connect the resolver signal connector of the The resolver IF cards stack in pairs (one card
motor to the inner harness. Note for three axes) are installed inside the RT motor
cover.
Connect the connector on the motor harness Resolver card Resolver card)
side to the resolver IF card. (ZUEP5764*) (ZUEP5764*A1)
RST1: For RT axis RST1: For RW axis
RST2: For UA axis RST2: For BW axis
On the resolver IF card, short-circuit the terminal RST3: For FA axis RTS3: For TW axis
between the PIN 1 and Pin2 of RST1, RST2 and
TST3 for more than 10 seconds. (Do not tough
any other things.)

ＲＳＴ1 to 3
RST3
１

RST2

RST1
２

Short-circuit

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4.2.2 Standard clamp torque for each bolt at motor replacement

(1) Bolts (2) Washers

Bolts Clamp torque Washer Name

M N•m kgf•cm SW Spring lock washer
3 20 ±0.02 20 ±0.2 CW Conical spring washer
4 4.5 ±0.05 46 ±0.5 PW Plain washer
5 9.8 ±0.1 100 ±1
6 18.5 ±0.2 188 ±2
8 37 ±0.4 380 ±4
10 74 ±0.7 750 ±8
12 128 ±1.3 1310 ±13
14 205 ±2.1 2090 ±21
16 319 ±3.2 3250 ±33
20 622 ±6.2 6350 ±64

4.2.3 Cautions
（1）Handle screws carefully not to drop them inside UA <SPECIAL TOOL> (Having hexagonal wrench enlarged.)
or RW body when working on RT and RW axes. If
screws fell in the UA or RW body, it is very difficult to Hexagonal wrench Torque wrench
pick them up. Recommended to use
Do not remove RT motor cover and RW cover unless • None round-ended type
you are working on those axes. • Magnet type.

（2）It is necessary to use a special tool as per figure on

the right or the like to remove or re-assemble the
servo motor of each of RT, UA, FA and RW axis.

100 to 120 mm length

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4.3 RT axis motor replacement

4.3.1 Replacing procedure
(1) Unscrew the screws (A) 8-M4x10.
(2) Remove RT motor cover (B).
(3) Disconnect the connectors of RT motor harness Part name Specification
(power cable and brake cable) under the RT motor A Screw 8-M4x10
cover.
B RT motor cover AKK22008
(4) Disconnect the connector of RT axis motor resolver
signal harness behind RT motor cover from the C Resolver IF card ZUEP5764*
resolver IF card (C). D CP bolt 4-M6x20 (CW)
(5) Unscrew the CP bolts (D) 4-M6x20. E Servo motor TS4614N8323
(6) Remove the servo motor (E). F 1 M5x15 (SW)
CP bolt *
(7) Unscrew the CP bolt (F) *1 M5x15. Torque:9.8 N•m (100 kgf•cm)
(8) Remove the motor collar 082 (G). G Motor collar 082 AFM40262
(9) Remove the pinion gear 31 (H). H Pinion gear 31 ADG41078
(10) Install a new motor.
(11) Re-assemble the unit in reverse order of the above Note
procedure. *1: Apply “Screw lock 1344 (product of Three bond)”,
(12) After completion of replacement, perforn encoder reset and then screw it at the specified torque.perforn
and origin adjustment without fail.

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4.3.2 Details of RT motor installation area

D C

RW motor cover
View from A

F
G

View from B

Motor axis part

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4.4 UA axis motor replacement

4.4.1 Replacing procedure
(1) Set the belt to RW body and wrist unit parts, and then
lift the arm with a crane or the like.
* Work with caution not to drop RW body and wrist
part. Part name Specification
(2) Unscrew the screws (A) 8-M4x10. A Screw 8-M4x10
(3) Remove RT motor cover (B).
B RT motor cover AKK22008
Then, disconnect the connectors of UA axis motor har-
ness (power cable, brake cable and resolver signal C CP bolt 4-M8x30 (CW)
harness) behind RT motor cover. D Servo motor TS4832N9030
(4) Unscrew the CP bolts (C) 4-M8x30 (CW), and then E M5x60 (SW)
CP bolt *1
remove the servo motor (D). Torque:9.8 N•m (100 kgf•cm)
(5) Unscrew the CP bolt (E) *1 M5x60 (CW), and then F Input gear 40 ADG32013
remove the input gear (F).
G O-ring Attachment of servo motor
(6) Install a new motor.
(Pay attention to the O-ring attached to the motor Note
when inserting the new motor into the UA body side.)
*1: Apply “Screw lock 1344 (product of Three bond)”,
(7) Re-assemble the unit in reverse order of the above and then screw it at the specified torque.
procedure.
(8) After completion of replacement, perforn encoder reset
and origin adjustment without fail.

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4.4.2 Details of UA motor installation area

B’

A
C

RT motor cover View from A

F
D

E
G

B-B’ cross section

F

Motor axis part

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4.5 FA axis motor replacement

4.5.1 Replacing procedure
(1) Set the belt to RW body and wrist unit parts, and then
lift the arm with a crane or the like. Part name Specification
* Work with caution not to drop RW body and wrist
A FA-axis servo TS4613N8337
part.
motor
(2) Pull out FA-axis motor harness (power cable, brake
cable and resolver signal cable) from the through hole B CP bolt 4-M6x20 (CW)
for harness at the side of FA-axis servo motor (A), and C CP bolt*1 M5x60 (SW)
disconnect the connectors. Torque:9.8 N•m (100 kgf•cm)
(3) Unscrew the CP bolts (B) 4-M6x20 (CW), and then D Input gear 20 ADG32013
remove FA-axis servo motor (A).
Note
(4) Unscrew the CP bolt (C) *1 M5x60 (SW), and then
remove the input gear (D). *1: Apply “Screw lock 1344 (product of Three bond)”,
and then screw it at the specified torque.
(5) Install a new motor.
(6) Re-assemble the unit in reverse order of the above
procedure.
(7) After completion of replacement, perforn encoder reset
and origin adjustment without fail.

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4.5.2 Details of FA motor installation area

A
B’

Motor harness
B

Harness through hole

View from A

C
C

B-B’ cross section

Motor axis part

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4.6 RW axis motor replacement

4.6.1 Replacing procedure
(1) Slightly loosen the cable grand (A).
(2) Unscrew the screws (B) 3-M4x10, and then remove Part name Specification
RW harness cover (C) with the cable grand (A) A Cable grand MG25AH208BST
attached.
B Screw 3-M4x10
(3) Disconnect the connectors of RW-axis motor harness
(power cable, brake cable and resolver signal harness) C RW harness AGK41021
behind RW motor cover, and then remove the cable cover
grand from the motor harness. D CP bolt*1 4-M5x15
(4) Unscrew the CP bolts (D)*14-M5x15(SW), and then Torque:9.8 N•m (100 kgf•cm)
remove the servo motor (E). E Servo motor TS4607N8337
(5) Unscrew CP bolts (F)*1 1-M4x19(SW), and then F CP bolt*1 1-M4x10
remove the motor collar 022 (G) and wave generator Torque:4.5 N•m (46 kgf•cm)
(H).
G Motor collar AFM40217
(6) Install a new motor.
H Wave generator SG17500R41R
(7) Re-assemble the unit in reverse order of the above
procedure. Note
(8) After completion of replacement, perforn encoder reset *1: Apply “Screw lock 1344 (product of Three bond)”,
and origin adjustment without fail. and then screw it at the specified torque.
• At reassembly, apply grease SK-1A(I) to the wave
generator,

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4.6.2 Details of RW motor installation area

C
RW motor mounting area

G
I F

Apply grease SK-1A

to the ball side of wave generator.

Wave generator mounting area

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4.7 BW motor replacement

4.7.1 Replacing procedure
(1) Unscrew the screws (A) 5-M4x10, and then remove
BW motor cover (B). Part name Specification
(2) Disconnect the connectors of BW motor harness A Screw 5-M4x10
(power cable, brake cable and resolver signal harness)
behind TWBW motor cover. B TWBW cover ADK32021
(3) Unscrew the CP bolts (C) 4-M6x12 (SW), and while C CP bolt 4-M6x12 (SW)
removing the timing belt (D), remove the servo motor D Timing belt 060S3M339
(E).
E Servo motor TS4607N8337
(4) Unscrew the CP bolts (F) *1 4-M3x8, and then remove
F CP bolt *1 4-M3x8
the pulley H (G).
Torque:2.0 N•m (20 kgf•cm)
(5) Loosen the set screws (H)*2 2-M3x3 and remove the
G Pulley H ADW41060
pulley shaft M (I).
(6) Install a new motor. H Set screw *2 2-M3x3
(7) Re-assemble the unit in reverse order of the above I Pulley shaft M ADS41069
procedure.
Note
(8) After completion of replacement, perforn encoder reset
and origin adjustment without fail. *1: Apply “Screw lock 1344 (product of Three bond)”,
and then screw it at the specified torque.
*2: Apply “Screw lock 1344 (product of Three bond)”,
and then screw it.

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4.7.2 Details of BW motor installation area

B A

C C’

C-C’ cross section

B A

Motor harness
E

View from A

D G

Motor mounting area

View from B

G F I H

Pulley H Pulley shaft M

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4.8 TW motor replacement

4.8.1 Replacing procedure
(1) Remove the torch and safety holder.
(2) In case of performing TW motor replacement work Part name Specification
alone, position the robot so that after the removal of A 6-M4x12 (SW)
CP bolt *1
TW axis, you can place the TW axis with the motor Torque:4.5 N•m (46 kgf•cm)
harness connected to the work bench.
B TW gear cover Type-1: ADA32027
(3) Unscrew the CP bolts (A) 6-M4x12 (CW) *1, and then Type-2: ADA32029
pull out the TW gear cover (B) for C-C’ to the end.
C CP bolt *2 4-M5x40 (SW)
(4) Unscrew CP bolts (C)*2 4-M5x40 and CP bolts (D)*2 Torque:9.8 N•m (100 kgf•cm)
2-M5x18, and then pull out the TW gear housing (E)
D CP bolt *2 2-M5x18 (SW)
with TW servo motor (F) attached. Please the removed
Torque:9.8 N•m (100 kgf•cm)
TW gear housing (E) on the work bench and then dis-
connect connectors of TW-axis motor harness (power E TW gear housing Type-1: ADH22013
cable, brake cable and resolver signal harness). Type-2: ADH22014
(5) Unscrew the CP bolts (G) *2 6-M4x12 (CW), and F TW servo motor TS4602N8030
remove the servo motor (F) with TW motor plate (H) Previous type: TS4602N8023(*)
attached. G 6-M4x12 (SW)
CP bolt *2
(6) Remove the snap ring (I) Torque:4.5 N•m (46 kgf•cm)
Loosen the setscrews (K)*3 2-M3x3 to remove the H TW motor plate AFP32028
wave generator (J), and then remove the other snap
ring (L). I Snap ring STW8
(7) Unscrew the CP bolts (M) 2-M4x12 (SW), and then J Wave generator SG1450QR61T
remove the TW motor plate (H). (Included in Harmonic reduc-
(8) Install a new motor. tion gear set.)
(9) Re-assemble the unit in reverse order of the above K Setscrew *3 2-M3x3
procedure.
L Snap ring STW8
(10) After completion of replacement, perforn encoder reset
and origin adjustment without fail. M CP bolt *2 2-M4x12 (SW)

Note
*1: Screw it at the specified torque.
*2: Apply “Screw lock 1344 (product of Three bond)”, and
then screw it at the specified torque.
*3: Apply “Screw lock 1344 (product of Three bond)”, and
then screw it.
• Be aware of harmonic grease SK-1A state at reassem-
bly.
(*) For products manufactured before November, 2007.

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 Reduction gear replacement and grease injection

4.8.2 Details of TW motor installation area

D
A B
C

C’
D’ View from B

C D

View from A TW gear housing Details of “View from B”

TW motor harness
H F
E

F
M

H
TW motor plate Details of inside of TW body

I
H L
J K

I J

K
L F

Wave generator Wave generator mounting area

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 Reduction gear replacement and grease injection

4.9 Wire feed motor replacement (for TAWERS)

4.9.1 Replacing procedure
(1) Disconnect welding torch (A), gas hose (B), user cable
connector (C), cabtire cable (D), flexible conduit (E) Part name Specification
and feeder cable connector (F) from the wire feeder.
A Welding torch
(2) Unscrew the upset bolt (H) connecting the feeder fixing
bracket 2 (G) to remove the wire feeder. B Gas hose Included in the welding torch
C User cable con- Included in the welding torch
<In case of replacing the wire feeder as a set> nector
(3) Connect each part of the new wire feeder according to D Cabtire cable
the following procedure (5) to (1).
E Flexible conduit

<In case of replacing the motor only> F Feeder cable

For procedure after the above (2), please refer to the sec- G Feeder fixing AFM41711
tion "4.9.3 How to replace the wire feeder motor" on page bracket 2
46.
H Upset bolt 4-M6x20

4.9.2 Details of wire feeder installation area

A
B
E

D
B

Wire feeder A

C
G

Torch cable connecting part

Wire feeder mounting area

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 Reduction gear replacement and grease injection

4.9.3 How to replace the wire feeder motor

(1) Refer to section “"4.9.1 Replacing procedure" on page
45 and remove the wire feeder. Part name Specification
(2) Unscrew the CP bolts (A) 4-M5x40 (W, SW), and the A CP bolt 3-M5x40 (W, SW)
remove the motor unit (B) and feed unit (C).
B Motor unit ADU01550
(3) Loosen the cable grand (D), and then remove it from
the feeder fixing bracket 3. C Feed unit ADU01489
(4) Unscrew the CP bolts (F) 3-M5-55 (CW), and then D Cable grand MG25AH208BST
remove the feeder fixing bracket 1 (G) with the feeder E Feeder fixing AFM41712
fixing bracket 2(H) attached. bracket 3
(5) Unscrew the CP bolts (I) 6-M4-30 (N), and then open
F CP bolt 3-M5x55 (CW)
the gear boxes L (J) and R (K).
* Work with caution not to loose the M4 nuts. G Feeder fixing AFM41719
(6) Disconnect the motor (L) lead connector (M). bracket 1
(7) From the gear box L (J), remove motor (L), coupling H Feeder fixing AFM41711
(motor side boss) (N), coupling (spacer) (O), coupling bracket 2
(worm gear side boss) (P) and worm gear (Q). I CP bolt 6-M4x30 (N)
(8) Loosen the setscrews (R) 2-M3x5, and remove the
J Gear box L ADH12523
coupling (motor side boss) (N) and coupling (spacer)
(O) from the motor (L). K Gear box R ADH12522
(9) Loosen the coupling “worm gear side boss) (P) and L Motor TS4602N3030
setscrews (S) 2-M3x5 to remove them. Previous type: TS4602N3023(*)
• In case of not replacing the worm gear (Q), it is not
M Motor lead con- Included in motor
necessary to remove the coupling (worm gear side
nector
boss). Loosen the setscrews (S) 2-M3x5 for temporary
joint. N Coupling (motor MCOG20-8-0
• In case of replacing work gear (Q), remove the bear- side boss) (A set of N,O and P)
ings (U) at the both sides. O Coupling (spacer) MCOG20-8-0
(10) Attach the coupling (motor side boss) to the new motor (A set of N,O and P)
(L).
P Coupling (worm MCOG20-8-0
*Of the coupling, set the side with smaller hole diame-
gear side boss) (A set of N,O and P)
ter to the motor.
• Match the flat surface of the setscrew (R) and that of Q Work gear ADW41068
the motor shaft. R Setscrew (motor 2-M3x5
• Fasten the setscrew (R) lightly until the setscrew lightly side boss) (Included in coupling)
touch the flat surface of the motor shaft) then insert the
S Setscrew (worm 2-M3x5
shaft until the motor shaft slightly protrude from the
gear side boss) (Included in coupling)
coupling (motor side boss).
• Then fasten the setscrew (R) tight. T Worm wheel ADW41064
(11) Attach the coupling (worm gear side boss) (P). U Bearing 6000ZZ (2 pieces)
*Of the coupling, set the side with larger hole diameter (*) For products manufactured before November, 2007.
to the worm gear.
• Match the flat surface of the setscrew (S) and that of
the motor shaft and fasten the setscrew (S) lightly for
temporary joint.
(12) Attach the new motor (L) with the coupling (motor side
boss (N) attached to the gear box L (J).
(13) Set the coupling (spacer) (O) to the coupling (motor
side boss) (N).
(14) Set the coupling (worm gear side boss) (P) to the cou-
pling (spacer) (O).
(15) Apply adequate amount of Albania No.2 grease to the
worm gear (Q) and work wheel (T).
(16) Re-assemble the unit in reverse order of the above
procedure.

<How to install the wire feeder>

For procedure to install the wire feeder, please refer to sec-
tion "4.9.1 Replacing procedure" on page 45.

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 Reduction gear replacement and grease injection

4.9.4 Details of wire feeder motor installation area

Feed unit mounting area Feed unit mounting area

E E G H

D F

Feed unit mounting area Feed unit mounting area

Do not loose the nuts.

Gear boxes L and R mounting area

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 Reduction gear replacement and grease injection

K J

When the gear boxes L and R are open

Q P O N L

Inside the gear box L

P O N R
P O N
Q
L

H R
Removed motor, coupling and worm gear Coupling mounting area

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 Reduction gear replacement and grease injection

U Q U L
P O N
Flat surface Flat surface

Flat surface
Flat surface of the work gear Coupling

Flat surface of motor shaft

Coupling

Worm gear side boss Motor side boss

(Larger hole diameter) Spacer (Smaller hole diameter)

Q S P O N R L

Worm gear side coupling (boss) Coupling (spacer)

Motor side coupling (boss)

Shaft slightly protrudes

Enlarged (motor side coupling (boss)

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 Reduction gear replacement and grease injection

N P
O
L S
Q

Coupling (spacer) mounting area Worm gear mounting area

Adjust to ensure 0.5 mm space.

(Place a ruler with 0.5 mm thickness
Q
S to adjust it.)

Apply adequate amount of

Albania No.2 grease.

Adjusting space of the coupling Applying grease to the worm gear part

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 Reduction gear replacement and grease injection

5. Reduction gear replacement and grease injection

5.1 Cautions for reduction gear replacement
Possible causes of looseness of axis or abnormal noise Please note that it is necessary to perform “Encoder reset”
are not only failure in RV reduction gear or harmonic reduc- and then “Origin adjustment” after replacing the reduction
tion gear but also in bearing. It is recommended to replace gear (if the connector between the resolver R and D is dis-
the bearing at the same time as a replacement of RV connected) as the replacement procedure includes
reduction gear and harmonic reduction gear. removal of the motor.

Under the main power off condition, when the resolver is

disconnected, the message “Sensor cable disconnected.
Check sensor cable. And reset encoder.” appears.

5.1.1 Points of grease injection to RV reduction gear at RV reduction gear replacement

(1) Grease type
RT, UA and FA axis: VIGOGREASE RE0
(2) After mounting RV reduction gear and motor, remove <Dedicated grease pump for VIGOGREASE RE0>
the sunk plugs of the grease supply/air relief (SP1/8B,
for RT axis, M6x12 bolt is used as air relief plug). PT1/8 nipple
Inject VIGOGREASE RE0 using the dedicated grease
pump. Inject it until a small amount of grease overflows
from the air relief.
(3) Apply the silicon sealing agent 1211 (product of
THREE BOND) to the sunk plugs (SP1/8B) and M6x12
bolts, and then put the plugs and bolts back in place
and fasten them tight.

5.1.2 Points of grease application to harmonic reduction gear at HDC replacement

(1) Grease type (5) Apply the grease to the inner circumference of the
RW and TW axes: Harmonic grease SK-1A gear surface side of the flexspline and the front side of
BW axis: Harmonic grease SK-2 the outer circumference of the wave generator.
(2) Apply the grease until the gear surfaces of both the cir- (6) Apply the grease to the bearing part of the wave gen-
cularspline and flexspline are covered. erator until the grease runs over from the other side.
(3) Apply a small amount of the grease to the boss part of Rotate the wave generator a couple of times so that
the wave generator and the flange part of the flex- the grease is applied evenly. (See the section “Photos
spline as rust-proofing. of grease applied surface”.)
(4) Apply 1 to 2 grams of grease to the inner circumfer- (7) At the time of replacing the harmonic reduction gear,
ence of the flexspline evenly. make sure to replace the circularspline, flexspline and
the wave generator as a set.
(8) Apply the specified harmonic grease to the oil seal lip
to each attached to the motor.

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 Reduction gear replacement and grease injection

<Reference data for grease injection>

In case of using a grease gun to supply the grease (SK-
1A), count the number of push required to eject a certain
amount of grease so as to find out the amount of ejected
grease per push with a mass meter, such as an electric
platform weighing machine, beforehand.
* Please be aware of the measurable range of the meter.

For example,
The grease gun on the right was pushed 30 times to eject <Grease gun>
19.2 g of grease. That means, it eject 0.64 g of grease per
push. <1 g of SK-1A grease>
• To inject 1 g of the grease, push 1.5 times.
• To inject 2 g of the grease, push 3 times.
• To inject 9 g of the grease, push 14 times.
Never exceed the specified amount.
If the excessive grease is applied and the robot comes to
an alarm stop, remove the motor and remove the exces-
sive grease direct. (See section “Motor replacement” and
“Points of grease application to harmonic reduction gear”.)

5.1.3 Specific gravity for each grease

Specific gravity for each grease at the temperature of 15
degrees Celsius is as follow.
Harmonic grease: SK-1A........................................... 0.92
RV reduction gear grease: VIGOGREASE RE0........ 0.87

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 Reduction gear replacement and grease injection

5.2 Photos of grease applied surface

5.2.1 RT, UA and FA axes: RV reduction gear

Grease type: VIGOGREASE RE0

Enclosed capacity: [RT axis] 547g (+30g for ceiling specification)
[UA axis] 329 g
[FA axis] 192 g
* Fill the grease after installation and replace the contents with new one every three years (or 6000 hours).

RT axis UA, FA axis

5.2.2 RW axis: Harmonic reduction gear and RW body gear

Grease type: SK-1A

Enclosed capacity: 86g (Resupply 17 every three years.)
* Fill the grease after installation and resupply 17 grams every three years.

Flexspline Wave generator

RW output gear RW input gear

Motor plate

RW body (when RW gear cover is removed)

Circularspline RW harmonic reduction gear

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 Reduction gear replacement and grease injection

5.2.3 BW axis

Grease type: SK-2

Enclosed capacity: 21g
* Fill the grease after installation and resupply 4 grams every three years.

Apply to the ball side BWHD shaft

Wave generator

BWHD cover

HD housing side Wave generator BWHD cover side

5.2.4 TW axis

Grease type: SK-1A

Enclosed capacity: 55.5g
* Fill the grease after installation and resupply 11 grams every three years.

Wave generator Flexspline Circularspline

TW housing side TW-axis motor RW harmonic reduction gear side

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 Reduction gear replacement and grease injection

5.3 Resupply of grease for reduction gears and location of grease supply/air
relief ports
5.3.1 TW, BW and RW axis
Resupply the grease to the TW, BW and RW-axis harmonic reduction gear and
TW, BW and RW-axis gear every three years (or every 6000 hours).

(1) TW axis:
Remove the setscrew (1) for air relief.
Inject 1 g of “SK-1A” from the sank plug (2) (supply (1) Setscrew
(2-M6x6)
port). (2) Sunk plug
(SP1/8B)
(2) TW axis:
Then apply silicon sealing agent 1211 (product of
THREE BOND) to the setscrew (1) before screwing
them tight.

TW housing (Left) TW housing (Right)

(3) BW axis:
Unscrew the setscrew (3) (air relief) at the TW body
and then unscrew the setscrew (4) (M4x6) (supply
port). (4) Setscrew (3) Setscrew
Then inject 4 g of “SK-2” grease from (4). (M4x6) (M4x6)

(4) BW axis:
Then apply silicon sealing agent 1211 (product of
THREE BOND) to setscrews (3) and (4) before screw-
ing them tight.

Behind TWBW cove Above BW body

(Right)

(5) RW axis: (7) Sunk plug

(SP1/8B)
Remove the sunk plugs (5) and (6) (air relief) and also
sunk plug (7) (supply port).
Then inject 17 g of “SK-1A” from the plug (7).

(6) RW axis:
Apply silicon sealing agent 1211 (product of THREE (6) Sunk plug
(SP1/8B)
BOND) to (5), (6) and (7) before screwing them tight.

RW gear cover (Front)

Note
• Application of grease in excess of the specified amount (5) Sunk plug
increases motor load, as a result, the robot may comes (SP1/8B)
to an alarm stop.
• At the time of overhaul or harmonic reduction gear
replacement, apply the specified amount of grease.

RW gear cover (Left) RW motor plate

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 Reduction gear replacement and grease injection

5.3.2 FA, UA and RT axes

Replace the grease in the FA, UA and RT-axis RV reduction gear with new one
at the time of three-year (or 6000 hours) periodical inspection.

FA axis:
（1）Remove the sunk plugs ((1) Supply port, (2) Air
relief), and then inject “VIGOGREASE RE0” from the (2) Sunk plug
(SP1/8B)
sunk plug (1).

（2）While injecting new grease from the sunk plug (1),

the residual grease is drained from the sunk plug (2).
Stop injecting the new grease when the new grease
comes out from the sunk plug (2).
(The sunk plug (3) is air relief port when replacing
the reduction gear.)
(3) Sunk plug (1) Sunk plug
(SP1/8B) (SP1/8B)
（3）After completion of injection, apply silicon sealing
agent 1211 (production of THREE BOND) to the
sunk plugs (1) and (2), and then fasten them tight.

UA axis:
(5) Sunk plug
（4）Remove the sunk plug ((4) Supply port, (5) Air relief), (SP1/8B)
and then inject “VIGOGREASE RE0” from the sunk
plug (4).

（5）While injecting new grease from the sunk plug (4),

the residual grease is drained from the sunk plug (5).
Stop injecting the new grease when the new grease
comes out from the sunk plug (5).
(The sunk plug (6) is air relief port when replacing (6) Sunk plug (4) Sunk plug
the reduction gear.) (SP1/8B) (SP1/8B)

（6）After completion of injection, apply silicon sealing

agent 1211 (production of THREE BOND) to the
sunk plugs (4) and (5), and then fasten them tight.

RT axis:
（7）Remove RT motor cover, RSIF mounting plate, the
sunk plug ((7) Air relief) and CP bolt; M6x12 ((8)
Supply port), and then inject “VIGOGREASE RE0”
from the sunk plug (8).

（8）While injecting new grease from the sunk plug (8), (8) Hex. bolt
the residual grease is drained from the sunk plug (7). (M6x12)
Stop injecting the new grease when the new grease
comes out from the sunk plug (7).
(The sunk plug (9) is air relief port when replacing (7) Sunk plug
the reduction gear.) (SP1/8B)

（9）After completion of injection, apply silicon sealing

agent 1211 (production of THREE BOND) to the (9) Sunk plug
(SP1/8B)
sunk plugs (7) and (8), and then fasten them tight.

When the RT base cover is removed

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 Reduction gear replacement and grease injection

5.4 Standard clamp torque for each bolt at reduction gear replacement
5.4.1 Bolts

Bolts Clamp torque Note

M N•m kgf•cm • Refer to the clamp torque in the table on the left when
3 20 ±0.02 20 ±0.2 replacing reduction gear of each axis unless otherwise
specified.
4 4.5 ±0.05 46 ±0.5
• For Servo motor mounting CP bolts for each axis (except
5 9.8 ±0.1 100 ±1 TW axis), do not apply to the above table (standard
6 18.5 ±0.2 188 ±2 torque). Fasten them at the clamp torque specified for in
the section explaining replacement procedure.
8 37 ±0.4 380 ±4
10 74 ±0.7 750 ±8
12 128 ±1.3 1310 ±13
14 205 ±2.1 2090 ±21
16 319 ±3.2 3250 ±33
20 622 ±6.2 6350 ±64

5.4.2 Washers

Washer Name
SW Spring lock washer
CW Conical spring washer
PW Plain washer

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 Reduction gear replacement and grease injection

5.5 RT axis RV reduction gear replacement

5.5.1 Replacing procedure
(1) Set the belt to the RW body and wrist unit parts, and
then lift the arm with a crane or the like. Part name Specification
(2) Remove the RT motor cover (A), RSIF mounting plate A RT motor cover AKK22008
(B), and BKSW mounting plate (C).
B RSIF mounting AKK32048
(3) Inside the UA body (D), disconnect all connectors of
plate
the swiveling harness (E).
(4) Lift the robot main body with a crane or the like and lay C BKSW mount- Standard spec.: AKK41136
it down so that the arm part is sit on a piece of wood or ing plate UL, CE spec.: AEU01418
the like. D UA body ADA11089
(5) Unscrew the screws (F) 4-M4x10, and then remove E Swiveling har- AWC12818
the RT bottom cover (G). ness
(6) Cover the each connector part of the swiveling har- F Screw 4-M4x10
ness (E) with vinyl or the like and lead them to the RT
base (H) side. G RT bottom ADK41057
cover
(7) Remove the sunk plug (I) on the RT motor and the
sunk plug (J) on the bottom part so as to let air in from H RT base ADB12003
the sunk plug (I) and drain the grease through the sunk I Sunk plug SP1/8B
plug (J) on the bottom. Make sure to place a vinyl bag
or the like at the bottom part. J Sunk plug SP1/8B
(8) Unscrew the CP bolts (K) 4-M6x20 (CW) and then K CP bolt 4-M6x20 (CW)
remove the RT motor (L). L RT motor TS4614N8337
(9) Unscrew the CP bolts (M) *1 15-M8x25 (CW), and then M CP bolt *1 15-M8x25 (CW)
remove the RT base (H) Torque:37 N•m (380 kgf•cm)
(10) Unscrew the CP bolts (N) *1 18-M6x65 (CW), and then N CP bolt *1 18-M6x65 (CW)
remove the RV reduction gear (O). Torque:18.5 N•m (188 kgf•cm)
(11) From the RV reduction gear (O), remove the V-ring (P) O RV reduction 28L001-0
and input gear 31 (Q) with bearing (R), and then gear
remove the inner tube (S). (Be aware of O-ring (T).)
P V-ring V45A
(12) Attach the O-ring (T) (apply the grease “Albania No.2”
to the O-ring), inner tube (S), input gear 31 (Q) with Q Input gear 31 ADG32009
bearing (R) and V-ring (P) to the new RV reduction R Bearing 6811ZZ
gear (O).
S Inner tube AGG41054
(13) Re-assemble the unit in reverse order of the above
procedure. T O-ring AS568-163
(14) After completion of replacement, apply the grease Note
(VIGOGREASE RE0) and perform encoder reset and
• *1: Screw it at the specified torque.
origin adjustment without fail.
• Apply liquid sealing agent “1211” (product of THREE
BOND) to sunk plugs before putting them in place.
• Failure in bearing may be a cause of looseness of
axis or abnormal noise, therefore, it is recommended
to replace the bearing (R) at the same time as a
replacement of RV reduction gear.

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5.5.2 Details of RT axis RV reduction gear motor mounted area

A B

A’
B
C C’

When BKSW mounting plate is removed When RT motor cover is removed

F
L
K

Base part of the robot when laid down RT motor mounting area

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 Reduction gear replacement and grease injection

H
M J

M J H

N N

G
O

T
Q

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 Reduction gear replacement and grease injection

5.5.3 Details of RT axis RV reduction gear

(1) Apply the liquid sealing agent “1211” (product of

THREE BOND) to the tube holder 35C and inner tube. THREE BOND 1211
Do not disassemble as it is press fit. Inner tube

Tube holder 35 C O-ring

(AFM32032) (S48NBR)

(2) Insert the inner tube assembly into the new RV reduc- Inner tube assembly RV reduction gear
tion gear. (28L001-0)

(3) Wipe off the oil in the groove of the O-ring of the RV Bearing V-ring
reduction gear, and then apply the grease “Albania (6811ZZ) (V45A)
No.2” to it. Then install it to the RV reduction gear.
Set the input gear 31, bearing and V-ring to the inner
tube part.
Make sure to apply the grease “Albania No.2” to the V-
ring.

Input gear 31 O-ring

(ADG32009) (AS568-163)

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5.6 UA axis RV reduction gear replacement

5.6.1 Replacing procedure
(1) Set the belt to the RW body and wrist unit parts, and
then lift the arm with a crane or the like. Part name Specification
(2) Remove the RT motor cover (A), RSIF mounting plate A RT motor cover AKK22008
(B), and BKSW mounting plate (C).
B RSIF mounting AKK32048
(3) Inside the UA body (D), disconnect all connectors of
plate
the swiveling harness (E) and connectors of UA motor
harness (power cable, brake cable and resolver signal C BKSW mount- Standard spec.: AKK41136
harness). ing plate UL, CE spec.: AEU01418
(4) Remove the fixing bracket of the wrist harness (E) of D UA body ADA11089
the UA body (D), and then pull out the harness from E Wrist harness TB-1400:(Old) AWC12820
the UA body. (New) AWC12824
(5) Remove the sunk plug (F) on the UA arm and the sunk TB-1000:(Old) AWC12821
plug (G) on the UA body so as to let air in from the (New) AWC12825
sunk plug (F) and drain the grease through the sunk
F Sunk plug SP1/8B
plug (G). Make sure to place a vinyl bag or the like at
the bottom part. G Sunk plug SP1/8B
(6) Unscrew the CP bolts (H) 4-M8x30 (CW) and then H CP bolt 4-M8x30 (CW)
remove the UA servo motor (I).
I UA servo motor TS4832N9030
(* Be aware of the O-ring (J) attached to the motor.)
J O-ring Attachment of motor.
(7) Unscrew the CP bolts (K) *1 6-M14x33 (CW), and then
remove the UA arm (L). K CP bolt *1 6-M14x33 (CW)
Torque:205 N•m (2090 kgf•cm)
(8) Unscrew the CP bolts (M) *1 16-M8x40 (CW), and then
remove the RV reduction gear (N). L UA arm TB-1400: ADA11097
(* Be aware of O-ring (O).) TB-1000: ADA11099
M CP bolt *1 Standard spec.:16-M8x40 (CW)
< Note > Torque:205 N•m (2090 kgf•cm)
For UL specification: CP bolts (M) *1 14-M8x40 (CW) UL spec.:14-M8x40 (CW)
Torque:205 N•m (2090 kgf•cm)
(9) Attach the O-ring (O) to the new RV reduction gear
(M). N RV reduction 35E029K0
(10) Re-assemble the unit in reverse order of the above gear
procedure. O O-ring AS568-258
(11) After completion of replacement, apply the grease
Note
(VIGOGREASE RE0) and perform encoder reset and
origin adjustment without fail. • *1: Screw it at the specified torque.
• Apply liquid sealing agent “1211” (product of THREE
BOND) to sunk plugs before putting them in place.
• Remove the sealing agent at the RV reduction gear
side of the UA arm and then newly apply the liquid seal-
ing agent “1211” (product of THREE BOND).

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5.6.2 Details of UA axis RV reduction gear motor mounted area

First,
remove the cabtire cable

A C
B
B
A’

E
When RT motor cover is removed Sunk plug mounting area

Pull out the wrist harness

from UA body

E H

D
L

View from A: UA motor mounting area

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 Reduction gear replacement and grease injection

J
K

When UA motor is removed UA arm mounting area

M
N

When UA arm is removed Before reassemble, remove the

old seal agent and then newly
apply THREE BOND 1211.

N C J
L
I

M
A-A’ cross section

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 Reduction gear replacement and grease injection

5.6.3 Details of UA axis RV reduction gear

(1) Wipe off the oil in the groove of the O-ring of the RV
reduction gear, and then apply the grease “Albania
No.2” to it. Then install it to the RV reduction gear. RV reduction gear
Set the input gear 31, bearing and V-ring to the inner (35E029K0)
tube part.

O-ring
(AS568-258)

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5.7 FA axis RV reduction gear replacement

5.7.1 Replacing procedure
(1) Set the belt to the RW body and wrist unit parts, and
then lift the arm with a crane or the like. Part name Specification
(2) Unscrew the screws (A) 6-M4x10, and then remove A Screw 6-M4x10
TWBW cover (B). B TWBW cover AGK41024
(3) Unscrew the screws (C) 6-M4x10, and then remove C Screw 6-M4x10
RW cover (D).
D RW cover ADK32026
(4) Unscrew the screws (E) 6-M4x10, and then remove
RW rear cover (F). E Screw 6-M4x10
(5) Unscrew the screws (G) 3-M4x10, and then remove F RW rear cover AGK41023
RW harness cover (H). G Screw 3-M4x10
(6) Disconnect connectors of BWTW motor harness (I) H RW harness cove AGK41021
(power cable, brake cable and resolver signal har- I BWTW motor har- Included in wrist harness
ness). ness AWC12826
(7) Unscrew the screws (J) 2-M4x10, and then remove J Screw 2-M4x10
cable holder (K).
K Cable holder 1 AFP41230
(8) Unscrew the screws (L) 4-M4x10, and then remove
L Screw 4-M4x10
saddle (small) (M) and saddle (large) (N) from the
cable holder (K). M Saddle (small) H616-222
(9) Unscrew the screws (O) 2-M4x10, and then remove N Saddle (large) H616-322
saddle (large) (P), and then pull out the BWTW motor O Screw 2-M4x10
harness (I) to RW body. P Saddle (large) H616-322
(10) Disconnect connectors of feeder motor harness (Q) Q Feeder motor har- Included in wrist harness
(power cable, brake cable and resolver signal harness) ness AWC12826
behind RW rear cover (F).
R Gas hose Included in wrist harness
Disconnect gas hose (R) (including grounding cable).
AWC12826
(11) Disconnect connectors of RW motor harness (S)
S RW motor harness Included in wrist harness
(power cable, brake cable and resolver signal harness)
AWC12826
at RW harness cover.
(12) Remove the wrist harness mounting bracket (T) of RW T Wrist harness Included in wrist harness
body, and then pull out the wrist harness (U) from RW mounting bracket AWC12826
body. U Wrist harness AWC12826
* Be aware that the end of the wrist harness are V UA arm ADA41004
branched to three directions. W Sunk plug SP1/8B
(13) Unplug the sunk plug (W) of UA arm (V) and sunk plug X Sunk plug SP1/8B
(X) of RW body, and then blow air from RW body side
Y CP bolt *1 4-M10x20 (CW)
to drain grease inside the reduction gear.
Torque:7.84 N•m (80 kgf•cm)
* Make sure to place a plastic bag or the like to the UA
arm side to catch the grease. Z FA servo motor TS4613N8337
a CP bolt *2 6-M10x30 (CW)
(14) Unscrew CP bolt s (Y) *1 4-M6x20 (CW), and remove
Torque:74 N•m (750 kgf•cm)
FA servo motor (Z).
(15) Unscrew CP bolts (a) *2 6-M10x30 (CW), and remove b RW body ADA11102
RW body (b) from UA arm (V). d CP bolt *2 Standard spec.:16-M6x35 (CW)
(16) Unscrew CP bolts (d) *216-M6x35 (CW), and remove Torque:18.5 N•m (188 kgf•cm)
RW reduction gear (e). UL spec.:14-M6x30 (CW)
* Be aware of O-ring (f). Torque:18.5 N•m (188 kgf•cm)
(17) From the UA arm (C) under the RW cover, disconnect e RV reduction gear 25E022J0
the wrist harness (D) and the connectors of the FA f O-ring S120NBR
motor harness (power cable, brake cable and resolver
Note
signal harness).
(18) Remove the fixing bracket of the wrist harness (D) of *1: Screw it at the specified torque.
the RW body (E), and then pull out the harness from *2: Screw it at the standard torque.
the UA body. *3: Apply screw lock (THREE BOND 1344) and then screw it
(19) Install the new RV reduction gear (M). at the standard torque.
(20) Re-assemble the unit in reverse order of the above • Apply liquid sealing agent “1211” (product of THREE
procedure. BOND) to sunk plugs before putting them in place.
(21) After completion of replacement, apply the grease • Remove the sealing agent at the RV reduction gear side of
(VIGOGREASE RE0) and perform encoder reset and the UA arm and then newly apply the liquid sealing agent
origin adjustment without fail. “1211” (product of THREE BOND).

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 Reduction gear replacement and grease injection

5.7.2 Details of FA axis RV reduction gear motor mounted area

C D A B G

Remove wrist harness mounting

bracket and pull it out from
J RW body

I
K O

N
M
L I
P

When TWBW cover (left) is removed

RW body (when RW cover is removed)

K

When cable holder is removed

R S
Q

When RW harness cover is removed

RW body (when RW rear cover is removed)

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 Reduction gear replacement and grease injection

U T

Wrist harness mounting bracket

Remove the wrist harness
mounting bracket and pull out
the harness from the body.
V
Caution:
b Be aware that the end of the
harness is wired to three directions;
RW cover and TWBW cover part,
RW rear cover part, and
RW harness cover part.

W X

Sunk plug mounting area

Y V

b
a

FA motor mounting area UA arm mounting area

e
f

When UA arm is removed Before reassemble, remove the

old seal agent and then newly
apply THREE BOND 1211.

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 Reduction gear replacement and grease injection

A’

E M K
C

L
A-A’ cross section

5.7.3 Details of FA axis RV reduction gear

Wipe off the oil in the groove of the O-ring of the RV reduc-
tion gear, and then apply the grease “Albania No.2” to it.
Then install it to the RV reduction gear.
Set the input gear 31, bearing and V-ring to the inner tube RV reduction gear
part. (25E033J0)

O-ring
(S120NBR)

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 Reduction gear replacement and grease injection

5.8 RW axis harmonic reduction gear replacement

5.8.1 Replacing procedure
(1) Set the belt to the wrist unit parts, and then lift the arm
with a crane or the like. Part name Specification
(2) Unscrew the screws (A) 3-M4x10, and then remove A Screw 3-M4x10
the RW harness cover (B).
B RW cover AG41021
(3) Disconnect connectors of RW motor harness (C)
(power cable, brake cable and resolver signal harness) C RW motor har- AWC12826
of the RW harness cover (B). ness (Included in wrist harness)
(4) Unscrew the CP bolts (D)*3 4-M5x15 (SW), and then D CP bolt *3 4-M5x15 (SW)
remove RW servo motor (E). Torque:7.84 N•m (80 kgf•cm)
(5) Unscrew the CP bolt (F)*2 M4x10 (SW), and then E RW servo motor TS4607N8337
remove the motor collar 022 (G) and the wave genera- F CP bolt*2 M4x10 (SW)
tor (H). Torque:4.5 N•m 46 kgf•cm)
(6) Unscrew the CP bolts (I)*2 6-M5x15, and then remove G Motor collar 022 AFM40217
the flex holder (J), Flexspline (K) and the grip (L).
H Wave generator SG1750QR41R
(7) Unscrew the CP bolts (M)*2 8-M4x20, and then (Harmonic reduction gear)
remove RW motor plate (N) and circularspline (O). I 6-M5x15
* Be aware of O-ring (P). CP bolt *2
Torque:9.8 N•m (100 kgf•cm)
(8) Apply the specified grease to the new harmonic reduc-
J Flex holder SG1750QR41R
tion gear and then install it.
(Harmonic reduction gear)
(9) After completion of replacement, re-assemble the unit
in reverse order of the above procedure. K Flexspline SG1750QR41R
(Harmonic reduction gear)
(10) After completion of replacement, perform encoder
reset and origin adjustment without fail. L grip SG1750QR41R
(Harmonic reduction gear)
M CP bolt *2 8-M4x20
Torque:4.5 N•m (46 kgf•cm)
N RW motor plate
O Circularspline SG1750QR41R
(Harmonic reduction gear)
P O-ring SG1750QR41R
(Harmonic reduction gear)
Note
*2: Apply “Screw lock 1344 (product of THREE BOND)”,
and then screw it at the specified torque.
*3: Apply “Screw lock 1344 (product of THREE BOND)”,
and then screw it.

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5.8.2 Details of RW axis harmonic reduction gear motor mounted area

D E

A
C

RW housing mounting area

G
When RW harness cover is removed

N M K J I

Wave generator

Set the grip under the

flexspline.
- Keep it free from grease
- match the mounting holes

Flexspline part

Circularspline

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 Reduction gear replacement and grease injection

A A’

J K O H P N E

A-A’ cross section

5.8.3 Details of RW axis harmonic reduction gear

(1) A set of harmonic reduction gear (SG1750QR41R)

Circularspline Wave generator

O ring

Flexspline

(2) Apply Albania grease to the O-ring and then insert it

into the circularspline.

(3) Insert the circularspline into the gear shaft side of RW

body, and then attach the motor plate.
Apply the grease (SK-1A) to the teeth of the circular- Grip Flex holder
spline.

(4) Apply the grease (SK-1A) to the teeth of the flexspline,

and then set grip, flexspline and then flex holder in this Motor plate Location of sunk plug
order.
With the bolts (2-M5x30), insert them into the circular-
spline while keeping them in position, and then fasten
the bolt lightly for temporary joint.
Apply screw lock to bolts (6-M5x15), and then switch it
with the bolts (2-M5x30) used for temporary joint.
Then fasten the bolts (6-M5x15) at the specified
torque.
Circularspline

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 Reduction gear replacement and grease injection

(5) Inject the grease (SK-1A) into the inside of the flex-
spline. Motor plate

Grease (SK-1A)

Flexspline

(6) Apply the grease (SK-1A) to the ball side of the wave
generator, and then insert it with the greased surface CP bolt (M4x10 SW)
down matching the key grooves of it and the motor 4.5 N•m (46 kgf•cm) Motor collar 022
shaft.
THen set the motor collar 022, and fit them with the
bolt (M4x10) (SW).
RW motor plate

Grease (SK-1A) at
ball side of wave generator Wave generator

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5.9 BW axis harmonic reduction gear replacement

5.9.1 Replacing procedure
(1) Remove the torch and safety holder first.
(2) Unscrew the screws (A) 6-M4x10, and then remove Part name Specification
the TWBW cover (B). Remove the other side. A Screw 6-M4x10
(3) While holding TW axis, unscrew CP bolts (C)
B TWBW cover ADK32036
4-M5x15 (SW), and then slide BW axis servo motor
(D) and remove the timing belt (E). C CP bolt* 2 4-M5x15 (SW)
Then, lightly fasten the servo motor with one of the CP Torque:4.5 N•m 46 kgf•cm)
bolts for temporary joint. D Servo motor TS4607N8337
(4) Unscrew the CP bolts (F)*1
12-M3x20 (SW) and the E Timing belt 060S3M699
CP bolts (G)*2 4-M3x15, and then pull out the BWHD F 12-M3x20 (SW)
CP bolt*2
cover (K) with pulley H (H), wave generator (I) and Torque:2.0 N•m 20 kgf•cm)
BWHD shaft (J) attached.
G CP bolt *3 12-M3x15
(5) Remove the snap ring (L) from the BWHD shaft (J),
Torque:2.0 N•m 20 kgf•cm)
and then loosen the setscrews (M) 2-M3 to remove the
wave generator (I). H Pulley H ADW41060
(6) Unscrew the CP bolts (N)*1 6-M4x15, and then remove I Wave generator HG1780QR41B
the HD housing (O). (Harmonic reduction gear)
(7) Unscrew the CP bolts (P)*4 12-M3x25 (CW), and then J BWHD shaft ADS32013
remove flexspline with the crossed roller bearing K BWHD cover AGK31030
attached.
L Snap ring STW8

< If you do not replace bearing> M Setscrew 2-M3, HG1780QR41B

Move to the procedure (16). (Harmonic reduction gear)
N CP bolt *1 6-M4x15
<If you replace bearing (R), (b) and (f)> Torque:4.5 N•m (46 kgf•cm)
Perform the following procedures (8) to (15). O HD housing ADH32028
(8) From BWHD cover (K) pull out BWHD shaft (J) with
pulley H (H) attached. P CP bolt *4 12-M3x25
Torque:2.0 N•m 20 kgf•cm)
(9) From BWHD cover (K), remove bearing (R).
(10) Unscrew screw (S) 1-M4x8, and then remove the Q Flexspline HG1780QR41B
nylon clamp (T). (Harmonic reduction gear)
(11) Unscrew screw (U) 1-M4x8, and then remove the R Bearing 6800ZZ
nylon clamp (V). S Screw 1-M4x8
(12) Disconnect the connector (X) of TW harness (W) and
T Nylon clamp KCA64
pull out the harness.
U Screw 1-M4x8
(13) While holding TW axis, unscrew the CP bolts (Y)*1
6-M4x15 (SW), and then remove the bearing fix 1 (Z), V Nylon clamp KCA64
bearing fix 2 (a) and bearing (b) set. W TW harness AWC42334
*Be aware of V-ring (d) and O-ring (e).
X Connector Included in TW harness
*Be aware of TW harness (a) when removing TW axis.
(Harmonic reduction gear)
(14) Remove the bearing (f).
Be aware of conical springs for bearing (h), two pieces Y CP bolt *1 6-M4x15 (SW)
of it are set back-to-back and place at the back of the Torque:4.5 N•m (46 kgf•cm)
bearing (f). Z Bearing fix 1 ADH32039
(15) Unscrew the CP bolts (i) 6-M4x12 on the bearing fix 2 a Bearing fix 2 ADH41039
(b) side, and then remove the bearing fix 2 (a) side and
bearing (b). b Bearing 6812LULUP03
d V-ring V75A
e O-ring G85NBR
f Bearing 624zz
h Conical spring BDS13 two piece.
for bearing

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 Reduction gear replacement and grease injection

(16) Apply the specified grease to the new harmonic reduc-

tion gear and then install it. Part name Specification
(17) After completion of replacement, re-assemble the unit i CP bolt *2 6-M4x20
in reverse order of the above procedure. Torque:4.5 N•m (46 kgf•cm)
(18) After completion of replacement, perform encoder Note
reset and origin adjustment without fail.
*1: Screw it at the specified torque.
*2: Apply “Screw lock 1344 (product of THREE BOND)”,
and then screw it at the specified torque.
*3: Apply “Screw lock 1344 (product of THREE BOND)”,
and then screw it.
*4: Apply “Screw lock 1344 (product of THREE BOND)”,
and then screw it at the specified torque.

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 Reduction gear replacement and grease injection

5.9.2 Details of BW axis harmonic reduction gear motor mounted area

A
B
A
B

C C’

E X U
H
D V

W
View from A
(When cover is removed) View from A
(When cover is removed)

C
D

N
F View from A J
(When cover is removed)

H
I
L
G

K
K
O
K

BWHDC cover Wave generator mounting area

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 Reduction gear replacement and grease injection

A B

B
C-C’ cross section
A

N F J H G K E
O
P

R
I
M
Q
L
f

T h

S V

b a

d i

e Z
Harmonic reduction gear

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 Reduction gear replacement and grease injection

5.9.3 Details of BW axis harmonic reduction gear

(1) A set of harmonic reduction gear (SG1750QR41R).

Flexspline Wave generator

Crossed roller bearing

(2) Insert the harmonic (assembly of circularspline, flex-

spline and crossed roller bearing) into BW body, and
then fasten them with the CP bolts *4 (12-M3x25 CW).
BW body
< Note >
CP bolt*4: Apply “Screw lock 1344 (product of THREE Harmonic
BOND)”, and then screw it at the specified torque.

CP bolt
12-M3x25(CW)

(3) Place HD housing over it and screw it with the CP bolts

*1 (6-M4x15 CW).

< Note > CP bolt

6-M4x15
CP bolt*1: Screw it at the specified torque.

HD housing

Apply grease (SK-2)

(4) Apply grease (SK-2) to the ball side of the wave gener-
ator, and then insert it into the Pulley H, BWHD cover
Apply grease (SK-2)
and BWHD shaft assembly.
Fix the wave generator with the snap ring and set-
screws (2-M3).

BWHD shaft

Snap ring
Wave generator

BWHD cover

Setscrew (2-M3) Pulley H

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 Reduction gear replacement and grease injection

5.9.4 Details of BW axis harmonic reduction gear motor mounted area

When TWBW cover is removed F

L I
G

H
When the timing belt is removed K When the BWHD cover is removed

J
R

When TWBW cover is removed

a
Z i Z
b
Z

i d
e
When TW harness is removed

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 Reduction gear replacement and grease injection

A-A’ cross section

N F R G

Q K

S T

b
a

e Z

Y
Harmonic reduction gear

W
T i
V L J
S
U f

y h

TW harness holder Fixing part of the flexspline

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 Reduction gear replacement and grease injection

5.10 TW axis harmonic reduction gear replacement

5.10.1 Replacing procedure
(1) Remove the torch and safety holder first.
(2) In case of performing TW motor replacement work Part name Specification
alone, position the robot so that after the removal of A CP bolt*1 6-M4x12 (CW)
TW axis, you can place the TW axis with the motor Torque:4.5 N•m 46 kgf•cm)
harness connected to the work bench. B TW gear cover Type-1: ADK32027
(3) Unscrew the CP bolts (A) 6-M4x12 (CW) *1, and then Type-2: ADK32029
pull out the TW gear cover (B) for C-C’ to the end.
C CP bolt*2 4-M5x40 (CW)
(4) Unscrew CP bolts (C)*2 4-M5x40 and CP bolts (D)*2 Torque:9.8 N•m 100 kgf•cm)
2-M5x18, and then pull out the TW gear housing (E)
D CP bolt*2 2-M5x18 (CW)
with TW servo motor (F) attached. Please the removed
Torque:9.8 N•m 100 kgf•cm)
TW gear housing (E) on the work bench and then dis-
connect connectors of TW-axis motor harness (power E TW gear housing Type-1: ADH22013
cable, brake cable and resolver signal harness). Type-2: ADH22014
(5) Unscrew the CP bolts (G)*2 6-M4x12 (CW), and F TW servo motor TS4602N8030
remove the servo motor (F) with TW motor plate (H) Previous type: TS4602N8023(*)
attached. G 6-M4x12 (CW)
CP bolt*2
(6) Remove the snap ring (I) Loosen the set screws (K)*3 Torque:4.5 N•m 46 kgf•cm)
2-M3x3 to remove the wave generator (J).
H TW motor plate AFP32028
(7) Unscrew the CP bolts (L) 6-M4x12 (SW), and then
remove the flex holder (M), flexspline (N) and grip (O). I Snap ring STW8
2
(8) Unscrew the CP bolt (P)* 6-M4x15, and then remove J Wave generator SG1450QR61T
the circularspline (Q) from TW gear housing (E). (Harmonic reduction gear)
* Be aware of TW packing (R). K Setscrew*5 2-M3x3

< If you do not replace bearing> L CP bolt*2 6-M4x12 (CW)

Move to the procedure (28) Torque:4.5 N•m 46 kgf•cm)
M Flex holder SG1450QR61T
<If you replace bearing (f), (g), (n) and (p)> (Harmonic reduction gear)
• For Type-1 models: YA-1QMR41*00, YA-1RMR41*00 N Flexspline SG1450QR61T
Perform the following procedures (9) to (20). (Harmonic reduction gear)
(9) Wipe off grease inside TW gear housing (E).
O Grip SG1450QR61T
Unscrew the CP bolts (S)*2 6-M4x15 (CW), and then (Harmonic reduction gear)
remove TW input gear (T).
* Be aware of shim plates (U) and (V). P CP bolt*2 6-M4x15
Torque:4.5 N•m 46 kgf•cm)
(10) Unscrew the CP bolts (W)*2 6-M4x25 (CW), and then
remove TW output gear (X). Q Circularspline SG1450QR61T
2 (with O ring) (Harmonic reduction gear)
(11) Unscrew the CP bolts (Y)* 10-M4x10 (CW), and then
remove bearing holder TW (Z). R TW packing AFQ41241
(12) Pull out the assembly of TW gear shaft 1 (d), TW gear S CP bolt*2 6-M4x15 (CW)
shaft 2 (e), bearing (f) and bearing (g). Torque:4.5 N•m 46 kgf•cm)
(13) Unscrew the CP bolts (h)*2 6-M4x20 (CW), and then T TW input gear ADG32016
remove TW gear shaft 2 (e).
U Shim plate AKC41132
(14) From the gear shaft 1 (d), remove bearings (f) and (g),
and two pieces of shim plates for bearing (j) and (k). V Shim plate AKC41133
(15) Pull out the assembly of TW gear shaft 3 (t), TW gear W CP bolt*2 6-M4x25 (CW)
shaft 4 (m), bearing (j) and bearing (k). Torque:4.5 N•m 46 kgf•cm)
(16) Remove V-ring (q), then remove TW gear shaft 4 (m). * Not needed for type-2 models.
(17) Unscrew the CP bolts (z)*2 6-M4x25 (CW), and then X TW output gear ADG32017 for type-1 models.
remove TW gear shaft 3 (t). ADG32022 for type-2 models.
(18) From TW gear shaft 4 (m), remove bearings (n) and
(p), and shim plates for bearing (u) and (y). Y CP bolt*2 6-M4x10 (CW)
Torque:4.5 N•m 46 kgf•cm)
(19) Apply the grease (SK-1) to the new bearing.
(20) Re-assemble the unit in reverse order of the above Z Bearing holder AFP41243A
procedure. TW1 * For type-1 models.
* Then move to the procedure (28). a Bearing holder AFP41243A
TW1 * For type-2 models.

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 Reduction gear replacement and grease injection

• For Type-2 models: YA-1QMR42*00, YA-1RMR42*00

Part name Specification
* Perform the following procedures (21) to (27).
(21) Wipe off grease inside TW gear housing (E). b Bearing holder AFP41244A
TW2 * For type-2 models.
Unscrew the CP bolts (S)*2 6-M4x15 (CW), and then
remove TW input gear (T). d TW gear shaft 1 ADS41075
* Be aware of shim plates (U) and (V). e TW gear shaft 2 ADS41076
(22) Unscrew CP bolts*2 (Y) 10-M4x10 (CW) for the bear- f Bearing 690C2
ing holders TW1 (a) and TW2 (b) and then remove the
g Bearing 690C2
bearing holder TW1 (a).
(23) Pull out the assembly of bearing holder TW2 (b), bear- h CP bolt* 2 6-M4x20 (CW)
ings (n) and (p), shim plates for bearing (u) and (y), Torque:4.5 N•m 46 kgf•cm)
and bearing nut (r) from TW output gear (X). i Gear shift 1 ADS41075
(24) Pull out the assembly of TW gear shaft 1 (d), TW gear j Shim plate for AKC41138
shaft 2 (e), bearings (f) and (g) and shim plates for bearing
bearing (j) and (k) at the input side.
k Shim plate for AKC41139
(25) Unscrew CP bolts*2 (W) 6-M4x20 (CW), and then bearing
remove TW gear shaft 2 (e).
m TW gear shift 4 ADS41078
(26) From the gear shaft 1(d), pull out the bearings (f) and
* Not needed for type-2 models.
(g), and shim plates for bearing (j) and (k).
(27) Remove the bearing nut (r) on the output side, and n Bearing 6811ZZC2
then remove the bearings (n) and (p), shim plates for p Bearing 6811ZZC2
bearing (u) and (y), and then bearing holder TW2 (b). q V-ring V55A
* Then move to the procedure (28).
r Bearing nut AMN41038*3
---
Torque:319 N•m 3250 kgf•cm)
* Only for type-2 models.
(28) Apply the specified grease to the new harmonic reduc- t TW gear shift 3 ADS41077
tion gear and then install it. u Shim plate for AKC41136
(29) After completion of replacement, re-assemble the unit bearing
in reverse order of the above procedure.
y Shim plate for AKC41137
(30) After completion of replacement, perform encoder bearing
reset and origin adjustment without fail.
z CP bolt*2 6-M4x25 (CW)
Torque:4.5 N•m 46 kgf•cm)
Note
*1: Screw it at the specified torque.
*2: Apply “Screw lock 1344 (product of THREE BOND)”,
and then screw it at the specified torque.
*3: Apply “Screw lock 1344 (product of THREE BOND)”,
and then screw it.
• Rattling of TW axis may be caused failure in bearing as
well as harmonic reduction gear. Therefore, it is recom-
mended to replace the bearing together with the har-
monic gear. For details of the bearing replacement,
please refer to procedures 9 to 19.
*It is necessary to use a dedicated jig and to per-
form shim plate adjustment when replacing the
bearing, therefore, please consider replacing TW
gear housing unit.
• Make sure to avoid grease to be attached to the grip
surface.
(*) For products manufactured before November, 2007.

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5.10.2 Details of TW axis harmonic reduction gear motor mounted area

A D
B
C

C’
D’

C D

H F
E

Ａ 矢視（カバー内詳細） ＴＷ アウトプットフランジ部詳細

F
M

G
H
H
H
J

I I

K F J
ＴＷ モータプレート部詳細 ＴＷ 軸外観詳細

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 Reduction gear replacement and grease injection

N M L E P O R

When TW motor and motor plate is removed When the flexspline and flex holder are removed.

E b

Y
R

When the circularspline is removed

k f
j R
Z Q

e N

Y J

U V
F

S
I

d
K
T
L
W

H
X
P
n
M
m O
u
y q
p r

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5.10.3 Details of TW axis harmonic reduction gear

(1) A set of harmonic reduction gear (SG1750QR41R).

Circularspline O-ring

Wave generator

Flex holder

(2) Insert TW packing into TW housing, set the circular-

spline and then place the grip at the center.
Apply grease (SK-1A) to the teeth surface of the circul-
arspline.

< Note > Flexspline

Grip
Apply grease carefully and keep the grip oil-free.
Make sure to keep the mounting hole of the grip in
position.

(3) Apply grease (SK-1A) to the teeth surface of the flex- O-ring
spline.
Place the flexspline on the grip, set the flex holder and
then screw it with CP bolts* (6-M5x15). Then apply
grease (SK-1A) to the inner side of the flexspline. Place the grip on this surface.
Align the mounting holes.
< Note > Make sure to keep the grip oil-free (including grease).
CP bolt*: Apply “Screw lock 1344 (product of THREE
BOND)”, and then screw it at the specified torque.
Circularspline

Grease
(SK-1A)

(4) Apply grease (SK-1A) to the ball side of the wave gen-
erator, and set the snap ring to the motor shaft (with
TW motor plate attached). Insert the wave generator Snap ring
and set the snap ring and fix them with setscrew.
Setscrew

TW motor plate
Wave generator

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5.10.4 Details of TW axis bearing mounted area

TW gear housing part of Type-1; YA-1QMR41***, YA-1RMR41***）

X W S T Shim plates
E X T U (AKC41132, AKC41133)

Rear side

TW output gear, TW input gear and shim plates

When gear cover is removed

X n p e f d y Z d E
m

When TW input gear and TW output gear are removed When the bearing holder TW is removed

CAL pin M4

m z d h c
Front t
Rear q Front j Rear
n u
e f
p k
y
p f e
n

Bearing and gear shaft on the output side Bearing and gear shaft on the input side

Bearings Shim plates for bearing Bearings Shim plates for bearing
(6811C2) (AKC41136, AKC41137) (690C2) (AKC41138, AKC41139)

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e j k f

d
Z
U V

T
q
X

m t

n
u y p

TW gear housing part of Type-2; YA-1QMR42***, YA-1RMR42***）

b X S T E

TW input gear Shim plates

(ADG32016) (AKC41132, AKC41133)

When the gear cover is removed

b X a d E
E
d
Bearing holder TW1
(AFP41243A)

When TW input gear and

TW output gear are removed After TW input gear and then bolts for
bearing holder are removed

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n
u y

p
r

Bearing holder TW2 Bearings Shim plates for bearing Bearing nut
(AFP41244A) (6811ZZC2) (AKC41136, AKC41137) (AMN41038A)

d h c
j
e f
k

f Bearings Shim plates for bearing

e (690C2s) (AKC41138, AKC41139)

e j k f

d
c
U V

q
X

n r
u y p

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6. Timing belt and pulley replacement

6.1 Replacement procedure: BW axis
6.1.1 Timing belt
(1) Remove TWBW cover (A) on the right side.
(2) While holding the BW axis, unscrew the CP bolt (B) 4-
M5x15 (SW). A
* Be aware of descending movement of the BW axis
due to its own weight such as torch.
(3) From the pulley H (C), remove the timing belt (D).
(4) Install a new timing belt.
(5) Re-assemble the unit in reverse order of the above
procedure.
BW cover part
(6) After completion of replacement, perform origin adjust-
ment without fail. TW BW cover part
Note
Make sure that the timing belt is strained when installing it.
D B
C C

When the right side cover is removed

When the left side cover is removed

BW motor mounting area

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6.1.2 Pulley
(1) Remove the TW covers (A) on the both left/right sides.
(2) Loosen the CP bolts (B) 4-M6x12 (fixing BW axis
A
motor) and the timing belt.
(3) While holding the TW axis, unscrew the CP bolts (D)*1
4-M3x8 (fixing pulley H (C).
* Be aware of descending movement of the BW axis
due to its own weight such as torch.
(4) From the pulley shaft H (E), pull out the pulley H (C)
with the timing belt (G) attached.
BW cover part
(5) Set the timing belt to the new pulley H (C) and then
install it.
(6) Re-assemble the unit in reverse order of the above
procedure.
(7) After completion of replacement, perform origin adjust-
ment without fail.

Note B
*1: Apply “Screw lock 1344 (product of Three bond)”, and
then screw it at the standard torque specified in "5.4 When TWBW cover (left)
Standard clamp torque for each bolt at reduction gear is removed
replacement" on page 57
• Make sure that the timing belt is strained when installing
it.

Motor mounting area

When TWBW cover (right)
is removed

D C
C D

E E

Pulley H (Enlarged) Pulley H (Enlarged)

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7. Resolver battery replacement

• Six backup batteries in parallel are provided with robot manipulator and controller respectively (total 12 batteries) to
maintain absolute data of the resolver.
• Replace the batteries with new ones every two years or so (under the use environment of 8 hours a day and 5 days a
week.) However, battery life varies with use environment.
• When the remaining battery level is getting low, the error message “E8000 Encoder battery is consumed: The battery
in the controller” is displayed on the teach pendant.
• If the robot operation is continued at low remaining battery level without replacing it with a new one, the resolver data
won’t be retained longer, as a result, maintenance work such as origin adjust will become necessary.

7.1 Location of the resolver battery

Set six lithium batteries

are set in the battery case.

View from A (When RT motor cover is replaced)

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7.2 Resolver battery replacement

7.2.1 Replacing batteries on the manipulator side
<Replacing procedure>
(1) Prepare the replacement batteries for all axes.
Battery product number: ER6VCT (product of
TOSHIBA) When the RT axis motor cover is removed.

(2) To provide against accidents, make a backup copy. (If

it is not possible to make a backup copy, check the ori-
gin data if it is the same as the values in the origin data
card inside the controller. If not, change the values in
the origin data card.)

(3) For safety operation, turn off power to the system.

(4) Remove the RT axis motor cover of the manipulator.

(5) Remove the RSIF mounting plate and pull out the bat-
tery with the resolver IF card attached. RSIF mounting plate
(ZUEP5764)
(6) Unscrew the screws (2-M4x10) that are fixing the bat-
tery case, and replace the batteries. Resolver IF card
(ZUEP5764)
(7) After completion of the replacement, connect connec-
tors correctly and completely and then fix them back in
place.

(8) Re-assemble the RSIF mounting plate and the RT axis

motor cover.

(9) After power activation, the encoder reset screen is dis-

played. Perform encoder reset and adjust the origin. Screw
(For detail procedure, please refer to the service man- 2-M4x10
ual of the controller.)

Battery case Lithium battery

(AKH41006) (6 pcs.)

Lithium battery
ER6VCT(Product of TOSHIBA)

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7.2.2 Replacing batteries on the controller side

<Replacing procedure>
(1) Prepare the replacement batteries for all axes.
Battery product number: ER6VCT (product of
TOSHIBA) Upper front inside the robot controller
(2) Using the backup function, save and verify all data.
(3) For safety operation, turn off power to the system.
(4) Open the front panel of the controller, and then remove
the two M4 nuts, disconnect the white connectors of
the BAT relay card, and then remove the battery unit.
(5) Unscrew the two M4 screws at the battery unit, and
then replace it. Nut
(6) After completion of the replacement, connect connec- 2-M4
tors correctly and completely and then fix them back in
place.
(7) Turn on the power and then use the backup function to
Main CPU card Battery unit
load and verify all data.
(ZUEP5859) (AEU01417)

White connector

BAT relay card

(ZUEP5765)

Screw
(2-M4x10)

Lithium batteries (6 pcs.)

Lithium battery
ER6VCT(Product of TOSHIBA)

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8. Brake release
For manipulator models YA-1QMR61U**, YA-1QMR61E**, YA-1RMR61U** and YA-1RMR61E**:
Note Please refer to the operating instructions of each model. The brake release switch is incorporated
into the manipulator

Note
• The following methods are to release all axes. In case there is any axis you do not want to release the
brake, disconnect the connector of the motor harness (power cable) of the axis
• Prior to performing brake release, make sure to bring the manipulator to a safe position. The manipula-
tor makes weight drop when the brake release is executed.

8.1 All axes brake release method (1)

In case that a DC power dedicated to brake release (24
VDC, rated current: 0.5 A) is provided, connect the 24 VDC
direct to the brake pin of the Molex connector of the manip-
ulator to release all axes brakes.

Molex connector
(58691-0010)

Slot 1

Slot 2

Slot 3
4-2 pin
4-1 pin

Slot 4

Slot 5

24 VDC
Slot 6

Brake release unit

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8.2 All axes brake release method (2)

In case that a DC power dedicated to brake release is not
provided, short-circuit the pin #1 of the RSV2connector and
the pin #1 of the BRK connector and the pin#3 of the RSV2
connector and the pin#2 of the BRK connector of the power
card (ZUEP5757) inside the controller. Then turn the power
ON to release all axes brakes.

ＢＲＫ

④ ③ ② ①

Short-circuit

ＲＳＶ２

③ ② ①

Connect the PC. Board (ZUEP55639) for amplifier mea-

surement (maintenance use), and open the rear panel of
the G2 controller.

See section “Servo amp.: signal check” of the operating

instructions of the applied controller.
<Controller> <Operation instructions>
G2: SM00037E**
GX, GXP: SM00043E**
TAWERS* SM00056E**

PC. Board (ZUEP55639)

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9. RT axis mechanical stopper replacement

The operating range of the robot RT axis may need to be limited in order to ensure the safety area for operation.
In such case, adjust the mechanical stopper.
Please note that it is necessary to adjust the soft limit together with the mechanical stopper.

9.1 How to change the mechanical stopper

Normally, the robot is equipped with the “RT stopper with
OT dog” at the front of the RT axis at shipment, whose
operating rang is set to ±170°.

(1) Decide the limiting range.

M10 Taps are provided at the bottom of the UA body at
30 degrees intervals for mounting.

(2) Unscrew the screw (M4x10) at one side of the RT dog

base attached to the UA body side. And then remove
the limit dog RT.

(3) Unscrew the CP bolt (M10x20), and then remove the M10 taps
RT dog base. (For mounting)

(4) With the attached RT dog base (accessory), mount the

limit dog RT that was removed in the previous proce-
dure.

(5) To taps of the predetermined limiting range on the UA

body, attach the RT dog base with the limit dog RT
using the CP bolt (M12x25). Make sure to attach the
OT dog to the both taps.

(6) Move the RT axis left and right and make sure the soft
limit activates before the limit switch. Screw (M4x10) CP bolt (M10x20)

Note
<Accessories>
• The photo on the right shows the limit switch of the RT
axis whose operating range is set to -170 degrees to
+140 degrees.

RT dog base CP bolt (M10 x 20)

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10. Assembly drawings

10.1 RT and UA axes: parts layout

O-ring
Screw Motor attachment
Upset (Attach C00216)
(*1)
Upset (*3)
(*1)

Stick two seal packings

(ABQ41027)

Upset (Apply 1211)

Screw

Screw (*1)
(*1)

(Apply 1344)

Screw

RT base side
rubber cover
attachment

Screw
(Apply 1211)
(*5)
A-A
Screw
(Torque: 280 kgf•cm)

Upset bolt <Note>

See “Sealing treatment
of RV reduction gear”
in FA/RW axes.

Screw (Apply 1211)

(Apply 1211) * Or apply 1211 to UA arm side.
Prune if any

Conical machine screw

E-E

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(*1)
(*3, *4, *5) (*5)

(*1)

D-D Upset bolt

(*1) Screw Screw (*5)
Screw
Upset bolt
(Torque: 280 kgf•cm)
(*1) Screw

Nylon clamp NK4N

(Harness unit’s part)

(*1)
(*5)
Screw
(*1)
Screw

(*1) View from B (*5)

(*5) Screw

Screw

Screw

Screw

(*5)

(*1, *2) (*3) (*3) (*3)

Upset bolt
Screw Screw Upset bolt
2-M10x20 (Apply 1344) Conical machine screw
(1 piece is equipped.) for grounding (Nickel plated brass)

Apply 1211 to these two points

Screw

<Note>
(1) The part is used for UL spec. of YA-1Q series.
(2) The part is used for CE spec. of YA-1Q series.
(3) The part is used for standard spec. of YA-1Q series.
C-C
(4) The part is used for short arm spec. of YA-1Q series.
(5) The part is used for YA-1QAR series.

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10.2 RT and UA axes: parts list

No. Part name Part number Q’ty Note Class

1 UA arm ADA41004 1 D
2 UA body ADA41003 1 D
3 RT base ADB41005 1 D
4 Pinion gear 31 ADG41078 1 B
5 Input gear 31 ADG32009 1 B
6 Input gear 50 ADG32011 1 B
7 RT bottom cover ADK41057 1 B
8 Limit SW ass’y AEB31006 1 C
9 Tube holder 35C AFM32032 1 D
10 Motor collar 082 AFM40262 1 D
11 RT stopper ABQ41025 1 D
12 Resolver card cover AZS31003 1 D
13 Swiveling fixing bracket AFM41657 1 D
14 Masking rivet C30MR6 2 D
15 Cable plate AFM41674 1 D
16 Saddle AFS41020 2 D
17 Saddle space AGA41054 1 D
18 Inner tube AGG41054 1 D
19 Harness guide RT AGG41055 1 D
20 RT base cover AGK31027 1 D
21 UA arm cover ADK41056 1 D
22 Marking plate AKC41092 1 D
23 RSIF mounting plate AKK32048 1 D
24 Resolver card ZUEP5764* 1 C
25 Resolver card ZUEP5764* B1 1 C
26 PCBoard spacer SQ20 4 D
27 Spacer WLS20-0 2 D
28 Battery case AKH41006 1 D
29 Lithium battery ER6VCT 6 A
30 RT motor cover AKK22008 1 D
31 Terminal fixing bracket AKK32046 1 D
32 Rubber stopper H22 ABQ41007 2 D
33 Terminal plate AKK32047 1 D
34 BKSW mounting plate AKK41136 1 D
35 Brake card ZUEP5759 1 C
36 Spacer KGLS8RT 4 D
37 Stopper collar AMK41060 2 D
38 RT dog base ASB41002 1 D
39 Dog RT ASM41040 2 D
40 Servo motor TS4614N8337 1 RT axis C
41 Servo motor TS4832N9030 1 UA axis C
42 RV35C reduction gear 28L001-0 1 RT axis C
43 RV40E reduction gear 35E008L0 1 UA axis C
44 Bearing 6811ZZ 1 B

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No. Part name Part number Q’ty Note Class

45 O ring AS568-163 1 RT axis A
46 O ring AS568-258 1 UA axis A
47 Terminal KET09001 2 A
48 Nylon clamp NK12N 1 A
49 O ring S48NBR 1 A
50 Sunk plug SP1/8B 7 D
51 Nylon clamp NK11N 2 A
52 V ring V45A 1 A
53 Eyebolt XVN12FJ 2 D
54 Rubber cover AWK41012 2 D
55 Stopper collar AGA41055 1 D
56 Limit dogR40 ASM41041 2 U type only D
57 Limit SW ass’y AEB31006 2 U type only C
(57) Limit SW ass’y AEB31007 2 E type only
58 Nylon clamp NK4N 2 U type only A
59 BK release unit AEU01418 2 E/U types only C
60 Swiveling H cover ADK41060 1 D
61 Spacer AFQ41238 1 Harness unit’s part D
62 Connector KMBG36MG4 1 Harness unit’s part D
63 Pole plug CP30HP1 4 D
64 Pole plug CP30HP2 2 D
65 CAL pin M8 AAG41004 3 D
66 UA rubber cover AFQ41239 1 A
<Class>
A: Consumable parts, rather short replacement cycle.
B: Assemblies and parts of high frequency in motion.
C: Important electric parts.
D: Parts rather long replacement cycle.

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♦Remarks
(1) Standard grease application for RV reduction gear: 3 20 ±0.02 20 ±0.2
(Type) VIGOGREASE RE0
4 4.5 ±0.05 46 ±0.5
(2) Standard bolt clamping torque
5 9.8 ±0.1 100 ±1
• Bolts marked with ※ : Refer to the table of “Standard
torque for bolts” for proper clamping torque. 6 18.5 ±0.2 188 ±2
• Bolts marked with ☆: Apply the screw lock 1344(*) and 8 37 ±0.4 380 ±4
then tighten them at the torque listed on the “Standard 10 74 ±0.7 750 ±8
torque for bolts”.
(3) Applied washer types: Use one of the following wash- 12 128 ±1.3 1310 ±13
ers unless otherwise instructed. 14 205 ±2.1 2090 ±21
SW: spring lock washers,
16 319 ±3.2 3250 ±33
CW: Conical spring washers,
PW: Plain washers 20 622 ±6.2 6350 ±64
(4) Mounting screw part of the part(s) marked with ★:
apply the liquid sealing agent 1211(*) before fastening.
(5) Connector (KCBG36): Apply the screw lock TB1401(*)
before connection.
(6) Sealing of RV reduction gear joint part: • Amount of grease enclosed (Unit: g)
• Refer to “Sealing treatment of RV reduction gear” in
Amount of grease enclosed (Unit: g)
FA and RW axes.
• Apply the liquid sealing agent 1211(*) before fastening. by Refil
Axis Grease Manufactured Total
(7) Standard amount of grease to be enclosed: maker l
(a) To fill: See table “Amount of grease enclosed (as VIGO-
manufactured).” UA GREASE 0 329 329 -
RE0
(b) To refill: See table “Amount of grease enclosed
(Refill).” VIGO-
* In case of 4B No.2, refill is not needed. RT GREASE 0 547 547 -
RE0
(8) Apply the sealing agent to the following parts other
than screws. Joints between Note
(a) inner tube and tube holder 35C, In case of ceiling specification, add 30 g to the listed amount
(b) tube holder 35C and RV reduction gear (RT axis), for RT axis.
(c) UA axis motor and UA body, and
(d) RV reduction gear (UA axis) and UA arm (See
“Cross section E-E“.)
(*):
Product of THREE BOND.

• Standard torque for bolts

Standard torque for bolts
Bolt Clamping torque
name N•m kgf•cm

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10.3 FA and RW axes: Parts layout

(Remark 11)
(Remark 12) B-B
(To fasten outer ring of crossed roller bearing)
(Remark 12)
D part (3:3)

(To fasten RW gear shaft2)

(To fasten RW input gear)

(To fasten bearing keep)

(*1) (*2)

(Remark 11)

Screw (Apply grease to the side of pin.)

Screw
Screw

(Torque: 80 kgf•cm)

Screw
Screw

Screw (To fix gas valve)

Screw

Screw

Screw

(Torque: 80 kgf•cm)

C-C
(Apply grease to the side of pin.)

Apply “THREE BOND 1211” to the space

between RW gear cover and RW body
(shaded part in the above figure)

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(*2)

Be aware of drain tap

Apply THREE BOND 1211 to the shaded part.

“Sealing treatment of RV reduction gear”

Apply sealing agent here or to UA arm.
Make sure that no sealing agent to come into the inner side of the shaded part.

<Note>
(1) The part is used for standard spec..
(2) The part is used for UL spec..

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10.4 FA/RW-axis parts list

No. Part name Part number Q’ty Note Class
1 RW body ADA11102 1 D
2 RW gear shaft 1 ADS41080 1 D
3 RW gear shaft 2 ADS41081 1 D
4 RW gear cover ADK25007 1 D
5 RW cover 2 AGK41026 1 D
6 RW input gear ADG32018 1 B
7 RW output gear ADG32019 1 B
8 Servo motor TS4607N8337 1 RW axis C
9 RW motor plate AFP32029 1 D
10 Servo motor TS4613N8337 1 FA axis C
11 RV20E reduction gear 25E033J0 1 FA axis C
12 Harmonic SG1750QR41R 1 RW axis C
13 RW cover AGK41024 1 D
14 RW rear cover AGK41023 1 D
15 RW harness cover AGK41021 1 D
16 Crossed roller bearing BH5515AUUE01 1 C
17 Bearing 6811C2 1 B
18 Bearing keep AFP41229 1 D
19 V ring V55A 1 A
20 V ring V100A 1 A
21 V ring cover AGK41025 1 D
22 Stopper ABQ40015 2 D
23 CAL pin M8 AAG41004 1 FA axis D
24 CAL pin M4 AAG41005 1 RW axis D
25 Motor collar 022 AFM40217 1 D
26 Input gear 20 ADG32013 1 B
27 RW gear shaft 3 ADS32012 1 D
28 O-ring 120NBR 1 A
29 V ring V95A 1 A
30 Gas valve J540-738G 1 A
31 Coupling device PLGJ8-6 1 D
32 Terminal cap VC14x15 1 D
33 Elbow union KQ2L08-02S 1 D
34 Cable holder 1 AFP41230 1 D
35 Shim plate AKC41134 1 Note 1) D
36 Shim plate AKC41135 1 Note 1) D
37 Shim plate for bearing AKC41136 1 Note 1) D
38 Shim plate for bearing AKC41137 1 Note 1) D
39 Cable gland MG25AH208GST 1 D
40 Photo coupler PC8-02 1 D
41 Hole plug CP30HP11 2 T/Y types only D
42 Indicator lamp DM22K0LE03Y 2 E/U types only A
43 Limit dog R20 ASM41042 2 E/U types only D
44 Saddle H616-222 1 D
45 Saddle H616-322 2 D

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Note 1) Adjusting shim plates

Adjust shim plate so that gear rotates smoothly without rattling or unevenly all around the gear.
<Class>
A: Consumable parts, rather short replacement cycle.
B: Assemblies and parts of high frequency in motion.
C: Important electric parts.
D: Parts rather long replacement cycle.

Note About <Details of “D”>

Assemble the harmonic and other parts indicated in the
figure <Details of “D”> as per below instructions before
mounting on to the “D” part.
(1) Attach the flexspline to the HDC housing
(AFP32019).
(2) Insert the flexspline into the wave generator.
(3) Attach bearing (9607ZZ), pulley H (ADW41065)
and bearing (6906ZZ) to the wave generator in this
order.

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♦Remarks
(1) Standard grease application (Harmonic): (a) To fill: See Manufactured” column in the table
(a) RW axis: Harmonic grease SK-1A “Amount of grease enclosed.”
(b) Apply so that surfaces of circularspline and flex- (b) To refill: See table “Refill” column in the table
spline are covered. “Amount of grease enclosed.”
(c) Slightly apply over the boss part of the wave gener- * In case of 4B No.2, refill is not needed.
ator and the flange part of the flexspline for rust- (10) Standard grease application (8907Z)
proof. (a) Harmonic grease SK-1A
(d) Apply to the inner circumference of the flexspline as (b) Refer to the 8907Z application instructions.
thick as the radius of the bearing ball of the wave (11) Shim plate adjustment:
generator. Adjust shim plate so that gear rotates smoothly without
(e) Apply to the inner circumference of the rear side of rattling or unevenly all around the gear.
the flexspline gear and the outer circumference of (12) Cautions when fastening with a cloth roller:
the wave generator. Apply a half of the specified torque first, and then apply
(f) Apply the grease to the bearing part of the wave the specified torque.
generator until the grease runs over from the other (*):
Product of THREE BOND.
side. Rotate the wave generator a couple of times
so that the grease is applied evenly.
Then apply the grease once again. • Standard torque for bolts
(g) After assembling the RWFA unit, add grease from Standard torque for bolts
the grease supply port. Clamping torque
Bolt
(See table “Amount of grease enclosed”.)
name N•m kgf•cm
(2) Standard grease application for RV reduction gear:
(Type) VIGOGREASE RE0 3 20 ±0.02 20 ±0.2
(3) Standard bolt clamping torque 4 4.5 ±0.05 46 ±0.5
• Bolts marked with ※ : Refer to the table of “Standard 5 9.8 ±0.1 100 ±1
torque for bolts” for proper clamping torque.
6 18.5 ±0.2 188 ±2
• Bolts marked with ☆: Apply the screw lock 1344(*) and
then tighten them at the torque listed on the “Standard 8 37 ±0.4 380 ±4
torque for bolts”. 10 74 ±0.7 750 ±8
(4) Applied washer types: Use one of the following wash-
12 128 ±1.3 1310 ±13
ers unless otherwise instructed.
SW: spring lock washers, 14 205 ±2.1 2090 ±21
CW: Conical spring washers, 16 319 ±3.2 3250 ±33
PW: Plain washers
20 622 ±6.2 6350 ±64
(5) Mounting screw part of the part(s) marked with ★:
apply the liquid sealing agent 1211(*) before fastening.
(6) Connector (KCBG36): Apply the screw lock TB1401(*) • Amount of grease enclosed (Unit: g)
before connection.
Amount of grease enclosed (Unit: g)
(7) Sealing of RV reduction gear joint part:
• Refer to “Sealing treatment of RV reduction gear” in Axis Grease by maker Manufactured Total Refill
FA and RW axes. RW SK-1A 0 86 86 17
• Apply the liquid sealing agent 1211(*) before fastening. VIGO-
(In case of 4B No.2, refill is not needed.) FA GREAS 0 192 192 -
(8) Standard no-load running torque of RW shaft part: E RE0
0.2-0.35 N•m (2.1-3.8 kgf•cm)
(9) Standard amount of grease to be enclosed:

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M E M O

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10.5 BW and TW axes: parts layout: YA-1QMR41*00/YA-1RMR41*00

Apply 1211 to
Between TW gear cover and TW gear housing:.

23 47
Set screw
(Torque: 80 kgf•cm)

View
direction

To fasten TW gear housing and TW body 46 39 15 Set screw

(Apply grease to
Apply 1211 to the mounting surface the side of the pin.)
of harmonic and TW body:.

Set screw
2 22 21 11
5 (Apply 1344)
33
13 Set screw
(Apply 1344)

Be aware of the
6
mounting direction.
C (2:1) E (1:1)

(Remark 6)
43 42 B (1:1)
44 16 4 18

27 24 25 17
(Remark 6)

38 37

10

(Remark 6) 29 26
41 40 5 35 34 1

8 7 36 15
(Apply grease to the side of the pin.)

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14
Screw

15 28 32 45

21 11 20 30
Set screw
(Apply 1344)

A-A
4 18 31 12
48
(Apply 1211 to around the guide)
* Install it with the notched part up.
17

Screw
19 D-D

Screw

Screw

34 1 49 3

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10.6 BW/TW-axis parts list: YA-1QMR41*00/YA-1RMR41*00

No. Part name Part number Q’ty Note Class
Servo motor TW axis
1 TS4602N8030 1 C
Previous type: TS4602N8023(*)
2 Harmonic HG1780QR41B 1 BW axis C
3 Servo motor TS4607N8337 1 BW axis C
4 O-ring G85NBR 1 A
5 Snap ring STW8 3 A
6 Conical spring for bear BDS13 2 B
7 Parallel pin XPJ4A10F 1 B
8 V-ring V55A 1 A
9 Bearing 6906C2 2 B
10 Bearing 6811ZZC2 2 B
11 Bearing 6800ZZ 1 B
12 Bearing 6812LULP03 1 B
13 Bearing 624ZZ 1 B
14 Timing belt 060S3M699 1 A
15 CAL pin M4 AAG41005 2 C
16 V-ring V75A 1 A
17 Nylon clamp KCA64 2 A
18 Bearing fix 1 ADH32029 1 D
19 TW motor plate AFP32 1 D
20 BWHD shaft ADS32013 1 D
21 BWHD cover AGK31030 1 D
22 HD housing ADH32028 1 D
TW gear cover Type-1: ADK32027
23 1 D
Type-2: ADK32029
24 TW gear shaft 2 ADS41076 1 D
25 TW gear shaft 1 ADS41075 1 D
26 TW output gear ADG32017 1 B
27 TW input gear ADG32016 1 B
28 Pulley H ADW41060 2 B
29 Harmonic SG1450QR61T 1 TW axis C
30 TWBW cover ADK32026 2 D
31 Bearing fix 2 ADH41039 1 D
32 Pulley shaft H ADS41052 2 D
33 Key XPA3F3F8 1 B
34 TW gear shaft 3 ADS41077 1 D
35 TW gear shaft 4 ADS41078 1 D
36 Bearing keep TW AFP32031 1 D
37 Shim plate AKC41132 1 D
38 Shim plate AKC41133 1 D
39 Hole plug CP30HP13 1 D
40 Shim plate for bearing AKC41136 1 D
41 Shim plate for bearing AKC41137 1 D
42 Shim plate for bearing AKC41138 1 D
43 Shim plate for bearing AKC41139 1 D

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No. Part name Part number Q’ty Note Class

44 TW packing AFQ41241 1 A
45 BW body ADA11103 1 D
46 TW body ADA11106 1 D
TW gear housing Type-1: ADH22013
47 1 D
Type-2: ADH22014
48 TC safety guide 1 AGG41080 1 D
49 TC safety guide 2 AGG41083 1 D
<Class>
A: Consumable parts, rather short replacement cycle.
B: Assemblies and parts of high frequency in motion.
C: Important electric parts.
D: Parts rather long replacement cycle.
(*) For products manufactured before November, 2007.

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 Reduction gear replacement and grease injection

♦Remarks
(1) Standard grease application: • Standard torque for bolts
(a) Harmonic grease SK-1A and SK-2.
Standard torque for bolts
(b) Apply so that surfaces of circularspline and flex-
spline are covered. Bolt Clamping torque
(c) Slightly apply over the boss part of the wave gener- name N•m kgf•cm
ator and the flange part of the flexspline for rust- 3 20 ±0.02 20 ±0.2
proof.
4 4.5 ±0.05 46 ±0.5
(d) Apply to the inner circumference of the flexspline as
thick as the radius of the bearing ball of the wave 5 9.8 ±0.1 100 ±1
generator. 6 18.5 ±0.2 188 ±2
(e) Apply to the inner circumference of the rear side of
8 37 ±0.4 380 ±4
the flexspline gear and the outer circumference of
the wave generator. 10 74 ±0.7 750 ±8
(f) Apply the grease to the bearing part of the wave 12 128 ±1.3 1310 ±13
generator until the grease runs over from the other 14 205 ±2.1 2090 ±21
side. Rotate the wave generator a couple of times
so that the grease is applied evenly. 16 319 ±3.2 3250 ±33
Then apply the grease once again. 20 622 ±6.2 6350 ±64
(2) Standard bolt clamping torque
• Bolts marked with ※ : Refer to the table of “Standard
torque for bolts” for proper clamping torque.
• Bolts marked with ☆: Apply the screw lock 1344(*) and
then tighten them at the torque listed on the “Standard
torque for bolts”.
(3) Applied washer types: Use one of the following wash- • Amount of grease enclosed (Unit: g)
ers unless otherwise instructed.
Amount of grease enclosed (Unit: g)
SW: spring lock washers,
CW: Conical spring washers, Axis Grease by maker Manufactured Total Refill
PW: Plain washers TW SK-1A 0 55.5 55.5 11
(4) Mounting screw part of the part(s) marked with ★: BW SK-2 0 21 21 4
apply the liquid sealing agent 1211(*) before fastening.
(5) Sealing of RV reduction gear joint part:
• Refer to “Sealing treatment of RV reduction gear” in
FA and RW axes.
• Apply the liquid sealing agent 1211(*) before fastening.
(In case of 4B No.2, refill is not needed.)
(6) Shim plate adjustment:
Adjust shim plate so that gear rotates smoothly without
rattling or unevenly all around the gear.
(*):
Product of THREE BOND.

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M E M O

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10.7 BW and TW axes: parts layout: YA-1QMR42*00/YA-1RMR42*00

Apply 1211 to
Between TW gear cover and TW gear housing:.

23 47

Set screw

(Torque: 80 kgf•cm)

View

To fasten TW gear housing and TW body 46 39 15

(Apply grease to
the side of the pin.)
Apply 1211 to the mounting surface
of harmonic and TW body:.

5 Set screw
(Apply 1344)
2 22 21
33
13
Set screw
(Apply 1344)

6
Be aware of the
mounting direction.

(Remark 6)
16 4
43 42 44

27 35 24 25
(Remark 6)

38 37

10

29
41 40 5 8 26 36 34

(Apply grease to the side of the pin.)

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 Reduction gear replacement and grease injection

47 14
Screw

39 15 28 32 45
Setscrew

22 21 11 20 30
Setscrew
(Apply 1344)

16 4 18 31 12 48
(Apply 1211 to around the guide)
* Install it with the notched part up.

25 17
Screw

19
Screw

Screw

52 50 1 49 3

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10.8 BW/TW-axis parts list: YA-1QMR42*00/YA-1RMR42*00

No. Part name Part number Q’ty Note Class
Servo motor TW axis
1 TS4602N8030 1 C
Previous type: TS4602N8023(*)
2 Harmonic HG1780QR41B 1 BW axis C
3 Servo motor TS4607N8337 1 BW axis C
4 O-ring G85NBR 1 A
5 Snap ring STW8 3 A
6 Conical spring for bear BDS13 2 B
8 V-ring V55A 1 A
9 Bearing 6906C2 2 B
10 Bearing 6811C2 2 B
11 Bearing 6800ZZ 1 B
12 Bearing 6812LULP03 1 B
13 Bearing 624ZZ 1 B
14 Timing belt 060S3M699 1 A
15 CAL pin M4 AAG41005 2 C
16 V-ring V75A 1 A
17 Nylon clamp KCA64 2 A
18 Bearing fix 1 ADH32029 1 D
19 TW motor plate AFP32028 1 D
20 BWHD shaft ADS32013 1 D
21 BWHD cover AGK31030 1 D
22 HD housing ADH32028 1 D
23 TW gear cover ADK32027 1 D
24 TW gear shaft 2 ADS41076 1 D
25 TW gear shaft 1 ADS41075 1 D
26 TW output gear ADG32022 1 B
27 TW input gear ADG32016 1 B
28 Pulley H ADW41060 2 B
29 Harmonic SG1450QR61T 1 TW axis C
30 TWBW cover ADK32026 2 D
31 Bearing fix 2 ADH41039 1 D
32 Pulley shaft H ADS41052 2 D
33 Key XPA3F3F8 1 B
34 Bearing nut AMN41038 1 D
35 Bearing holder TW1 AFP41243 1 D
36 Bearing holder TW2 AFP41244 1 D
37 Shim plate AKC41132 1 D
38 Shim plate AKC41133 1 D
39 Hole plug CP30HP13 1 D
40 Shim plate for bearing AKC41136 1 D
41 Shim plate for bearing AKC41137 1 D
42 Shim plate for bearing AKC41138 1 D
43 Shim plate for bearing AKC41139 1 D
44 TW packing AFQ41241 1 A
45 BW body ADA11103 1 D

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 Reduction gear replacement and grease injection

No. Part name Part number Q’ty Note Class

46 TW body ADA11104 1 D
47 TW gear housing ADH22013 1 D
48 TC safety guide 1 AGG41080 1 D
49 TC safety guide 2 AGG41083 1 D
<Class>
A: Consumable parts, rather short replacement cycle.
B: Assemblies and parts of high frequency in motion.
C: Important electric parts.
D: Parts rather long replacement cycle.
(*) For products manufactured before November, 2007.

SM0710064E07 117
 Reduction gear replacement and grease injection

♦Remarks
(1) Standard grease application: • Standard torque for bolts
(a) Harmonic grease SK-1A and SK-2.
Standard torque for bolts
(b) Apply so that surfaces of circularspline and flex-
spline are covered. Bolt Clamping torque
(c) Slightly apply over the boss part of the wave gener- name N•m kgf•cm
ator and the flange part of the flexspline for rust- 3 20 ±0.02 20 ±0.2
proof.
4 4.5 ±0.05 46 ±0.5
(d) Apply to the inner circumference of the flexspline as
thick as the radius of the bearing ball of the wave 5 9.8 ±0.1 100 ±1
generator. 6 18.5 ±0.2 188 ±2
(e) Apply to the inner circumference of the rear side of
8 37 ±0.4 380 ±4
the flexspline gear and the outer circumference of
the wave generator. 10 74 ±0.7 750 ±8
(f) Apply the grease to the bearing part of the wave 12 128 ±1.3 1310 ±13
generator until the grease runs over from the other 14 205 ±2.1 2090 ±21
side. Rotate the wave generator a couple of times
so that the grease is applied evenly. 16 319 ±3.2 3250 ±33
Then apply the grease once again. 20 622 ±6.2 6350 ±64
(2) Standard bolt clamping torque
• Bolts marked with ※ : Refer to the table of “Standard
torque for bolts” for proper clamping torque.
• Bolts marked with ☆: Apply the screw lock 1344(*) and
then tighten them at the torque listed on the “Standard
torque for bolts”.
(3) Applied washer types: Use one of the following wash- • Amount of grease enclosed (Unit: g)
ers unless otherwise instructed.
Amount of grease enclosed (Unit: g)
SW: spring lock washers,
CW: Conical spring washers, Axis Grease by maker Manufactured Total Refill
PW: Plain washers TW SK-1A 0 55.5 55.5 11
(4) Mounting screw part of the part(s) marked with ★: BW SK-2 0 21 21 4
apply the liquid sealing agent 1211(*) before fastening.
(5) Sealing of RV reduction gear joint part:
• Refer to “Sealing treatment of RV reduction gear” in
FA and RW axes.
• Apply the liquid sealing agent 1211(*) before fastening.
(In case of 4B No.2, refill is not needed.)
(6) Shim plate adjustment:
Adjust shim plate so that gear rotates smoothly without
rattling or unevenly all around the gear.
(*):
Product of THREE BOND.

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 Reduction gear replacement and grease injection

10.9 Wire feeder

10.9.1 TAWERS specification (YA-1QMR41T00)

1 Feed unit ADU01489

2 Motor unit ADU01488
3 Name plate GRS ANH42361

For UL spec.,UF base cover is provided

2 4(*)

5(*)
Feeder fixing bracket 2 Feeder fixing bracket 1
(AFM41711) (AFM41710)
6(*)

7(*)
9

(*) 2-M2.5x6
Conical machine
screw N

(*)
2-M3x10
10 8(*)
Conical machine screw

Feeder fixing bracket 4 UF base cover ADK25005

(AFM41712) 5 E-shape snap ring XUC5FP
6 Pin MMP00006
9 Warning plate MNT00008
7 Warning plate MNT00008
10 Name plate OP ANH42254
8 Catch C-131

Note
• Parts marked with ＊ is for UL specifications.
• Location of the warning label, MNT00008:
Standard spec.: On the left side of the motor unit.
UL spec.: At the bottom of the UF base cover.

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 Reduction gear replacement and grease injection

10.9.2 Details of feeder fixing bracket

Feeder fixing bracket 1

(AFM41710)

Feeder fixing bracket 3

(AFM41712)

Feeder fixing bracket 2

(AFM41711)

Wire straightener (*1) After having set torch cable,

fix it at the center of the slide

Note
(*1)Install the wire straightener; AGU01006, (attachment of
peripheral unit; YA1QN412, for this system) to the wire
feeder.
In case of using pack wire, please purchase a wire
straightener separately for the wire drawing unit side.

120 SM0710064E07
 Reduction gear replacement and grease injection

10.10 Feed unit (ADU01489)

1 6

2 7

1
8
3

Screw

1
4 9

Conical machine screw

5
Upset bolt

Upset bolt

10 12 13
11

1 Pressure rod MDS00015 8 Pressure roller ass’y MDR00060

2 Pressure nut MMN00014 9 Feed roller MDR00051
3 Roller fitting pipe MDS00017 10 Conduit cable fitting bracket MFC00011
4 Feed gear assembly MDG00010 11 Stopper ass’y ABQ41021
5 Feed roller jig MDS00009 12 UF base ADB12002
6 Pressure spring MBP00007 13 Flexible conduit fitting MGW00016
7 Pressure control tube ass’y MNX00015

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 Reduction gear replacement and grease injection

2 3
4 5 6

2-point screw

Round head screw

Round head screw
Clamping torque: 3.0 0.3N•m
Clamping torque: 3.0 0.3N•m
(Apply 1305N)
(Apply 1305N)

Conical machine screw

8 9 Round head screw

1 E-shape snap ring XUC5FP 6 SUS tube MGT00004

2 Pressure arm spring MBP00003 7 Roll pin XPL3A20W
3 Pin MMP00006 8 Center tube 12S MGW00012
4 Pressure arm MDA00004 9 Wire guide fitting AFC41002
5 Pressure arm MDA00005

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10.11 Motor unit (ADU01550)

3 2
9
1
4 Round head
screw

5
10
6

Screw
11
7

12
Screw

13

Details of D (2:1)

1 Connector harness AWC42313 8 Bearing 6001LU

2 Grease inlet port AFN41639 9 Gearbox R ADH12522
3 Gearbox L ADH12523 10* Worm wheel ADW41067
4* Insulation AZT41032 11* Shaft ADS41074
5* Parallel key XPA3F4F14 12 Nylon clamp NK-8N
6 Parallel key XPA3F4F15 13 Wave washer BWW626
7 Washer UMMC0501

SM0710064E07 123
 Reduction gear replacement and grease injection

• Before installing the grease inlet port, apply bath cork to the mounting area
• After installation remove bath cork runs over.

4 3 2 1

Conical machine screw

(For feed unit mount)

6

(For main body mount)

Secure 0.5mm space between boss and spacer.

Details of E (2:1)

TS4602N3030 Note
1 Motor
Previous type: TS4602N3023(*) • Apply “Albania No.2” to the worm gear and the work
2 Coupling MC0G20-8-10 wheel so as to cover the bottom of the teeth of the
gear.
3 Worm gear ADW41063
• Apply “Albania No.2” to the bearing 6001LU (2 pieces)
4 Bearing 6000ZZ
• Apply “Albania No.2” to the coupling spacer.
5 Connector plate AKK41148 • Parts made with “*” vary with specification.
6 Gearbox cover ADK32023 (The table on the left shows parts numbers of standard
specification.)
(*)
:For products manufactured before November, 2007.

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10.12 Welding torch assembly drawing (YT-CBT351): YA-1QMR41*00/YA-

1RMR41*00

Shunt lead

Safety holder

Power cable Gas hose

Torch body

Signal cable

O ring Liner

Plug signal connection

Wire color Signal name Pin No.
Red Safety holder 1
Yellow Safety holder 2
White +Mag-Force 3
Black -Mag-Force 4
Green Voltage F/B 5

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 Reduction gear replacement and grease injection

10.13 Welding torch assembly drawing (YT-CCT351): YA-1QMR42*00/YA-

1RMR42*00

Shunt lead

Safety holder

Torch body
Power cable Gas hose

Signal cable

O-ring Liner

Plug signal connection

Wire color Signal name Pin No.
Red Safety holder 1
Yellow Safety holder 2
White +Mag-Force 3
Black -Mag-Force 4
Green Voltage F/B 5

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 Reduction gear replacement and grease injection

10.14 Welding cable (AWC32776)

It is located in the RT axis of the manipulator

Fixed side Motion side

Round-shaped Round-shaped
crimp terminal crimp terminal

Insert the bundle of harnesses

Tight winding at both ends into the coil spring.
(Length: 21 mm)
Heat shrinkable tube Heat shrinkable tube
SUMI tube FZ25x0.4 (25 dia., black) SUMI tube FZ25x0.4 (25 dia., black)

Note
+ 10
(1) Cut the cable (RMFEU-MS455) into five pieces of 1000 – 0 mm long.
(2) As for Heat shrinkable tube, use SUMI tube FZ25x0.4.
(3) Marker is not needed.
(4) Bind the cable to the spring with the binding band for both ends.
Cross bind the two rolls after the tight winding part/

Binding band
SKB4M (product of KITAGAWA) or the like

(5) Do not cover the terminal mounting surface with the heat shrinkable tubr.

Align the end of the crimp part.

Terminal mounting surface

Heat shrinkable tube

SM0710064E07 127
 Reduction gear replacement and grease injection

10.15 Limit SW (AEB31006)

(1) 1. Operating position (OP) tolerance: OP - 24±0.5
(2) 2. Difference in response between contact 1(OT1) and
contact 2 (OT2): 0.25 or less.

Name Number Q’ty

1 OT housing 1 ASK31007 1
2 OT housing 2 ASK31008 1
3 OT plunger ASS41008 1
4 OT fixer ASK41024 2
5 Press fit plunger PFPSN6 1
6 Coil spring WF10-10 1
7 CR-shaped snap ring CRTW12 1

Connection instruction 8 Micro switch D2SW3L1HS 2

Wire color Pin# Connector OTSW side 9 Nut M14x17x2.5 1
Red 1 OT1 NC 10 Cable MSSB4-10 300mm
Pink 2 OT2 NC 11 Cable UL1007-AWG24 130mm
DF11-4DEP-2C
Green/Yellow 12 Relay plug DF11-4DEP-2C 1
4
(Shield) 13 Cramping socket DF11-4DS-2C 1
Black 1 OT1 C 14 Contact DF11-EP2428PCA 3
Gray 2 OT2 C 15 Contact DF11-2428SCA 3
DF11-4DS-2C
Green/Yellow 16 SUMI tube F (Z) 8x0.25 (8 dia., black) 40mm
4
(Shield)

128 SM0710064E07
 MEMO

SM0710064E07 129
パナソニック溶接システム株式会社 Panasonic Welding Systems Co., Ltd.
〒 561-0854 大阪府豊中市稲津町 3 丁目 1 番 1 号 1-1, 3-chome, Inazu-cho, Toyonaka, Osaka 561-0854,
TEL: (06)-6866-8556（代表） Japan
FAX: (06)-6866-0709 TEL: 81-6-6866-8505
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URL:http://panasonic.net/pws/

© Panasonic Welding Systems Co., Ltd. 2009. Printed in Japan.

SM0710064E07