1CD

MOTOMAN-UP130,UP165,UP200
MAINTENANCE MANUAL
TYPE : YR-UP130-A00
YR-UP165-A00
YR-UP200-A00
Procedures described in this maintenance manual should be carried out by the person who took the
maintenance-relevant trainings offered by Yaskawa.
Upon receipt of the product and prior to initial operation, read these instructions thoroughly, and retain
for future reference.
MOTOMAN INSTRUCTIONS
MOTOMAN SETUP MANUAL
MOTOMAN-UP130, -165 INSTRUCTIONS
MOTOMAN-UP200 INSTRUCTIONS
YASNAC XRC INSTRUCTIONS
YASNAC XRC OPERATORS MANUAL
YASNAC XRC OPERATORS MANUAL for BEGINNERS
The YASNAC XRC operators manuals above correspond to specific usage.
Be sure to use the appropriate manual.
Part Number: 170903-1CD

Revision: 1
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MANUAL NO.
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Copyright 2015, Yaskawa America, Inc. All Rights Reserved.
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Table of Contents
Table of Contents
1 Introduction
1.1 NOTES FOR SAFE OPRERATION . . . . . . . . . . . . . . . . 1-2
1.2 Definition of Terms Used Often in This Manual . . . . . 1-4
1.3 AN EXPLANATION OF WARNING LABLES . . . . . . . 1-5
2 Notes for Maintenance

2.1 Battery Pack Connection for S-, L-,
and U-Axis Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.2 Battery Pack Connection for R-, B-,
and T-Axis Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
3 Home Position Return Operation

3.1 How to Return to the Home Position in the Case of
Replacing the Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.1.1 How to Use the Robot Calibration (MOTOCALV EG) . . . . . . . .3-1
3.1.2 How to Set the Teaching Point for Home Position
Setting before Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
Preparation before Replacement . . . . . . . . . . . . . . . . . . . . .3-1
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2
Home Position Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . .3-3
3.2 How to Return to the Home Position in the
Case of the Exhaustion of the Motor Battery
of the Robot Axis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3.2.1 The Method by Using the Home Position Alignment
Function for Restoration at the Time of Battery Backup . . . . . .3-4
3.2.2 The Method by Using the Keys . . . . . . . . . . . . . . . . . . . . . . . . .3-4
Calibration Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4
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4 L-axis Fixing Jig Operating

4.1 Fixing Jig Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.1.1 Specific Jig Installing Posture and Installing Position . . . . . . . . 4-2
4.2 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.3 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
4.4 Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
5 Grease Replenishment/Exchange
5.1 Grease Replenishment/Exchange for
S-Axis Speed Reducer and Gear . . . . . . . . . . . . . . . . . . . 5-1
5.1.1 Grease Replenishment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.1.2 Grease Exchange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
L-Axis Speed Reducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5.2.2 Grease Exchange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
U-Axis Speed Reducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
5.3.2 Grease Exchange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
R-Axis Speed Reducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
5.4.2 Grease Exchange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
B-Axis Speed Reducer and Gear . . . . . . . . . . . . . . . . . . . 5-9
5.5.2 Grease Exchange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
T-Axis Speed Reducer and Gear . . . . . . . . . . . . . . . . . . 5-11
5.6.1 Grease Replenishment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
5.6.2 Grease Exchange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
5.7 Grease Replenishment for
Balancer Connection Part . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
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6 Disassembly and Reassembly of the Motor

6.1 Disassembly and Reassembly
of the S-Axis Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1
Reassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1
of the L-Axis Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-5
Reassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-5
of the U-Axis Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-9
Reassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-9
of the RBT-Axes Motors . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-12
Reassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-12
7 Disassembly and Reassembly of the Speed Reducer

of the S-Axis RV Speed Reducer . . . . . . . . . . . . . . . . . . 7-1
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1
Reassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1
of the L-Axis RV Speed Reducer . . . . . . . . . . . . . . . . . . 7-5
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-5
Reassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-5
of the U-Axis RV Speed Reducer . . . . . . . . . . . . . . . . . . 7-9
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-9
Reassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-9
7.4 Disassembly and the Reassembly
of the R-Axis Cyclo Speed Reducer. . . . . . . . . . . . . . . 7-12
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-12
Reassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-12
of the B-Axis RV Speed Reducer . . . . . . . . . . . . . . . . . 7-16
Reassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-16
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of the T-Axis Cycle Speed Reducer . . . . . . . . . . . . . . . 7-20
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20
8 Disassembly and Reassembly of the Wrist Unit

8.1 Disassembly and Reassembly of the Wrist Unit . . . . . 8-1
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
9 Adjustment the Tension of the RBT-Axes Belts

9.1 Disassembly and Reassembly of the R-, B- and
T-Axis Timing Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
9.2 Adjustment of the RBT-Axes Timing Belts . . . . . . . . . . 9-3
10 Battery Pack Replacement
11 Cable Wiring
Remove Operation of the Cable . . . . . . . . . . . . . . . . . . . . . 11-1
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-5
12 Parts List
12.1 UP130, UP165 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1
12.1.1 S-Axis Driving Unit(1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1
12.1.2 S-Axis Driving Unit(2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-3
12.1.3 L-Axis Driving Unit(1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-5
12.1.4 L-Axis Driving Unit(2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-9
12.1.5 U.R.B.T-Axis Link Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-11
12.1.6 Wrist Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-14
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1 Introduction
1 Introduction
This maintenance manual is intended to explain operating instructions and maintenance

procedures primarily for the MOTOMAN-UP130,UP165, and UP200.
General items related to safety are listed in the Safety Manual Chapter 1: Safety. To ensure correct
and safe operation, carefully read the Setup Manual before reading this manual.
Some drawings in this manual are shown with the protective covers or shields removed for clarity.
Be sure all covers and shields are replaced before operating and maintenance this product.
The drawings and photos in this manual are representative examples and differences may exist
between them and the delivered product.
YASKAWA may modify this model without notice when necessary due to product improvements,
modifications, or changes in specifications. If such modification is made, the manual number will
also be revised.
If your copy of the manual is damaged or lost, contact a YASKAWA representative to order a new
copy. The representatives are listed on the back cover. Be sure to tell the representative the
manual number listed on the front cover.
YASKAWA is not responsible for incidents arising from unauthorized modification of its products.
Unauthorized modification voids your product's warranty.
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1 Introduction
1.1 NOTES FOR SAFE OPRERATION
Read this manual carefully before executing maintenance inspection of the YASNAC XRC.
In this manual, the Notes for Safe Operation are classified as "DANGER", "WARNING",
"CAUTION", "MANDATORY", or "PROHIBITED".
Indicates an imminent hazardous situation which, if not avoided,

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

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

could result in minor or moderate injury to personnel and
damage to equipment. It may also be used to alert against
unsafe practices.
Always be sure to follow explicitly the items listed under this

heading.
Must never be performed.
Even items described as "CAUTION" may result in a serious accident in some situations. At
any rate, be sure to follow these important items.
NOTE To ensure safe and efficient operation at all times, be sure to follow all instructions,
even if not designated as "DANGER", "WARNING" and "CAUTION".
Maintenance and inspection must be performed by specified personnel.
Failure to observe this caution may result in electric shock or injury.
For disassembly or repair, contact your Yaskawa representative.
Do not remove the motor, and do not release the brake.
Failure to observe these safety precautions may result in death or serious injury from
unexpected turning of the manipulator's arm.
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1 Introduction
Before maintenance, inspection and wiring, make sure to turn the primary power supply off,
and put up a warning sign. (ex. DO NOT TURN THE POWER ON).
Failure to observe this warning may result in electric shock or injury.
After completing the maintenance inspection, make sure where is the home position before
operating the manipulator.
Failure to observe this warning may cause unexpected manipulator motion, resulting in
collision or injury.
Before operating the manipulator, check that servo power is turned OFF when the emergency
stop buttons on the playback panel or programming pendant are pressed.When the servo
power is turned OFF, the SERVO ON READY lamp on the playback panel and the SERVO
ON LED on the programming pendant are turned OFF.
Injury or damage to machinery may result if the emergency stop circuit cannot stop the
manipulator during an emergency. The manipulator should not be used if the emergency stop
buttons do not function.
Emergency Stop Button
Once the emergency stop button is released, clear the cell of all items which could interfere
with the operation of the manipulator. Then turn the servo power ON.
Injury may result from unintentional or unexpected manipulator motion.
TURN
Release of Emergency Stop

Observe the following precautions when performing teaching operations within the working
envelope of the manipulator:
-Be sure to use a lockout device to the safeguarding when going inside. Also, display the sign
that the operation is being performed inside the safeguarding and make sure no one closes
the safeguarding.
-View the manipulator from the front whenever possible.
-Always follow the predetermined operating procedure.
-Keep in mind the emergency response measures against the
manipulators unexpected motion toward you.
-Ensure that you have a safe place to retreat in case of emergency.
Improper or unintended manipulator operation may result in injury.
Confirm that no persons are present in the manipulator's work envelope and that you are in a
safe location before:
-Turning on the YASNAC XRC power
-Moving the manipulator with the programming pendant
-Running check operations
-Performing automatic operations
Injury may result if anyone enters the working envelope of the manipulator during operation.
Always press an emergency stop button immediately if there are problems. The emergency
stop button is located on the right side of both the YASNAC XRC playback panel and
programming pendant.
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1 Introduction
Perform maintenance inspection with the specific person who has took the maintenance training
course in Yaskawa.
Failure to observe this may result in electric shock or injury.
When the maintenance inspection is performed, be sure to mount the battery unit before removing
the motor encoder connector.
Failure to observe this caution may result in disappearance of the home position data.
Perform the following inspection procedures prior to conducting manipulator teaching. If problems
are found, repair them immediately, and be sure that all other necessary processing has been
performed.
-Check for problems in manipulator movement.

-Check for damage to insulation and sheathing of external wires.
Always return the programming pendant to the hook on the XRC cabinet after use.
The programming pendant can be damaged if it is left the manipulator's work area, on the
floor, or near fixtures.
Read and understand the Explanation of the Alarm Display in the Setup Manual before operating
the manipulator.
1.2 Definition of Terms Used Often in This Manual
The MOTOMAN is the YASKAWA industrial robot product.

The MOTOMAN usually consists of the manipulator, the controller, the playback panel, the
programming pendant, and manipulator cables.
In this manual, the equipment is designated as follows:
Equipment Manual Designation
YASNAC XRC Controller XRC (Robot Controller)
YASNAC XRC Playback Panel Playback Panel
YASNAC XRC Programming Pendant Programming Pendant
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1 Introduction
1.3 AN EXPLANATION OF WARNING LABLES
The following warning labels are attached to the manipulator.

Always follow the warning on the labels.
Also, an identification label with important information is placed on the body of the manipula-
tor. Prior to operating the manipulator, confirm the contents.
Note: Taking the maintenance-relevant trainings offered by Yaskawa is indispensable for

replacing the L-axis motor in the balancer-equipped manipulator.
MOTOMAN-UP130, UP165, UP200

Warning label C
Warning label A Warning label B
Nameplate
Warning label C
Warning label A
Warning label B
Nameplate Warning Label A Warning Label C
Warning Label B
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Remove the old battery pack after connecting the new one so that the encoder absolute
NOTE data does not disappear.
Do not remove the battery pack in the base connector.
2.1 Battery Pack Connection for S-, L-, and U-Axis

Motors
Refer to the Fig. 2-1 "S-, L- and U-Axis Battery Pack Replacement" in this chap-
ter.
The connector for the battery pack connection is attached to the main body of the S-, L-, and U-axis
motors. Connect the battery pack according to the following procedure.
1. Remove the cap attached to the battery backup connector of the motor.
2. Connect the S-, L- and U-Axis battery pack (HW9470932-A) with the battery backup
connector. (Under such a condition, remove the encoder connector and perform the
maintenance inspection.)
3. Confirm all connectors connection after the maintenance check ends, and remove the
battery pack connection cable for the motor and the battery pack.
4. Install the cap attached to the battery backup connector of the motor.
<The case of the battery pack installed improperty>
Some of the motors for the S axis and L axis are unable to install the battery pack.
(HW9470932-A) directly because that the type of the battery backup connector is differ
ent. The battery pack connection cable (HW9470945-A) are necessary in this case.
Connect the battery pack connection cable with the motor, then connect the battery
pack with it.
2.2 Battery Pack Connection for R-, B-, and T-Axis

Motors
Refer to the Fig. 2-2 "R-, B- and T-Axis Battery Pack Connection" in this chapter.
The connector (insertion-type pin terminal) for the battery backup is installed in the end point of the
cable for the encoder of the R-, B-, and T-axis motors (BAT and OBT are marked).
Connect the battery pack according to the following procedure.
1. Connect the battery pack (HW9470932-B) for the R-, B-, and T-axis with the battery
backup connector (BAT and OBT are marked) located in the end point of the cable for
the encoder. (Under such a condition, remove the encoder connector and perform the
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maintenance inspection.)
2. Confirm all connectors connection after the maintenance inspection ends, and remove
the battery pack.
Connector for the battery backup
S, L, U-axis motors
0BT a b 0BT1
BAT b a BAT1
Battery pack for S, L, U-axis (HW9470932-A)
Battery pack connection cable for the motor (HW9470945-A)

Fig. 2-1 S-, L- and U-Axis Battery Pack Replacement
R, B, T-axis motors
Encoder cable
0BT a b 0BT4
BAT b a BAT4
Battery pack for R, B, T-axis (HW9470932-B)

Connector for the battery backup
Fig. 2-2 R-, B- and T-Axis Battery Pack Connection
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In the following cases, perform calibration and set the robot geometrical position.
NOTE Change in the combination of the MOTOMAN and the control unit.
Replacement of the motor or encoder.
Clearing stored memory.
Home position deviation caused by hitting the MOTOMAN against a workpiece, etc.
Replacement, disassembly, and assembly of the main parts of the speed reducer in
performing calibration, be sure to satisfy the following conditions. Avoid applying external
force to the robot.
Remove the hand of the wrist part and other parts.

Replacing the Motor
3.1.1 How to Use the Robot Calibration (MOTOCALV EG)

The MOTOCALV EG allows the home position reset by teaching the five-point-in-five-posture.
Refer to MOTOCALV EG Operators Manual (152646-1CD) for details on the operation.
3.1.2 How to Set the Teaching Point for Home Position

Setting before Replacement
YASNAC-XRC holds the position data of the job program (hereinafter called the JOB) as the pulse
number from the home position of each axis. Therefore, by adjusting the home position precisely, the
JOB had been used before replacement can be used after replacement without correction.
This section explains how to set the YASNAC-XRC.
Preparation before Replacement

Refer to the Fig. 3-3 "Preparation before replacement (Ex.)" in this chapter.
Before replacement, create the standard position (hereinafter called the checked point) for home
position adjustment after replacement. The checked point must satisfy the following conditions. Create
the JOB so that safety moving to the checked point from the standby position can be ensured.
(Hereinafter called the checked JOB)
1 The position is not deviated by turning the power ON or OFF, or lowering air pressure. Do not create
the position in the working part of the tool (end effecter) or the jigs (related unit including the rotary
table). Using specific jigs is recommended if necessary.
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2 Use pointed jigs to create the position so that the deviation is easily found. Keep a distance as long
as possible from the rotational center of the replacing axis.
3 Considering the moving direction of the replacing axis, create the position so that the deviation is
easily found and the axis will not interfere with the jigs even if it is deviated.
One of the checked point when replacing the U-axis on the UP130-A00 Spot System is shown below as
an example.
The check-point cannot be created without operating each axis. Therefore, the check-
point cannot be created if the axis cannot operate for some reasons including failure. It is
recommended to create the check-point for each axis under normal operating conditions.
Next, check the home position of the replacing axis. Move the replacing axis to the 0 pulse position, the
home position, on the position screen, and check the position of the home position mark. If it is
deviated, adjust it.
An example of the U-axis of UP130-A00 is shown below.
View observed from the arrow A
Fig. 3-3 Preparation before replacement (Ex.)
Replacement
Refer to the Fig. 3-4 "Replacement (Ex.)" in this chapter.
The attitude cannot be hold because the motor is removed for replacement. Hold the arm using the
chain block. If not, it is seriously dangerous. Replace it with due care.
The example of the U-axis of UP130-A00 is shown below.
Fig. 3-4 Replacement (Ex.)

Remove the motor and replace it.
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Home Position Adjustment

After completing the replacing work, move the replaced axis to the position of the home position mark.
Perform the home position alignment only for the replaced axis.
(For more detailed information, refer to "YASNAC XRC INSTRUCTIONS".)
Move the axis to the checked point by the checked JOB. (Care must be taken so that the axis may not
interfere with the jigs in moving the axis.) Move only the replaced axis to adjust the deviation from the
point created before the work for alignment.
Display the position screen (command value).

The example of U-axis is shown below.
Command value R1
S:007 Interpolation: Link Speed: 25.00%
[Command value] Instruction tool: 0 [Present value] Operation tool: 0
R1:S 3458 R1:S 3458
L 5638 L 5638
U -2989 U -3067
R 80 R 80
B -10754 B -10754
T -10 T -10
Using the above values, calculate the amount of deviation. (Subtract the command value from the
present value.)
Present value - Command value = the amount of deviation

U(-3067) - (-2989) = -78
Move the replaced axis to a position where it will not interfere with the jigs when it moves to the home
position by stepping back of the Checked JOB. (Care must be taken so that the axis may not interfere
with the jigs in moving the axis.) Move the replaced axis to the pulse position equal to the amount of
deviation on the position screen.
The example is shown below.
Command value R1
S:007 Interpolation: Link Speed: 25.00%
[Command value] Instruction tool: 0 [Present value] Operation tool: 0
R1:S 58 R1:S 58
L 0 L 0
U 0 U -78
R 0 R 0
B -11700 B -11700
T 0 T 0
Perform the home position alignment only for the replaced axis on this position.
(For more detailed information, refer to "YASNAC XRC INSTRUCTIONS".)
Move the axis to the Checked point by the Checked JOB again. Check that it is in the point created
before the work for completing the work. If it is deviated, repeat the adjustment procedures.
Check the operation by using the JOB before replacement. When no problem is found, write the home
position data (ABSO data) and the date in the label attached on the inside of the XRC.
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the Exhaustion of the Motor Battery of the Robot Axis
3.2.1 The Method by Using the Home Position Alignment

Function for Restoration at the Time of Battery Backup
This is the method for operating the software of the "Backup alarm restoration" on Programing Pendant.
After moving the robot to the posture close to the home position (within 1motor rotation) by teaching
operation. The multi-turn data is updated in this method.
3.2.2 The Method by Using the Keys

This is the method for writing a differential pulse between the key position and the home position at the
time of the MOTOMAN shipment in the home position label attached on the inside of the YASNAC
panel. When the home position disappears, move the robot to the key position, form which set
mentioned above the differential pulse as the home position.
Calibration Operation
Table 3-1 Required Parts List
UP130 and UP165
Drawing number (Product number) Name Number Remark
HW9405595-1 Pin 6 For all the axes
HW9405584-1 Jig 1 For the R-axis
MSTH6-20 Knockout pin 2 For the R-axis
HW9405597-1 Jig 1 For the T-axis
MSTH10-30 Knockout pin 2 For the T-axis
UP200
Drawing number (Product number) Name Number Remark
HW9405595-1 Pin 4 For the S-, L-, U- and

R-axis
HW9405627-1 Pin 1 For the B-axis
HW9405626-1 Pin 1 For the T-axis
HW9405624-1 Jig 1 For the R-axis
MSTH6-20 Knockout pin 2 For the R-axis
HW9405625-1 Jig 1 For the T-axis
HW0404355-1 Knockout pin 2 For the T-axis
Prepare the Table 3-1 "Required Parts List" parts for performing calibration.
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1. S-axis Positioning
As shown in the Fig. 3-5 "S-axis Positioning", insert the pin (HW9405595-1) from the
hole of the pin (6 +0018
0 dia.) of the S head into the slot of the base part for positioning by
the teach box.
HW9405595-1 Pin
1800.1
Fig. 3-5 S-axis Positioning

2. L-Axis Positioning
As shown in the Fig. 3-6 "L-Axis Positioning", insert the pin (HW9405595-1) from the
0 dia.) of the S head into the slot of the L-arm for positioning by the
teach box.
L-Arm
HW9405595-1 Pin
S head
Fig. 3-6 L-Axis Positioning
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3. U-Axis Positioning
As shown in the Fig. 3-7 "U-Axis Positioning", insert the pin (HW9405595-1) from the
0 dia.) of the L-arm into the slot of the casing for positioning by the
teach box.
Casing
HW9405595-1 pin
L-Arm
Fig. 3-7 U-Axis Positioning

4. R-axis Positioning
(1) UP130 and UP165
As shown in the Fig. 3-8 "R-Axis Positioning", fasten the jigs (HW9405584-1) to the
U-arm with two knockout pins (MSTH6-20), and insert the pin (HW9405595-1) into
the slot of the wrist unit for positioning by the teach box.
(2) UP200
As shown in the Fig. 3-8 "R-Axis Positioning", fasten the jigs (HW9405624-1) to the
U-arm with two knockout pins (MSTH6-20), and insert the pin (HW9405595-1) into
the slot of the wrist unit for positioning by the teach box.
U-arm Wrist unit

135.5 (165)*
40
HW9405595-1 Pin
MSTH6-20
two Knockout pins
HW9405584-1 Jigs
(HW9405624-1 Jigs)*
*: Inside of ( ) indicates the type and dimension for UP200 model.
Fig. 3-8 R-Axis Positioning
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5. B-Axis Positioning
(1) UP130 and UP165
As shown in the Fig. 3-9 "B-Axis Positioning", insert the pin (HW9405595-1) from
the hole of the pin (6 +0018
0 dia.) of the B-axis speed reducer part into the slot of the
wrist part for positioning by the teach box.
(2) UP200
As shown in the Fig. 3-9 "B-Axis Positioning", insert the pin (HW9405627-1) from
the hole of the pin (8 +0018
0 dia.) of the B-axis speed reducer part into the slot of the
wrist part for positioning by the teach box.
Wrist part
B-axis
speed reducer part
HW9405595-1 Pin
(HW9405627-1 Pin)*
*: inside of ( ) indicates the types and dimension for UP200
Fig. 3-9 B-Axis Positioning
6. T-Axis Positioning
(1) UP130 and UP165
As shown in the Fig. 3-10 "T-Axis Positioning", fasten the jigs (HW9405597-1) with
two knockout pins (MSTH10-30), and insert the pin (HW9405595-1) from the hole of
the T-axis flange into the slot of the wrist part for positioning by the teach box.
(2) UP200
As shown in the Fig. 3-10 "T-Axis Positioning", fasten the jigs (HW9405625-1) with
two knockout pins (HW0404355-1), and insert the pin (HW9405626-1) from the hole
of the T-axis flange into the slot of the wrist part for positioning by the teach box.
MSTH10-30
HW9405597-1 Jigs two Knockout pins (MISUMI.corp)
(HW9405625-1 Jigs)* (HW0404355-1, two Knockout pins)*
T-axis flange
91(101)*
HW9405595-1 Pin
(HW9405626-1 Pin)*
Wrist part 62.50.02 62.50.02

(460.02)* (460.02)*
*: inside of ( ) indicates the types and dimension for UP200
Fig. 3-10 T-Axis Positioning
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Maintenance and inspection must be performed by specified personal.

Failure to observe this warning may result in electric shock or injury.
4.1 Fixing Jig Operating

In the MOTOMAN-UP130 series, different from the conventional SK series, the "Linkless mechanism
with the balancer" is adopted. Therefore, releasing the L-axis holding power including removing the
L-axis motor or releasing the brake is seriously dangerous because it will cause a L-arm rotation
different from the conventional model's rotation, depending on the edge load, wrist load posture, U-axis
posture, and L-axis posture. (For outlined mechanism, refer to section 4.4 Mechanism in this chapter.)
When releasing the L-axis holding power for L-axis motor replacement, or releasing the brake, be sure
to hold the L-arm using the fixing jigs specified in this manual and following the procedures.
After mount this fixing jig, be sure to release the brake and confirm the L-axis is completely fixed.
Set the L-arm in the recommended posture in Fig. 4-12 "UP130 external view"..
Avoid using the fixing jigs at the angles below. The manipulator axis may move when the brake is
released.
UP130 -15 to +15 (-30423 to +30423 pulse)
UP165, UP200 -15 to +15 (-35039 to +35039 pulse)
-15 +15
Fig. 4-11 L-arm Posture Range to be Avoided
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If fix the axis at the above range under necessity such as the motor cannot be driven, turn the brake
ON and OFF by inches to move the arm gradually when release the brake. Repeat this until the
arm no longer moves.
In this case, the tip of the flange may move by several hundred mm. If there are interfering objects
around, move the rotation axis or other axes to perform the above in the posture without interference.
This section explains the procedures for fixing the L-arm in the attitude shown in Fig. 4-12 "UP130
external view".
4.1.1 Specific Jig Installing Posture and Installing Position

Set the L-arm in the posture in Fig. 4-12 "UP130 external view".
L-axis: -60 (-121692 pulse for UP130 and -140154 pulse for UP165 and UP200)
Rotate the U-arm in the direction shown in Fig. 4-12 "UP130 external view" (the direction to minimize
the relative angle of the L-axis and U-axis) so that the relative angle of the L-axis and U-axis can be
minimized. At this time, care must be taken so that the arm including the work and hand may not
interfere with the peripheral devices and the main unit of the robot. Install the specific fixing jigs in the B
part (the rear of the balancer) shown in Fig. 4-12 "UP130 external view".
U-arm
Edge load
L-arm
L-arm P point
L-axis motor
A
A
B part
Balancer
Fig. 4-12 UP130 external view
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4.2 Installing
Refer to the Table 4-2 "L-Axis Fixing Jigs List" and Fig. 4-13 "Detail View of
Installing the Specific Jigs".
1. Remove the three rubber caps and three screws (Hexagon socket head cap screw M8
(15 screws) or M12 (18 screws) installed on the rear of the balancer.
2. Insert the M45xP1.5 screw side of the stud (Two types of screws, M55xP2 and
M45xP1.5, are processed in the stud.) into the hole of the rear of the balancer, and
screw them into the screw part of the rod (M45xP1.5), a component part of the
balancer. At this time, screw them in tightly so that there is no "looseness" between the
stud and rod.
3. Screw the nut into the stud until it touches the rear of the balancer. At this time screw it
in tightly so that there is no "looseness" between the edge of the nut and the contact
surface of the rear of the balancer.
4. Install the shaft HW9405579-1 with three hexagon socket head cap screws M8
(length: 40mm) or M12 (length: 40mm).
5. Tighten the three hexagon socket head cap screws M8 (length: 40 mm) or M12
(length: 40mm) equally with the tightening torque (M8: 20Nm, M12: 58Nm)
Avoid using the same hexagon socket head cap screws M8 (length: 40mm) or M12
NOTE (length: 40mm) repeatedly. Replace them with new ones.
Use a bolt with tensile strength of 1200 N/mm2 or more for the hexagon socket head cap
screws M8 (length: 40mm) or M12 (length: 40mm).
6. Release the L-axis brake to confirm that the L-axis is firmly fixed.
(Prepare for the shock at the time of arm motion by releasing the brake by inches.)
Table 4-2 L-Axis Fixing Jigs List
Drawing number (Product number) Name Number
HW9402997-1 Plate 1
HW9402998-1 Plate 1
HW9405579-1 Shaft 1
ANE12-300 Total screw 2

(Manufacturer: MISUMI.corp)
Hexagon socket head cap screw M8 (15mm) 3
Hexagonal nut M12 4
HW9405580-1 Stud 1
HW9405581-1 Nut 1
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Rubber cap
Hexagon socket head cap screws M8x15 (3 screws)

(or Hexagon socket head cap screw M12x18 (3 screws))
Hexagon socket head cap screws M8x40 (3 screws)

M55xP2
Nut (HW9405581-1) Before installing the jigs
Stud (HW9405580-1) M4.5xP1.5
Shaft (HW9405579-1)
Rod
Case
When installing the jigs
Fig. 4-13 Detail View of Installing the Specific Jigs
For removal procedures, check that the L-axis holding power has been restored first, and
NOTE then perform the installing procedures in inverted order. In some attitudes of the robot,
removing them may be impossible. (because of the mesh of the stud and rod) In this
case, before performing the removal work, as shown in, Fig. 4-14 "Detail View of
Removing the Specific Jigs" install the plates (HW9402997-1 and HW9402998-1), insert
the total screw with double nut (M12) installed on the edge of the plate, and screw in the
total screw while pressing the plate of the rear of the balancer so that the nut can be
moved by hand.
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4.3 Removing
Refer to Fig. 4-14 "Detail View of Removing the Specific Jigs".

1. Remove the shaft (HW9405579-1) and nut (HW9405581-1) installed on the stud.
When the nut is hard to remove, after installing the plate (HW9402997-1) on the stud
(HW9405580-1) and installing the plate (HW9402998-1) in the case, screw the total
screw until the nut loosens.
2. Remove the stud from the rear of the balancer.
3. Remove the stud, plate (HW9402997-1) installed on the case, plate (HW9402998-1),
and total screw.
Rubber cap
Hexagon socket head cap screw M8x15 (3 screws)

Hexagon socket head cap screw M8x40 (3 screws)

Nut (HW9405581-1)
Stud (HW9405580-1) M55xP2

Before installing
Plate (HW9402997-1) the jigs
M45xP1.5
Hexagonal nut M12 (4 nuts)
2-ANE 12-300 *MISUMI.corp*
Plate (HW9402998-1)
Rod
Case
When installing
the jigs
Fig. 4-14 Detail View of Removing the Specific Jigs
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4.4 Mechanism
Refer to Fig. 4-15 "The L-Arm Rotating Direction".
The L-arm rotating direction depends on the extent of the torque Tb generated by the balancer, and the
load torque TL generated around the L-axis. The torque Tb generated by the balancer is always
generated toward the directions where the L-arm becomes 0 from the posture vertical against the
ground, and its extent varies depending on the L-axis angle. The load torque TL generated around the
L-axis works around the center of the L-axis rotation, and its direction and extent vary depending on the
edge load, postures of the wrist, the U-arm, and the L-arm.
When no load is applied to the edge, for the L-arm rotating direction, 3 patterns are assumed as
described in the Fig. 4-15 "The L-Arm Rotating Direction".
It is quite difficult to accurately compare the extent of the torque works around the L-axis and the extent
of the torque generated by the balancer on the actual work site. Although the loaded torque direction
generated around the L-axis could be identified in the conventional series, the rotational direction
cannot be identified in this unit; therefore, handling this unit in the same way as the conventional series
is seriously dangerous, as the L-arm may rotate in a direction that the operator does not expect.
60

65

55

75
Posture in which the L-arm

Posture in which the L-arm operates Posture in which the L-arm does
operates in the counterclockwise
in the clockwise direction not operate
direction
Fig. 4-15 The L-Arm Rotating Direction
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5.1 Grease Replenishment/Exchange for S-Axis

Speed Reducer and Gear
Refer to the Fig. 5-16 "S-Axis Speed Reducer and Gear Diagram".
Si: Grease inlet S-axis speed reducer

So: Grease exhaust Grease zerk (A-PT 1/4)
Hexagon socket head (PT 1/8) plug
Fig. 5-16 S-Axis Speed Reducer and Gear Diagram
5.1.1 Grease Replenishment

1. Remove the So exhaust plug.
NOTE If grease is added without removing the exhaust plug, the grease will go inside the motor
and may damage it. It is absolutely necessary to remove the plug.
2. Inject grease into the Si grease inlet using a grease gun.
Grease type: Molywhite RE No.00

Amount of grease: 530cc
(1060cc for 1st supply)
3. Move the S-Axis for a few minutes to discharge the excess grease.
4. Reinstall the So exhaust plug. (Spread the modifier silicon caulk on the screw of the
plug.)
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5.1.2 Grease Exchange

1. Remove the So exhaust plug.
2. Inject grease into the Si grease inlet using a grease gun.
3. The grease replacement is complete when new grease appears in the So exhaust port.
The new grease can be distinguished from the old grease by color.

4. Move the S-Axis for a few minutes to discharge the excess grease.
5. Wipe the So exhaust port with a cloth and reinstall the plug. (Spread the modifier
silicon caulk on the screw of the plug.)
NOTE If the plug is installed when grease is being exhausted, grease will go inside the motor and
may damage it.
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5.2 Grease Replenishment/Exchange for L-Axis

Speed Reducer
Refer to the Fig. 5-17 "L-Axis Speed Reducer Diagram".
L-axis speed reducer Lo: Grease exhaust

Hexagon socket head (PT 1/8) plug
Li: Grease inlet

Grease Zerk (A-PT 1/8)
Fig. 5-17 L-Axis Speed Reducer Diagram

1. Make the L-Arm vertical for ground.
2. Remove the Lo exhaust plugs.
NOTE If grease is added without removing the exhaust plug, grease will go inside the motor and
may damage it. It is absolutely necessary to remove the plugs.
3. Inject grease into the Li grease inlet using a grease gun.

4. Move the L-Axis for a few minutes to discharge the excess grease.
5. Wipe the Lo exhaust plugs with a cloth and reinstall the plugs. (Spread the Modifier
silicon Caulk on the screw of the plug.)
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1. Make the L-Arm vertical for ground.
2. Remove the Lo exhaust plugs.
NOTE If grease is added without removing the exhaust plugs, grease will go inside the motor and
3. Inject grease into the Li grease inlets using a grease gun.

Amount of grease for Li: approx. 2000cc
4. The grease replacement is complete when new grease appears in the Lo exhaust
ports. (The new grease can be distinguished from the old grease by color.)
5. Move the L-Axis for a few minutes to discharge the excess grease.
6. Wipe the Lo exhaust plugs with a cloth and reinstall the plugs. (Spread the Modifier
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5.3 Grease Replenishment/Exchange for U-Axis

Speed Reducer
Refer to the Fig. 5-18 "U-Axis Speed Reducer Diagram".

Uo: Grease exhaust
Hexagon socket head (PT1/8)plug
U-axis speed reducer
Ui: Grease inlet

Grease zerk (A-PT1/8)
Fig. 5-18 U-Axis Speed Reducer Diagram

1. Make the U-Arm horizontal for ground.
2. Remove the Uo exhaust plugs.
3. Inject grease into the Ui grease inlet using a grease gun.

Amount of grease for Ui: 250cc
4. Move the U-Axis for a few minutes to discharge the excess grease.
5. Wipe the Uo exhaust plugs with a cloth and reinstall the plugs. (Spread the Modifier
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1. Make the U-Arm horizontal for ground.
2. Remove the Uo exhaust plugs.
3. Inject grease into the Ui grease inlet using a grease gun.

Amount of grease for Ui: approx. 1650cc
4. The grease replacement is complete when new grease appears in the Uo exhaust
5. Move the U-Axis for a few minutes to discharge the excess grease.
6. Wipe the Uo exhaust plugs with a cloth and reinstall the plugs. (Spread the Modifier
NOTE If the plug is installed when grease is being exhausted, grease will go inside the motor and
may damage it.
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5.4 Grease Replenishment/Exchange for R-Axis

Speed Reducer
Refer to the Fig. 5-19 "R-Axis Speed Reducer Diagram".

Ro: Grease exhaust
R-axis speed reducer Hexagon socket head (PT1/8) plug
Ri: Grease inlet

Hexagon socket head (PT1/8)plug
Fig. 5-19 R-Axis Speed Reducer Diagram

1. Remove the Ro exhaust plugs.
NOTE If grease is added without removing the exhaust plugs, grease will go outside the grease
box and may damage it. It is absolutely necessary to remove the plugs.
2. Remove the Ri plug: PT1/8 and install the grease zerk (A-PT1/8) and inject grease into
the Ri grease inlet using a grease gun.
UP130 and UP165

Amount of grease for Ri: 28cc
UP200

Amount of grease for Ri: approx. 40cc
3. Move the R-Axis for a few minutes to discharge the excess grease.
4. Wipe the Ro exhaust plugs with a cloth and reinstall the plugs. (Spread the Modifier
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1. Remove the Ro exhaust plugs.
2. Remove the Ri plug: PT1/8 and install the grease zerk (A-PT1/8) and inject grease into
the Ri grease inlet using a grease gun.
UP130 and UP165

UP200

3. The grease replacement is complete when new grease appears in the Ro exhaust
4. Move the R-Axis for a few minutes to discharge the excess grease.
5. Wipe the Ro exhaust plugs with a cloth and reinstall the plugs. (Spread the Modifier
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5.5 Grease Replenishment/Exchange for B-Axis

Refer to the Fig. 5-20 "B-Axis Speed Reducer and Gear Diagram".
Bo: Grease exhaust

Hexagon socket head (PT1/8) plug
B-axis speed reducer

Bi: Grease inlet
Grease zerk (A-MT6) (1 zerk)
Fig. 5-20 B-Axis Speed Reducer and Gear Diagram

1. Remove the Bo exhaust plugs.
2. Inject grease into the Bi grease inlet using a grease gun.

UP130 and UP165

Amount of grease for Bi: 200cc
UP200

Amount of grease for Bi: 260cc
3. Move the B-Axis for a few minutes to discharge the excess grease.
4. Wipe the Bo exhaust plugs with a cloth and reinstall the plugs. (Spread the Modifier
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1. Remove the Bo exhaust plugs.
NOTE If grease is added without removing the exhaust plugs, grease will go outside
the grease box and may damage it. It is absolutely necessary to remove the plugs.
2. Inject grease into the Bi grease inlet using a grease gun.

UP130 and UP165

Amount of grease for Bi: approx. 900cc
UP200

Amount of grease for Bi: approx. 1300cc
3. The grease replacement is complete when new grease appears in the Bo exhaust
4. Move the B-Axis for a few minutes to discharge the excess grease.
5. Wipe the Bo exhaust plugs with a cloth and reinstall the plugs. (Spread the Modifier
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5.6 Grease Replenishment/Exchange for T-Axis

Refer to the Fig. 5-21 "T-Axis Speed Reducer And Gear Diagram".
T-axis speed reducer
To: Grease exhaust Ti: Grease inlet

Hexagon socket head (M6) plug Grease zerk (A-MT6) (1 zerk)
Fig. 5-21 T-Axis Speed Reducer And Gear Diagram

1. Remove the To exhaust plugs.
2. Inject grease into the Ti grease inlet using a grease gun.

UP130 and UP165

Amount of grease for Ti: 200cc
UP200

3. Move the T-Axis for a few minutes to discharge the excess grease.
4. Wipe the To exhaust plugs with a cloth and reinstall the plugs. (Spread the Modifier
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1. Remove the To exhaust plugs.
2. Inject grease into the Ti grease inlet using a grease gun.

UP130 and UP165

UP200

3. The grease replacement is completed when new grease appears from the To exhaust
port. (The new grease is distinguished from the old grease by color.)
4. Move the T-Axis for a few minutes to discharge the excess grease.
5. Wipe the To exhaust plugs with a cloth and reinstall the plugs. (Spread the Modifier
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5.7 Grease Replenishment for Balancer Connection

Part
Refer to the Fig. 5-22 "Balancer Connection Part".
Air exhaust Air exhaust

Hexagon socket head plug (PT1/8)
Connection
Vc: Grease inlet
Connection
Connection Needle bearing
2 Tapper roller bearings
Connection Vc: Grease inlet

Grease zerk (A-PT1/8) (2 zerks)
Fig. 5-22 Balancer Connection Part
1. Remove the air exhaust plugs of connection 1 and 2 . (Refer to Fig. 5-22 "Balancer
Connection Part".)
2. Inject grease into Vc grease inlets of connection 1 and 2 using a grease gun.
Grease type: Alvania EP Grease 2

NOTE Grease is not exhausted from the exhaust ports 1 and 2 . Do not inject excessive
grease into the gear grease inlet.
3. Reinstall the plugs of connection 1 and 2 . (Spread the modifier silicon caulk on the
screw of the plug.)
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6 Disassembly and Reassembly of the

Motor
6.1 Disassembly and Reassembly of the S-Axis Motor
Refer to Fig.6-23 (a) Disassembly and Reassembly of the S-Axis Motor and
Fig.6 (x) Disassembly and Reassembly of the S-Axis Motor.
Refer to chapter 2 "Notes for Maintenance",chapter 3 "Home Position Return Operation",

NOTE Table 4 "L-axis Fixing Jig Operating" and chapter 5 "Grease Replenishment/Exchange",
and chapter 9 "Adjustment the Tension of the RBT-Axes Belts" in this manual.
Disassembly
1. Turn OFF the robot controller.
2. Connect the backup battery. (Refer to chapter 2 "Notes for Maintenance" in this book.)
3. Remove the MS connector (encoder, power) connected to the S-axis motor 1 .
4. Remove the hexagon socket head cap screws 2 , and remove the S-axis motor 1
from the gear unit 5 with the tapped holes on the motor flanged surface. At this time,
be careful not to scratch the oil seal in the gear unit 5 .
5. Remove the hexagon socket head cap screws 6 to remove the shaft 3 and the key
4 .
Reassembly
1. Mount the key 4 on the S-axis motor 1 . (The key 4 is attached to the S-axis motor
1 .)
2. Apply sealing bond (ThreeBond 1206C) between the S-axis motor 1 flanged surface
and the shaft 3 , and mount the S-axis motor 1 and the shaft 3 .
3. Tighten the hexagon socket head cap screws 6 (apply LOCTITE 242 to the screw
parts) with the tightening torque shown in Table 6-3 "The Comparison Table for Parts".
4. Apply sealing bond (ThreeBond 1206C) between the S-axis motor 1 flanged surface
and the gear unit 5 . Being careful not to scratch the oil seal in the gear unit 5 , mount
the S-axis motor 1 on the gear unit 5 .
5. Tighten the hexagon socket head cap screws 2 with the tightening torque shown in
Table 6-3 "The Comparison Table for Parts".
6. Mount the MS connector (encoder, power) of the internal cable on the S-axis motor 1 .
7. Supply grease (Molywhite RE No.00) from the grease supply part.
8. Remove the backup battery.
9. Turn ON the robot controller.
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Table 6-3 The Comparison Table for Parts
No Name Number Notes
1 S-axis Motor HW9381382-A 1
2 Hexagon Socket Head Cap Screws 4 each Tightening torque 84Nm

M12x40 Conical Spring Washer 2H-
12
3 Shaft HW9381446-A 1
4 Key 1
5 Gear Unit 1
6 Hexagon Socket Head Cap 1 each Tightening torque 82Nm

ScrewsM10x110 Conical Spring
Washer 2H-10
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Fig. 6-23 (a) Disassembly and Reassembly of the S-Axis Motor
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1 the part to apply the sealing
4
5
Fig. 6 (x) Disassembly and Reassembly of the S-Axis Motor
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6.2 Disassembly and Reassembly of the L-Axis Motor

Refer to Fig.6-25 (a) Disassembly and Reassembly of the L-Axis Motor and
Fig.6-25 (b) Disassembly and Reassembly of the L-Axis Motor (UP130).
Execute disassembly and reassembly of the L-axis motor after mounting the L-axis fixing jig on the
balancer. Also, be sure to confirm that the L-axis is firmly fixed by releasing the L-axis motor
brake.
Failure to observe this leads unexpected L-arm rotation at the moment when the L-axis
motor is removed and it may result in damage to machinery or death or serious injury.
Refer to chapter 4 "L-axis Fixing Jig Operating" in this book about how to fix the balancer.
Disassembly
1. Turn OFF the robot controller, fasten the balancer, and drain grease.
2. Connect the backup battery. (Refer to chapter 2 "Notes for Maintenance".)
3. Remove the MS connector (encoder, power) connected to the L-axis motor 1 .
4. Remove the hexagon socket head cap screws 2 , and remove the L-axis motor 1
from the motor base with the tapped holes on the L-axis motor 1 flanged surface. At
this time, be careful not to scratch the oil seal in the motor base.
5. Remove the hexagon socket head cap screws 8 , and remove the shaft 3 , the key
4 , the pipe 5 , the gear 6 and the shaft 7 .
Reassembly
1. Mount the key 4 on the L-axis motor 1 . (The key 4 is attached to the L-axis motor
1 .)
2. Apply sealing bond (ThreeBond 1206C) between the L-axis motor 1 flanged surface
and the shaft 3 , and mount the L-axis motor 1 , the shaft 3 , the pipe 5 , the gear
6 and the shaft 7 .
3. Tighten the hexagon socket head cap screws 8 (apply LOCTITE 242 to the screw
parts) with the tightening torque shown in the Table 6-4 "The Comparison Table for
Parts".
4. Apply sealing bond (ThreeBond 1206C) between the L-axis motor 1 flanged surface
and the motor base. Being careful not to scratch the oil seal in the motor base, mount
the L-axis motor 1 on the motor base.
the Table 6-4 "The Comparison Table for Parts".
6. Mount the MS connector (encoder, power) of the internal cable on the L-axis motor 1 .
8. Supply grease (Molywhite RE No.00).
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Num
No. Name Notes
ber
1 L-axis Motor HW9381261-A 1 For UP130 and UP165

L-axis Motor HW9381536-A 1 For UP200
2 Hexagon Socket Head Cap Screws M12x35 4 Tightening Torque84Nm
Conical Spring Washer 2H-12 each
3 Shaft HW9482306-B 1 For UP130
Shaft HW9482306-E 1 For UP165
Shaft HW9482339-A 1 For UP200
4 Key 1
5 Pipe HW9405134-1Retaining Ring ISTW-15 1 For UP130
6 Gear HW9482308-A 1 For UP130

Gear HW9482358-A 1 For UP165 and UP200
7 Shaft HW9481343-A 1
8 Hexagon Socket Head Cap Screws M8x115 1 Tightening Torque for UP130
Conical Spring Washer 2H-8 each :40Nm
Hexagon Socket Head Cap Screws 1 Tightening Torque for UP165
HW9482316-C Conical Spring Washer each :40Nm
ISTW12 1 Tightening Torque for UP200
Hexagon Socket Head Cap Screws each :68Nm
HW9482506-A Conical Spring Washer
ISTW12
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Fig. 6-25 (a) Disassembly and Reassembly of the L-Axis Motor
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3
7
2
5 The part to apply the sealing bond
6
4
1
Fig.6-25 (b) Disassembly and Reassembly of the L-Axis Motor (UP130)
3
4
2 1
Fig. 6-25 (c) Disassembly and Reassembly of the L-Axis Motor (UP165 and UP200)
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6.3 Disassembly and Reassembly of the U-Axis Motor

Refer to "Fig. 6-26 (a) Disassembly and Reassembly of the U-Axis Motor " and
"Fig. 6-26 (b) Disassembly and Reassembly of the U-Axis Motor ".
Disassembly
1. Turn OFF the robot controller, drain grease, and connect the backup battery.
2. Remove the MS connector (encoder, power) connected to the U-axis motor 1 .(Refer
to chapter " 2 Notes for Maintenance " in this manual).
3. Before removing the U-axis motor 1 , hold the U-arm not to rotate by chain block etc.
4. Remove the hexagon socket head cap screws 2 , and remove the U-axis motor 1
from the casing with the tapped holes on the U-axis motor 1 flanged surface. At this
time, be careful not to scratch the oil seal in the casing.
5. Remove the retaining ring 7 and the bolt 8 to remove the shaft 3 , the gear 4 , the
shaft 7 and the key 6 .
Reassembly
1. Mount the key 6 on the U-axis motor 1 . (The key 6 is attached to the U-axis motor
1 .)
2. Apply sealing bond (ThreeBond 1206C) between the U-axis motor 1 flanged surface
and the shaft 3 , and mount the U-axis motor, the shaft 3 , the gear 4 and the shaft
5 .
3. Mount the shaft 5 , the gear 4 and the retaining ring 7 , after tightening the bolt 8
(apply LOCTITE242 to the screw parts) with the tightening torque shown in the Table 6-
5 "The Comparison Table for Parts".
4. Apply sealing bond (ThreeBond 1206C) between the U-axis motor 1 flanged surface
and the casing. Being careful not to scratch the oil seal in the gear unit, mount the U-
axis motor 1 on the casing.
6. Mount the MS connector (encoder, power) of the internal cable on the U-axis motor 1 .
8. Supply grease (Molywhite RE No.00).
Num
No. Name Notes
ber
1 U-axis Motor HW9381261-A 1
2 Hexagon Socket Head Cap Screws M12x40 4 Tightening Torque 84Nm

Conical Spring Washers 2H-12 each
3 Shaft HW9482306-C 1

5 Shaft HW9481343-A 1
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Num
No. Name Notes
ber
6 Key 1
7 Retaining Ring ISTW-12 1
8 Bolt HW9482316-A 1 Tightening Torque 40Nm
Fig. 6-26 (a) Disassembly and Reassembly of the U-Axis Motor
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6
2
The part to apply the sealing bond
Fig. 6-26 (b) Disassembly and Reassembly of the U-Axis Motor
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6.4 Disassembly and Reassembly of the RBT-Axes

Motors
Refer to Fig.6-27 (a "Disassembly and Reassembly of the RBT-axes Motors" and
Fig.6-27 (b "Disassembly and Reassembly of the RBT-Axes Motors".
Disassembly
2. Remove the GT-SA bolts 12 13 to remove the covers 10 8 and the gaskets 11
9 .
3. Connect the backup battery to the connector on the upper part of the casing 7 . (Refer
to chapter 2 "Notes for Maintenance" in this manual.)
4. Remove the RBT-axis motors 1 connectors connected to the internal cable.
5. Remove the hexagon socket head cap screws 2 , and remove the RBT-axis motors
1 from the casing 7 with the notch on the casing 7 .
6. Remove the hexagon socket head cap screws 6 to remove the keys 3 , the pulleys
4 and B covers 5 .
Reassembly
1. Mount the key 4 on the RBT-axis motors 1 . (The key 4 is attached to the RBT-axis
motors 1 .)
2. Mount the pulleys 4 and the B covers 5 on the RBT axis motors 1 and tighten the
hexagon socket head cap screws 6 (apply LOCTITE 242 to the screw parts) with the
tightening torque shown in the Table 6-6 "The Comparison Table for Parts".
3. Apply sealing bond (ThreeBond 1206C) between the RBT-axis motors 1 and the
casing 7 , and mount the RBT-axis motors 1 on the casing 7 .
4. Adjust the tension of the belt, and tighten the hexagon socket head cap screws 2 with
the tightening torque shown in the Table 6-6 "The Comparison Table for Parts". (Refer
to the chapter 9 "Adjustment the Tension of the RBT-Axes Belts" in this manual.
5. Connect the connector connected to the internal cable to the connector on the upper
part of casing. Remove the backup battery.
6. Mount the covers 8 10 and the gaskets 9 11 , and tighten them with the GT-SA
bolts 12 13 .
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No. Name Number Notes
1 RBT-axis Motors : R-axis HW9380938-A 1

: BT-axis HW9381368-A 2
2 Hexagon Socket Head Cap Screws M6x30 4 each x 3 Tightening Torque 10.0 Nm
Conical Spring Washer 2H-6(BT-axis)
Collar HW9404231-1 4x3
3 Key 3
4 Pulley HW9482275-A 3 For UP130, 200 (RBT-Axes)

Pulley HW9482450-A 2 For UP165 (RB-Axes)
Pulley HW9482275-A 1 For UP165 (T-Axis)
5 B Cover HW9405163-1 3
6 Hexagon Socket Head Cap Screw M6x20 1 each x 3 Tightening Torque 16.5 Nm
Conical Spring Washer 2H-6
7 Casing HW9100889-1 1
8 Cover HW9302176-1 1
9 Gasket HW9381484-A 1
10 Cover HW9405439-1 1
11 Gasket HW9482427-A 1
12 GT-SA Bolts M6x15 4 Tightening Torque 10 Nm
13 GT-SA Bolts M6x15 7 Tightening Torque 10 Nm
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Fig. 6-27 (a) Disassembly and Reassembly of the RBT-axes Motors
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3
4
5 2
9
B-axis motor
6 A
T-axis motor
1 R-axis motor
View observed from the arrow A
(a scale of measurement 1 : 8)
8
10 12
11
Fig.6-27 (b) Disassembly and Reassembly of the RBT-Axes Motors
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Speed Reducer
Refer to Fig.7-28(a "Disassembly and Reassembly of the S-Axis Speed

Reducer" and Fig.7-28(b "Disassembly and Reassembly of the S-Axis Speed
Reducer" in this chapter.
7.1 Disassembly and Reassembly of the S-Axis RV

Speed Reducer
NOTE Refer to chapter 3 "Home Position Return Operation", chapter 4 "L-axis Fixing Jig
Operating" and chapter 5 "Grease Replenishment/Exchange" in this book.
Disassembly
1. Turn OFF the robot controller and drain grease.
2. Remove the hexagon socket head cap screws 11 2 , and remove the shaft 12 and
the gear unit 3 with the tapped holes.
3. Remove the hexagon socket head cap screws 4 to remove the upper part from the S
head of the robot.
4. Remove the hexagon socket head cap screws 5 to remove the RV speed reducer 1
from the base 13 .
5. Remove the tube 10 connected to the straight union 9 .
6. Remove the straight union 9 from the RV speed reducer 1 .
7. Remove the hexagon socket head cap screws 7 , and remove the shaft 6 and O-ring
8 with the tapped holes.
Reassembly
1. Mount the straight union 9 on the RV speed reducer 1 .
2. Mount O-ring 8 on the shaft 6 , apply sealing bond (ThreeBond 1206C) between the
RV speed reducer 1 and the shaft 6 , and tighten the hexagon socket head cap
screws 7 with the tightening torque shown in the Table 7-7 "The Comparison Table for
Parts".
3. Connect the tube 10 to the straight union 9 .
4. Apply sealing bond (ThreeBond 1206C) between the RV speed reducer 1 and the
base 13 , and tighten the hexagon socket head cap screws 5 (apply ThreeBond
1206C to the screw parts) with the tightening torque shown in the Table 7-7 "The
Comparison Table for Parts".
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5. Mount the upper part from the S head of the robot on (3), and tighten the hexagon
socket head cap screws 4 with the tightening torque shown in the Table 7-7 "The
6. Apply sealing bond (ThreeBond 1206C) between (4) and the gear unit 3 , and tighten
the hexagon socket head cap screws 2 (apply ThreeBond 1206C to the screw parts)
with the tightening torque shown in the Table 7-7 "The Comparison Table for Parts".
7. Mount the shaft 12 on the RV speed reducer 1 , and tighten the hexagon socket head
cap screws 11 (apply ThreeBond 1206C to the screw parts) with the tightening torque
shown in the Table 7-7 "The Comparison Table for Parts".
The
Num number
Name Notes
ber of the
parts
1 RV Speed Reducer HW9381388-A 1
2 Hexagon Socket Head Cap Screws M8x90 8 each Tightening Torque 24.5Nm
Spring Washers 2H-8
3 Gear Unit HW9171471-A 1
4 Hexagon Socket Head Cap Screws M12x55 17 each Tightening Torque 142Nm
Spring Washers 2H-12
6 Shaft HW9302385-1 1
Spring Washers 2H-6
8 O-ring G135 1
9 Straight union KQS10-01S 1
10 Tube NB-1075-1,1. 1
Spring Washers 2H-5
12 Shaft HW9302524-1 1
13 Base HW9100888-1 1
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Fig. 7-28(a Disassembly and Reassembly of the S-Axis Speed Reducer
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12
11
3 4
S-head
13
7
5
6
8 9
10
Fig.7-28(b Disassembly and Reassembly of the S-Axis Speed Reducer
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7.2 Disassembly and Reassembly of the L-Axis RV

Speed Reducer
Refer to Fig.7-29(a "Disassembly and Reassembly of the L-Axis Speed

Reducer" and Fig.7- 29 (b "Disassembly and Reassembly of the L-Axis Speed
Reducer" in this chapter.
Execute disassembly and reassembly of the L-axis motor after mounting the L-axis fixing jig on the
balancer. Also, be sure to confirm that the L-axis is firmly fixed by releasing the L-axis motor
brake.
Failure to observe this leads unexpected L-arm rotation at the moment when the L-axis
motor is removed and it may result in damage to machinery or death or serious injury.
Refer to chapter 4 "L-axis Fixing Jig Operating" about the way to fasten the balancer.
Disassembly
1. Turn OFF the robot controller, and fix the balancer.
2. Remove the L-axis motor 10 . (Refer to section 6.2 Disassembly and Reassembly of
the L-Axis Motor.)
3. Hold the L arm not to rotate by the chain block etc. before removing the RV speed
reducer 1 .
4. Remove the hexagon socket head cap screws 4 to remove the motor base 2 and
the oil seal 5 from the RV speed reducer 1 .
5. Remove the hexagon socket head cap screws 8 7 3 to remove the RV speed
reducer 1 and O-ring 6 from the S head 9 .
Reassembly
1. Mount the O-ring 6 on the RV speed reducer 1 .
2. Apply sealing bond (ThreeBond 1206C) between (1) and the S head 9 , and tighten
the hexagon socket head cap screws 3 7 8 with the tightening torque shown in
3. Mount the motor base 2 on the RV speed reducer 1 , and tighten the hexagon
socket head cap screws 3 with the tightening torque shown in the Table 7-8 "The
4. Mount the L-axis motor 10 . (Refer to section 6.2 Disassembly and Reassembly of the
L-Axis Motor.)
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The
Num number
Name Notes
ber of the
parts
1 RV Speed Reducer HW9381442-A 1 For UP130

RV Speed Reducer HW9381442-B 1 For UP165 and UP200
2 Motor Base HW9200895-1 1
5 Oil Seal Y507212.5 1
6 O-ring G300 1
9 S head HW9100894-1 1
10 L-axis motor 1
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Fig. 7-29(a Disassembly and Reassembly of the L-Axis Speed Reducer
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L-arm
8 7
The part to apply 4

the sealing bond
1
4 6 3
2
5
3 3
A
10 View observed from the arrow A(1:2)
Fig.7- 29 (b Disassembly and Reassembly of the L-Axis Speed Reducer
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7.3 Disassembly and Reassembly of the U-Axis RV

Speed Reducer
Refer to Fig.7-30(a "Disassembly and Reassembly of the U-Axis Speed

Reducer"Disassembly and Fig.7- 30 (b "Disassembly and Reassembly of the U-
Axis Speed Reducer" in this chapter.
Disassembly
2. Hold the U-arm unit 4 not to fall by the chain block etc before removing the U-axis
motor 6 .(Refer to section 6.3 Disassembly and Reassembly of the U-Axis Motor.)
3. Remove the U-axis motor 6 .
4. Remove the hexagon socket head cap screws 2 3 to remove the U-arm unit 4
from the body of the machine.
5. Remove the hexagon socket head cap screws 7 to remove the RV speed reducer 1
and the O-ring 5 from the U-arm unit 4 .
6. Remove the O-ring 5 from the RV speed reducer 1 .
Reassembly
1. Mount the O-ring 5 to the RV speed reducer 1 .
2. Mount 1. on the U-arm unit 4 , and tighten the hexagon socket head cap screws 7
with the tightening torque shown in the Table 7-9 "The Comparison Table for Parts".
3. Apply sealing bond (ThreeBond 1206C) between the RV speed reducer 1 and the
L-arm on the body, and tighten the hexagon socket head cap screws 2 3 with the
tightening torque shown in Table 7-9 "The Comparison Table for Parts".
4. Mount the U-axis motor 6 .(Refer to section 6.3 Disassembly and Reassembly of the
U-Axis Motor)
1 RV Speed Reducer HW9381465-A 1 For UP130

RV Speed Reducer HW9381465-C 1 For UP165 and UP200
Conical spring washers 2H-10
4 U-arm Unit 1
5 O-ring 1
6 U-axis Motor 1
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Fig. 7-30(a Disassembly and Reassembly of the U-Axis Speed Reducer
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2 The part to apply the

sealing bond
L-arm
3
1
7
Fig.7- 30 (b Disassembly and Reassembly of the U-Axis Speed Reducer
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7.4 Disassembly and the Reassembly of the R-Axis

Cyclo Speed Reducer
Refer to Fig.7-31(a "Disassembly and Reassembly of the R-Axis Cyclo Speed

Reducer", Fig.7- 31 (b "Disassembly and Reassembly of the R-Axis Cyclo Speed
Reducer" and Fig.7- 31 (c "Disassembly and Reassembly of the R-Axis Cyclo
Speed Reducer" in this chapter.
Disassembly
2. Remove the hexagon socket head cap screws 3 and the pin 4 , and use the tapped
holes to remove the wrist unit 5 from the cyclo speed reducer 1 .
3. Remove the hexagon socket head cap screws 2 , and use the tapped holes to remove
the cyclo speed reducer 1 from the U-arm 6 .
Reassembly
1. Apply sealing bond (ThreeBond 1206C) between the U-arm 6 and the cycle speed
reducer 1 , and tighten the hexagon socket head cap screws 2 with the tightening
torque shown in the Table 7-10 "The Comparison Table for Parts".
2. Mount the wrist unit 5 on the cycle speed reducer 1 with the hexagon socket head
cap screws 3 temporarily, and tighten the hexagon socket head cap screws 3 with
the tightening torque shown in the Table 7-10 "The Comparison Table for Parts" after
putting the pin 4 .
1 Cyclo Speed Reducer HW9381399-A 1 For UP130 and UP165

Cyclo Speed Reducer HW9381260-A 1 For UP200
2 Hexagon Socket Head Cap Screws M8x95 16 each Tightening Torque for UP130:
Spring Washers 2H-8 40Nm
Hexagon Socket Head Cap Screws M12x115 12 each Tightening Torque for UP165
Spring Washers 2H-12 and UP200: 142Nm
Washer HW9302581-1
4 Pin MSTM8-20 1
5 Wrist Base HW9100890-1 1 For UP130 and UP165

Wrist Base HW9100955-1 1 For UP200
6 U-arm 1
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Fig. 7-31(a Disassembly and Reassembly of the R-Axis Cyclo Speed Reducer
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Fig.7- 31 (b Disassembly and Reassembly of the R-Axis Cyclo Speed Reducer
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1 2 3
6 4 5
Fig.7- 31 (c Disassembly and Reassembly of the R-Axis Cyclo Speed Reducer
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7.5 Disassembly and Reassembly of the B-Axis RV

Speed Reducer

2. Remove the hexagon socket head cap screws 3 to remove the cover 2 .
3. Remove the hexagon socket head cap screws 4 5 6 12 , use the tapped holes
to remove the RV speed reducer 1 , the shims 8 , the gear 9 and the bearing 11 all
together from the wrist 10 .
4. Remove the hexagon socket head cap screws 7 to remove the shims 8 , the gear
9 and the bearing 11 from the RV speed reducer 1 . (Use the tapped holes in
removing the gear 9 .)
Reassembly
1. Mount the bearing 11 , the shims 8 and the gear 9 on the RV speed reducer 1 ,
and tighten the hexagon socket head cap screws 7 with the tightening torque shown
in the Table 7-11 "The Comparison Table for Parts".
2. Apply sealing bond (ThreeBond 1208D) between the RV speed reducer 1 and the
wrist 10 , and tighten the hexagon socket head cap screws 4 5 6 12 (Apply
ThreeBond 1208D only to the screw part of 4 .) with the tightening torque shown in the
Table 7-11 "The Comparison Table for Parts".
3. Mount the wrist 10 and the cover 2 on the RV speed reducer 1 , and tighten the
hexagon socket head cap screws 3 with the tightening torque shown in the Table 7-
11 "The Comparison Table for Parts".
1 RV Speed Reducer HW9380961-A 1 For UP130 and UP165

RV Speed Reducer HW9381453-A 1 For UP200
2 Cover HW0300889-1 1 For UP130 and UP165
Cover HW9302370-1 1 For UP200
3 Hexagon Socket Head Cap Screws M6x25 4 each Tightening Torque for UP130
Spring Washers 2H-6 and UP165: 10 Nm
Hexagon Socket Head Cap Screws M6x12 6 each Tightening Torque for UP200:
Spring Washers 2H-6 10 Nm
Spring Washers 2H-14 226Nm
5 Hexagon Socket Head Cap Screws M8x90 4 each Tightening Torque 40 Nm
Spring Washers2H-8
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7 Hexagon Socket Head Cap Screws M6x16 4 each Tightening Torque 16.5 Nm
Spring Washers 2H-6
8 Shim HW9403624-1 1
9 Gear HW9380983-A 1
10 Wrist HW9100896-1 1 For UP130 and UP165

Wrist HW9100954-1 1 For UP200
11 Bearing 6908Retaining ring C-type 51040 1 each
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Fig. 7-32(a Disassembly and Reassembly of the B-Axis RV Speed Reducer
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12
6 1
7
10
4
3
11 5 2
8 9
Fig.7- 32 (b Disassembly and Reassembly of the B-Axis RV Speed Reducer
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7.6 Disassembly and Reassembly of the T-Axis Cycle

Speed Reducer
Disassembly
2. Remove the hexagon socket head cap screws 2 to remove the flange 3 .
3. Remove the hexagon socket head cap screws 4 , remove the cycle speed reducer
1 , the gear 5 , the shims 6 and the washer 8 all together from the wrist 9 with
the tapped holes.
4. Remove the hexagon socket head cap screws 7 to remove the gear 5 , the shims
6 and the washer 8 from the cycle speed reducer 1 .
Reassembly
1. Mount the gear 5 , the shim 6 and the washer 8 on the cycle speed reducer 1 ,
and tighten the hexagon socket head cap screws 7 (Apply LOCTITE 242 to the screw
parts.) with the tightening torque shown in the Table 7-12 "The Comparison Table for
Parts".
2. Apply sealing bond (ThreeBond 1208D) between the cyclo speed reducer 1 and the
wrist 9 , and tighten the hexagon socket head cap screws 4 with the tightening
torque shown in the Table 7-12 "The Comparison Table for Parts". (For UP200, Apply
sealing bond (ThreeBond 1208D) to the screw part of 2 screws which are indicated
with "" and shown in " Fig. 7- 33 (c) Disassembly and Reassembly of the T-Axis
Cycle Speed Reducer (UP200) " out of 8 hexagon socket head cap screws 4 , and
tighten them with the tightening torque shown in Table 7-12 "The Comparison Table for
Parts".)
3. Apply sealing bond (ThreeBond 1208D) between the cyclo speed reducer 1 and the
flange 3 , and tighten the hexagon socket head cap screws 2 with the tightening
torque shown in the Table 7-12 "The Comparison Table for Parts"
1 Cyclo Speed Reducer HW0389042-A For UP130 and UP165

Cyclo Speed Reducer HW0389041-A For UP200
Conical spring washers 2H-8 and UP165: 40 Nm
Conical spring washers 2H-8 40 Nm
3 Flange HW9302056-1 1 For UP130 and UP165
Flange HW9302372-1 1 For UP200
GT-SH Washers M14 and UP165: 226 Nm
GT-SH Washers M14 226 Nm
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6 Shims HW9403620-1 to5 1
7 Hexagon Socket Head Cap Screws M5x16 1 each Tightening Torque 10 Nm

Conical spring washers 2H-5
8 Washer HW9403619-1 1
9 Wrist HW9100896-1 1 For UP130 and UP165

Wrist HW9100954-1 1 For UP200
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Fig. 7-33(a Disassembly and Reassembly of the T-Axis Cycle Speed Reducer
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The part to apply

the sealing bond
5 6 3
9 7
8 2 4
Fig.7- 33 (b Disassembly and Reassembly of the T-Axis Cycle Speed Reducer (UP130,UP165)
Fig.7- 33 (c Disassembly and Reassembly of the T-Axis Cycle Speed Reducer (UP200)
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Wrist Unit
8.1 Disassembly and Reassembly of the Wrist Unit
Disassembly
2. Remove the hexagon socket head cap screws 3 , remove the wrist unit 1 from the
cycle speed reducer 4 with the tapped holes on the wrist base part 2 .
Reassembly
1. Mount the wrist unit 1 on the cyclo speed reducer 4 with the hexagon socket head
cap screws 3 temporarily, and tighten the hexagon socket head cap screws 3 with
the tightening torque shown in the Table 8-13 "The Comparison Table for Parts".
1 Wrist Unit HW9171451-A 1 For UP130

Wrist Unit HW9171451-B 1 For UP165
Wrist Unit HW9171561-A 1 For UP200
2 Wrist Base HW9100890-1 1 For UP130 and UP165
Wrist Base HW9100955-1 1 For UP200
3 Hexagon Socket Head Cap Screw M12x35 8 each Tightening Torque for UP130
Spring Washer 2H-12 and UP165 : 142 Nm
Hexagon Socket Head Cap Screw M12x35 12 each Tightening Torque for UP200 :
Spring Washer 2H-12 142 Nm
4 Cyclo Speed Reducer HW9381399-A 1 UP130 and UP165
Cyclo Speed Reducer HW9381260-A 1 UP200
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4 2 3 1
Fig. 8-34 Disassembly and Reassembly of the Wrist Unit
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9 Adjustment the Tension of the RBT-

Axes Belts
Refer to Fig. 9-35 "Timing Belt Adjustment" in this chapter.
9.1 Disassembly and Reassembly of the R-, B- and

T-Axis Timing Belts
NOTE Refer to chapter 3 "Home Position Return Operation", and chapter 6 "Disassembly and
Reassembly of the Motor" in this manual.
Disassembly
1. Turn OFF the robot controller, and drain grease.
2. Remove the GT-SA bolts 9 and remove the cover 7 and gasket 8 .
3. Remove the T-axis motor 6 and remove the T-axis timing belt 3 . (Refer to section
6.4 Disassembly and Reassembly of the RBT-Axes Motors.)
4. Remove the B-axis motor 5 and remove the B-axis timing belt 2 . (Refer to section
5. Remove the R-axis motor 4 and remove the R-axis timing belt 1 . (Refer to section
Reassembly
1. Mount the R-axis timing belt 1 and mount the R-axis motor 4 . (Refer to section 6.4
Disassembly and Reassembly of the RBT-Axes Motors.)
2. Mount the B-axis timing belt 2 and mount the B-axis motor 5 . (Refer to section 6.4
3. Mount the T-axis timing belt 3 and mount the T-axis motor 6 . (Refer to section 6.4
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NO. Name Number Notes
1 R-Axis Timing Belt 200S8M976 1 For UP130 and UP200

R-Axis Timing Belt 200S8M960 1 UP165
2 B-Axis Timing Belt 200S8M800 1
3 T-Axis Timing Belt 200S8M656 1
4 R-Axis Motor 1
5 B-Axis Motor 1
6 T-Axis Motor 1
7 Cover 1
8 Gasket HW9302176-1 1
9 GT-SA Bolt M6 x 15 7 Tightening Torque: 10 Nm
9 7 8
L-arm
4
2
3 5
6
Fig. 9-35 Timing Belt Adjustment
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9.2 Adjustment of the RBT-Axes Timing Belts
Belt tension inspection part
Inspect the tension of the timing belt due to opening the cover of the belt tension
inspection part as shown above.
1. Remove the hexagon socket head cap screws (M16 x 15)(4 screws) the spring
washers 2H-6, and remove the cover (HW9405164-1) the gasket (HW9482310-A).
2. Loosen the hexagon socket head cap screws which are installed in the motor,
and tighten the hexagon socket head cap screws with the tightening torque
shown in the section 6.4 Disassembly and Reassembly of the RBT-Axes
Motors after adjustment the tension of the timing belt by the tension meter to
fall within the tension shown in the Table 9-15 "Tension of the timing belts".
Table 9-15 Tension of the timing belts
Tension
R-Axis 219 - 290N (22.3 - 29.6 kgf)
B-Axis 219 - 290N (22.3 - 29.6 kgf)
T-Axis 219 - 290N (22.3 - 29.6 kgf)
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Refer to Fig.10-36(a "Battery Location (Back View)", Fig.10- 36(b "Battery Loca-
tion (Top View)", Fig.10- 36(c "Battery Connection for SLU-Axis", Fig.10- 36(d
"Battery Connection for RBT-Axis" in this chapter
The battery packs are attached in the two positions indicated in Fig.10-36(a "Battery Location (Back
View)" and Fig.10- 36(b "Battery Location (Top View)".
If a battery alarm occurs in the XRC, replace the battery packs according to the following procedure:
Manipulator
base 1BC 2BC 3BC
Battery pack Connector base
Fig. 10-36(a Battery Location (Back View)
Pan head screw with washer M5 Pan head screw with washer M5
(8 washers) (8 washers)
Battery pack for Battery pack for

SLU-axes RBT-axes
(HW9470932-A) (HW9470932-B)
Fig.10- 36(b Battery Location (Top View)
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See Procedure 6 Battery pack for SLU-axes before replacement

See Procedure 7
0BT1 a b 0BT1
BAT1 b a BAT1
Internal wires for 0BT1 a b 0BT1

SLU-axes BAT1 b a BAT1
See Procedure 4 New battery pack

See Procedure 5
a: Insertion-type pin terminal(Male)
b: Insertion-type pin terminal(Female)
Fig.10- 36(c Battery Connection for SLU-Axis
See Procedure 6 Battery pack for RBT-axes before replacement

See Procedure 7
0BT4 a b 0BT4
BAT4 b a BAT4
Internal wires for 0BT4 a b 0BT4

RBT-axes BAT4 b a BAT4
See Procedure 4 New battery pack

See Procedure 5
a: Insertion-type pin terminal(Male)
b: Insertion-type pin terminal(Female)
Fig.10- 36(d Battery Connection for RBT-Axis
1. Turn the XRC main power supply off.

2. Remove the plate of the connector base to replace the battery unit.
3. Remove the mounting screw which mounted on the plate of battery unit.
4. Remove the plastic tape (insulation tape) protecting the connection part of the battery
pack in the manipulator.
5. Connect the new battery unit.
6. Remove the old battery unit.
NOTE Remove the old battery pack after connecting the new one so that the encoder absolute
date does not disappear.
7. Protect the connection part of the battery pack in the manipulator with plastic tape
(insulation tape).
8. Mount the battery unit with the screw, and then mount the connector base.
NOTE Do not pinch the cable when the base connector is installed.
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11 Cable Wiring
11 Cable Wiring
NOTE Remove the encoder cable connectors, after connecting new battery pack not to loose the
encoder absolute data.
Remove Operation of the Cable
Work Procedure
1 Undo the four hexagon socket head cap

screws (M6x12), and remove the cover
(HW9200891-1) beside the L-arm.
Cover
2 Remove the screws of the upper side of the

model GP holder (BGP-48) to remove the
flexible tube.
BGP-48
3 Remove the seven hexagon socket head cap

Gasket Cover
screws (M6x16) to remove the cover
(HW9302176-1) and the gasket
(HW9381484-1).
Hexagon socket head cap screw
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11 Cable Wiring
4 Remove the four (M6x16) and two (M6x12)

hexagon socket head cap screws to remove
the cover (HW9405439-1), the gasket
(HW9482427-A) and the cover
(HW9405310-1).
Cover
5 Remove the two pan head screws with Union (2)

washers (M4x10) to remove the connector
(JL05-2A-24-28S), and pull the air tube out of
the union.
JL Connector
6 Remove the hexagon socket head cap

screws (M6x16) to remove the ground wire
for the JL connector.
7 Verify that the R-, B- and T-axis motors

connect with the battery for backup. Then
remove the connector on the motor side of
the relay adopter in the casing.
8 Verify that the U-axis motor connects with the U-Axis connector
battery for backup. Then remove the U-axis
cable.
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11 Cable Wiring
9 Remove the support (HW9302140-1) from

the casing.
10 Take out the lead wire from the casing.
11 Verify that the S- and L-axis motors connect

with the battery for backup. Then remove the
S- and L-axis motor connector.
12 Remove the cover (HW9381532-1). Remove

the two hexagon socket head cap screws
(M6x20) to remove the plate (HW9405448-1)
from the support (HW9302335-1). Cover
Hexagon socket
head cap Screw
Plate
13 Remove the four cross recessed APS bolts

(M6x12) to remove the connector base
(HW9302338-A).
14 Remove the S-axis speed reducer grease

hose and the air tube from the union.
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11 Cable Wiring
15 Remove the ground wire of the S-axis base. Ground wire

(There are two points to remove.)
16 Remove the housings (1BC, 2BC and 3BC).
Housing
17 Remove the two pan head screws with

washers (M4x16) to remove the 4BC
connector mounted on the base.
2-pan head screw with

washer M4X16 Nut M4
HW9481087-E
Gasket
Detail view of installing JL connector
18 Remove the two hexagon socket head cap

screws (M5x12) to remove the saddle
(FCD-51).
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11 Cable Wiring
19 Remove the insert pin terminals of the battery

and the S-axis LS lead wire.
20 Extract the cable.
Direction of
extraction
Reassembly
1 Insert the cable.
Direction of
insertion
2 Mount the saddle (FCD-51) with the hexagon

socket head cap screws (M5x12).
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11 Cable Wiring
3 Mount the 4BC connector on the base with

the two pan head screws with washers
(M4x16).
2-Pan head screw with

washer M4 (16washers) Nut M4
HW9481087-E
Gasket
Detail view of installing JL connector
4 Mount the insert pin terminals on the battery

and the S-axis LS lead wire.
5 Mount the housing (1BC, 2BC and 3BC).
Housing
6 Mount the ground wire of the S-axis base. Ground wire

(There are two places to mount.)
7 Mount the grease hose and the air tube of the

S-axis speed reducer on the union.
8 Mount the connector base (HW9302338-A)

with the four cross recessed APS bolts
(M6x12).
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11 Cable Wiring
9 Mount the plate (HW9405448-1) on the

support (HW9302335-1) with the two
hexagon socket head cap screws (M6x20),
and then mount the cover (HW9381532-1). Cover
Hexagon socket
head cap Screw
Plate
10 Mount the S- and L-axis motor connector,

and remove the S- and L-axis battery for
backup.
11 Insert the lead wire into the casing.
12 Mount the support (HW9302140-1) with the

four hexagon socket head cap screws
(M6x20, applying the sealing bond).
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11 Cable Wiring
13 Mount the connector on the motor side of the

relay adopter in the casing. Then mount the
U-axis motor cable on the U-axis motor, and
remove the battery for the U-, R-, B- and T-
axis for backup.
14 Mount the ground wire attached to the casing

with the hexagon socket head cap screw
(M6x16).
15 Mount the JL connector (JL05-2A-24-28S) Union (2)

with the two pan head screws with washers
(M4x10), and mount the air tube.
JL Connector
16 Mount the cover (HW9405439-1), the cover

(HW9405310-1) and the gasket
(HW9482427-A) with the four (M6x16) and
two (M6x12) hexagon socket head cap
screws.
Cover
17 Mount the cover (HW9302176-1) and the

Gasket Cover
gasket (HW9381484-1) with the seven
hexagon socket head cap screws (M6x16).
Hexagon socket head cap screw
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11 Cable Wiring
18 Mount the flexible tube on the lower side of

the model GP holder, and fasten the upper
side of the model GP holder with the screws.
19 Mount the L-arm cover (HW9200892-1) with

the hexagon socket head cap screws.
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12 Parts List
12 Parts List
12.1 UP130, UP165
12.1.1 S-Axis Driving Unit(1)
1019
3062
1045
1046
1021
1022
1020
1023
1004
1015
1016
1003
1034
1027
1035 1006
1028
1033
1024
1005
1026
1012
1025 1011
1001
1014
1013
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12 Parts List
No. DWG No. Name Pcs.

1001 HW9100888-1 Base 1
1003 HW9381388-A Speed reducer 1
1004 AS568-281 O ring 1
1005 HW9302345-1 Shaft 1
1006 G135 O ring 1
1007 TC9011513 Oil seal 1
1008 VC801057 Oil seal 1
1009 AR-110 Clip 1
1010 6817ZZ Bearing 1
1011 M620 Socket screw 4
1012 2H-6 Conical spring 4
washer
1013 KQS10-01S Union 1
1014 NB-1075-1 Tube 1
washer
washer
1019 HW9100894-1 S head 1
1021 HW9405032-1 Bolt 1
washer
1024 HW9404486-1 Shaft 1
1025 LFF-3025 Oiless 1
1026 HW9404863-1 Stopper 1
washer
1029 S130 O ring 1
1030 HW9302346-1 Shaft 1
washer
1033 HW9470892-A Leads 1
washer
1036 HW9302335-1 Support 1
washer
1039 SGMDH-45A2B- Motor 1
YR12
washer
1042 HW9381446-A Shaft 1
washer
washer
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12 Parts List
12.1.2 S-Axis Driving Unit(2)
1031
1032
2028
1029
1040 1036
2026 2010
1041 2011 1037
2028
2031 1038
2009
1039
1030
1042
1017
1008
1044 2033
1018
1043 1010
2032
1009
2030
2025
1007
2029 2007
2008
2017
2006
2021
2027
2005
2026 2020
2025 2019
2017
2018 2002
2022 2016
2004
2024
2015
2023 2003
2012
2001
2014
2013
1019
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12 Parts List

1019 HW9100894-1 S head 1
2001 HW9381475-A Gear 1
2002 HW9405052-1 B stopper 1
washer
2005 HW9481231-A Bearing 1
2006 HW9405049-1 B stopper 1
washer
2009 HW9302141-1 Flange 1
washer
2012 HW9405048-1 Housing 1
washer
2015 G85 O ring 1
2016 HW9405304 Shim 1
2017 HR33206J Bearing 2
washer
2020 HW9405047-1 Shaft 1
2021 HW9381476-A Gear 1
2022 HW9405051-1 Cover 1
washer
2025 ISTW-35 Stopper 2
2027 HW9381477-A Gear 1
2028 IRTW-72 Stopper 2
2029 CIMR35-1 Shim 2
2030 Y507212.5 Oil seal 1
2032 HW9100893-1 Gear case 1
2033 PT1/8 Plug 1
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12 Parts List
12.1.3 L-Axis Driving Unit(1)
UP130 (UP160: Next page)
3001
3010
3025 3011 3002
3009 3003
3012
3013
3004 3062 3015
3014
3005 3008
3027 3017
3019
3006
3007
3053
3054
3051
3029
3050 3052
3028 3023
3046 3024
3022 3049 3016
3047
3021 3048
1019 3018
3051 3020
3054 3019
3053
3052 3049
3046
3055 3050
3061
3048 3033
3047
3035 3034
3030
3032
3031
3037
3036
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12 Parts List
UP165
3001
3002
3010 3003
3011 3015
3014
3009
3013
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12 Parts List

1019 HW9100894-1 S head 1
3001 SGMGH-44A2A- Motor 1
YR12
washer
3004 HW9200895-1 M base 1
3005 EZ0094-AO Air breezer 1
3006 POC6-01M Union 1
3007 UB-0640-0.1C Tube 1
3008 Y507212.5 Oil seal 1
3009 HW9482308-A Gear 1
(UP130)
HW9482358-A
(UP165)
3010 HW9482306-B Shaft 1
(UP130)
HW9482306-E
(UP165)
3011 HW9481343-A Shaft 1
3012 HW9405134-1 Pipe 1
3013 ISTW-15(UP130) Stopper 1
ISTW-12(UP165)
3014 M8115(UP130) Socket screw 1
HW9482316-C
(UP165)
3015 2H-8(UP130) Conical spring 1
2H-12(UP165) washer
(UP130)
HW9381442-B
(UP165)
washer
3021 GT-SH-12 Washer 18
3023 GT-SH-16 Washer 6
3024 G300 O ring 1
3025 HW9100895-1 L arm 1
3027 HW9200891-1 Cover 1
3028 M612 APS bolt 4
3029 A-PT1/8 G nipple 1
3030 HW9405162-1 Shaft 1
washer
3034 STW-90 C stopper 1
3035 HW9405161-1 Cover 1
washer
3038 HW9302054-1 Shaft 1
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12 Parts List

washer
3041 NA6912 Bearing 1
3042 AR-85 C stopper 1
3043 WR60 C stopper 1
3044 SB75955 Oil seal 1
3045 SB60789 Oil seal 1
3046 HW9405055-1 Shaft 2
washer
3049 KE901107 Oil seal 2
3050 HR32916J Bearing 2
3051 HW9405056-1 B cover 2
washer
3055 HW9405195-1 Shim 1
3056 HW9405195-2 Shim 2
3057 HW9405195-3 Shim 1
3058 HW9405195-4 Shim 1
3059 HW9405195-5 Shim 1
3060 HW9405195-6 Shim 1
3061 HW9405195-7 Shim 1
3062 PT1/8 Plug 2
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12 Parts List
12.1.4 L-Axis Driving Unit(2)
3080
3076
3077
3075
3074
3073
3072
3071
3070
3067
3066
3068
3070
3071 3065
3069 3064
3063
3079
3078
3045 3025
3043
3041
3042
3044
3038
3040
3039
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12 Parts List

3025 HW9100895-1 L arm 1
3063 HW9405057-1 Clevis 1
3065 PT1/8 Plug 2
3066 HW9200892-1 Frange 1
3067 HW9302126-1 Rod 1
3068 M8 Set screw with a 1
ball
3069 FD3187AO Dust seal 1
3070 SOB-607440 Oiless 2
3071 IRTW-75 C stopper 2
3072 HW9482271-A Coil spring 1
3075 HW9301853-1 Flange 1
3076 HW9100909-1 Case 1
washer
3080 EZ2228A0 Cap 1
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12 Parts List
12.1.5 U.R.B.T-Axis Link Unit
4049
4050
4047
4048
4051
4024
4024
4019 4066
4074 4052
4079 4020 4064 4053
4080
4079 4081
4080 4022 4062
4081 4076 4021 4061
4019AA 4063
4020 4075 4028 4065
4022 4029
4031 4030
4032 4036
4019 4033 4037
4034
4021
4035
4022 4046 4027
4100
4023 4020
4021
4073
4072
4071 4056
4054 4055
4079 4102
4080 4103
4081 4101
3025
4016
4017
4068 4015 4058
4067 4025 4057
4026 4018
4043 4020
4060 4014
4042 4008
4059 4083
4090
4041 4012
4011
4009
4045 4010 4007
4044 4084
4091
4070
4069
4013
4001 4093
4092
4005
4094 4006
4078
4077
4085
4003
4004 4002
4088 4082
4089 4095
4096 4087
4086
4096
4098
4099
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12 Parts List

3025 HW9100895-1 L arm 1
4001 6919DDU Bearing 1
4002 HW9405058-1 B cover 1
washer
4005 WR95 S stopper 1
4006 HW9302143-1 Shaft 1
4008 HW9381448-A Pulley 1
washer
4012 HW9381449-A Shaft 1
4013 HW9302142-A Shaft 1
4015 HW9381447-A Pulley 1
(UP130)
HW9381559-A
(UP165)
washer
4018 HW9482276-A Pulley 1
4019 HW9482275-A Pulley 2
(UP130)
HW9482450-A
(UP165)
4019AA HW9482275-A Pulley 1
4020 HW9402163-1 B cover 4
washer
YR22
YR12
washer
4027 HW9100889-1 Casing 1
(UP130)
HW9100889-2
(UP165)
4028 HW9405482-1 Flange 1
washer
4031 HW9482447-A Oil seal 1
4032 HW9405481-1 Collar 1
4034 HW9405439-1 Cover 1
4035 HW9482427-A Gasket 1
washer
4041 A-PT/1/8 G nipple 1
4042 HW9405165-1 Cover 1
4043 G45 O ring 1
washer
4046 PT1/8 Plug 2
4047 HW9302176-1 Cover 1
4048 HW9381484-A Gasket 1
washer
YR12
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12 Parts List

washer
(UP130)
HW9381465-C
(UP165)
4055 HW9405164-1 Cover 1
4056 HW9482310-A Gasket 1
washer
washer
4061 HW9482316-A Bolt 1
washer
4063 HW9482318-A Gear 1
(UP130)
HW9482451-A
(UP165)
4064 HW9481343-A Shaft 1
4065 ISTW-12 C stopper 1
4066 HW9482306-C Shaft 1
washer
washer
4071 G270 O ring 1
4072 POC6-01M Union 2
4073 UB-0640-0.1C Tube 1
4074 200S8M976 Timing belt 1
(UP130)
200S8M960
(UP165)
washer
washer
4081 HW9404231 Washer 3
4082 HW9200894-1 U arm 1
4083 6904LLU*NS7* Bearing 1
4084 6811LLU Bearing 1
4085 HW9482283-A Shaft 1
washer
4089 ISTW-70 C stopper 1
4090 51020 C stopper 1
4091 HW9482282-A Shaft 1
washer
4094 G185 O ring 1
4096 PT1/8 Plug 2
washer
4100 MSTM8-20 Pin 1
4101 HW9405310-1 Cover 1
washer
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12 Parts List
12.1.6 Wrist Unit
5020
5021
5014 5013
5015 5018
5019
5021 5016
5117~5121
5017 5024
5025 5023
5026
5028 5022
5027 5095
5096
5030
5029 5050 5094 5003
5004 5002
5053
5097 5075
5001 5074
5052
5032
5031
5076
5077
5038
5056
5041 5057
5062
5094 5007
5011 5058
5096 5051
5040 5055
5095
5110~5113 5061
5106~5109
5045
5043 5054 5069 5066
5042 5070
5051
5048 5068 5072
5046 5008
5045 5039 5073
5011 5063
5044 5067
5059 5065
5071
5047
5064 5102~5105
5051
5034 5087 5052

5011
5035
5009 5033 5085
5114~5116 5086
5006 5036 5084
5083 5061
5037 5098~5101 5050
5005 5051
5088
5012
5079
5091 5092
5082
5011
5093
5010 5090
5089
5081
5090
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12 Parts List

5001 HW9100890-1 Wrist base 1
washer
5004 MSTM8-20 Pin 1
5005 HW9100896-1 Wrist 1
washer
5012 ARP568-263 O ring 1
5013 HW9482260-A Shaft 1
washer
5016 HW9302055-A Shaft 1
5017 HW9481234-A Bearing 1
5018 HW9403607-1 B cover 1
washer
5022 HW9301424-1 Housing 1
5023 HW9405445-1 B nut 1
5024 M46 H set screw 1
5025 G70 O ring 1
5026 AC2651FO Oil seal 1
5027 6810 Bearing 1
5028 WR50 Clip 1
5029 AC1030FO Oil seal 1
5030 HW9380982-A Gear 1
washer
5033 HW9380983-A Gear 1
washer
5036 6908 Bearing 1
5037 51040 C stopper 1
5038 HW9380984-A Gear 1
5039 HW9380986-A Gear 1
5040 HW9481236-A Bearing 1
5041 HW9403609-1 Housing 1
5042 HW9403610-1 B cover 1
washer
5046 HW9405444-1 B nut 1
5048 HW9405097-1 Cover 1
5050 G110 O ring 1
5051 HR32004XJ Bearing 4
5052 6911 Bearing 1
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12 Parts List

5053 AE3290E3 Oil seal 1
5054 S60 O ring 1
5055 HW9403618-1 Housing 1
washer
5058 HW9380987-A Gear 1
5059 HW9380988-A Gear 1
5060 HW9380989-A Gear 1
5061 HW9405443-1 B nut 2
5062 M57 Set screw with a 4
ball
5063 HW9481235-A Bearing 1
5064 HW9405442-1 Shaft 1
5065 HW9403615-1 Washer 1
washer
5068 HW9403616-1 B cover 1
washer
5071 HW9403617-1 Housing 1
washer
5074 HW9200900-1 Cover 1
5075 A-MT1 G nipple 1
5077 M5 Washer 8
5079 HW9301409-1 Cover 1
washer
5082 PT1/8 Plug 1
5083 HW9380985-A Gear 1
(UP130)
HW9381049-A
(UP165)
5084 HW9403619-1 Washer 1
washer
5087 HW9380986-A Gear 1
(UP130)
HW9381048-A
(UP165)
5090 GT-SH-M14 washer 4
5091 HW9302056-1 Flange 1
5094 HW9481237-A Stopper 2
washer
5097 EZ5036AO Cap 2
5098 HW9403620-1 Shim 1
5099 HW9403620-2 Shim 1
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12 Parts List

5100 HW9403620-6 Shim 1
5101 HW9403620-7 Shim 1
5102 HW9403621-1 Shim 1
5103 HW9403621-2 Shim 1
5104 HW9303621-5 Shim 1
5105 HW9303621-6 Shim 1
5106 HW9303622-1 Shim 1
5107 HW9303622-2 Shim 1
5108 HW9303622-4 Shim 1
5109 HW9303622-6 Shim 1
5110 HW9303623-1 Shim 1
5111 HW9303623-2 Shim 1
5112 HW9303623-4 Shim 1
5113 HW9303623-5 Shim 1
5114 HW9303624-1 Shim 1
5115 HW9303624-2 Shim 1
5116 HW9303624-3 Shim 1
5117 HW9303625-1 Shim 1
5118 HW9303625-2 Shim 1
5119 HW9303625-4 Shim 1
5120 HW9303625-5 Shim 1
5121 HW9303625-6 Shim 1
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MOTOMAN-UP130, UP165, UP200
MAINTENANCE MANUAL
HEAD OFFICE
2-1 Kurosakishiroishi, Yahatanishi-ku, Kitakyushu 806-0004, Japan
Phone +81-93-645-7703 Fax +81-93-645-7802
YASKAWA America Inc. (Motoman Robotics Division)

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

Robotics Divsion )
Yaskawastrasse 1, 85391 Allershausen, Germany
Phone +49-8166-90-100 Fax +49-8166-90-103
YASKAWA Nordic AB
Bredbandet 1 vn. 3 varvsholmen 392 30 Kalmar, Sweden
Phone +46-480-417-800 Fax +46-480-417-999
YASKAWA Electric (China) Co., Ltd.

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

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

9F, KyoboSecuritiesBldg., 26-4, Yeouido-dong,Yeongdeungpo-gu, Seoul 150-737, Korea
Phone +82-2-784-7844 Fax +82-2-784-8495
YASKAWA Electric Taiwan Corporation

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

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

252/125-126 27th Floor, Tower B Muang Thai-Phatra Complex Building,
Rachadaphisek RoadHuaykwang, Bangkok 10320, Thailand
Phone +66-2693-2200 Fax +66-2693-4200
PT. YASKAWA Electric Indonesia

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

for ongoing product modifications and improvements.
111 of 111
MANUAL NO.
HW0480769 7

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MOTOMAN-UP130,UP165,UP200

Part Number: 170903-1CD

Copyright 2015, Yaskawa America, Inc. All Rights Reserved.

2 Notes for Maintenance

3 Home Position Return Operation

4 L-axis Fixing Jig Operating

6 Disassembly and Reassembly of the Motor

7 Disassembly and Reassembly of the Speed Reducer

7.6 Disassembly and Reassembly

8 Disassembly and Reassembly of the Wrist Unit

9 Adjustment the Tension of the RBT-Axes Belts

10 Battery Pack Replacement

This maintenance manual is intended to explain operating instructions and maintenance

1.1 NOTES FOR SAFE OPRERATION

Indicates an imminent hazardous situation which, if not avoided,

Indicates a potentially hazardous situation which, if not avoided,

Indicates a potentially hazardous situation which, if not avoided,

Always be sure to follow explicitly the items listed under this

Must never be performed.

Maintenance and inspection must be performed by specified personnel.

Failure to observe this caution may result in electric shock or injury.

For disassembly or repair, contact your Yaskawa representative.

Do not remove the motor, and do not release the brake.

Emergency Stop Button

Release of Emergency Stop

Improper or unintended manipulator operation may result in injury.

-Check for problems in manipulator movement.

1.2 Definition of Terms Used Often in This Manual

The MOTOMAN is the YASKAWA industrial robot product.

Equipment Manual Designation

YASNAC XRC Controller XRC (Robot Controller)

YASNAC XRC Playback Panel Playback Panel

YASNAC XRC Programming Pendant Programming Pendant

1.3 AN EXPLANATION OF WARNING LABLES

The following warning labels are attached to the manipulator.

Note: Taking the maintenance-relevant trainings offered by Yaskawa is indispensable for

MOTOMAN-UP130, UP165, UP200

Warning label A Warning label B

Nameplate Warning Label A Warning Label C

2 Notes for Maintenance

2 Notes for Maintenance

2.1 Battery Pack Connection for S-, L-, and U-Axis

2.2 Battery Pack Connection for R-, B-, and T-Axis

Connector for the battery backup

Battery pack for S, L, U-axis (HW9470932-A)

Battery pack connection cable for the motor (HW9470945-A)

Battery pack for R, B, T-axis (HW9470932-B)

Fig. 2-2 R-, B- and T-Axis Battery Pack Connection

3 Home Position Return Operation

3 Home Position Return Operation

3.1 How to Return to the Home Position in the Case of

3.1.1 How to Use the Robot Calibration (MOTOCALV EG)

3.1.2 How to Set the Teaching Point for Home Position

Preparation before Replacement

View observed from the arrow A

Fig. 3-3 Preparation before replacement (Ex.)

Fig. 3-4 Replacement (Ex.)

3 Home Position Return Operation

Home Position Adjustment

2-ANE 12-300 MISUMI.corp