Yk X
Yk X
Yk X
The origin position on the YK-X series robots is adjusted at the factory prior to
shipment. They are adjusted to the robot arm extended position, and the tempo-
rary reference coordinate is thus set previous to shipment.
The customer should set the origin position before any other job. There are 2
types of origin position settings as shown below.
[1] Setting the robot arm extended position (the origin position adjusted
at the factory prior to shipment) as the origin position
(When setting the origin position with the robot arm extended, you
must check that there will not be any interference from any periph-
eral equipment during the next absolute reset.)
[2] Setting a position OTHER than the robot arm extended position
(the origin position adjusted at the factory prior to shipment) as the
origin position
[1] To set the robot arm extended position (the origin position adjusted
at the factory prior to shipment) as the origin position
Absolute Reset
The YK-X series robots only require the absolute reset to be performed once
when the robot is introduced.
If the absolute reset is performed once, then the absolute reset is not required
when the power is turned on after that.
Set the origin position while referring to absolute reset methods in "3. Adjust-
ing the origin" in Chapter 4 of this manual and in "Absolute Reset" of the
"YAMAHA robot controller owner's manual". Setting of reference coordinates
is not required in the above case.
! CAUTION
Do not enter within the movement range of the robot since this is hazardous
while the robot servo is on.
[2] To set a position OTHER than the robot arm extended position (the
origin position adjusted at the factory prior to shipment) as the
origin position
1. Absolute reset
The YK-X series robots only require the absolute reset to be performed once
when the robot is introduced.
If the absolute reset is performed once, then the absolute reset is not required
when the power is turned on after that.
Set the origin position while referring to absolute reset methods in "3. Adjust-
ing the origin" in Chapter 4 of this manual and in "Absolute Reset" of the
"YAMAHA robot controller owner's manual".
Set the origin position with the absolute reset.
! CAUTION
Do not enter within the movement range of the robot since this is hazardous
while the robot servo is on.
Even though there is no problem with the robot, the following error messages are
issued when the robot and controller are connected and power first turned on.
(Actual error messages may differ according to how the robot and controller are
connected.)
Error messages issued when robot & controller are connected (RCX40)
17.27 : D?.ABS. backup failed (CPU)
17.80 : D?.ABS. backup failed (DRIVER)
17.81 : D?.ABS.battery wire breakage
17.92 : D?.Resolver disconnected during power off
17.93 : D?.Position backup counter overflow
17.94 : D?.ABS.battery low voltage
etc
Error messages issued when robot & controller are connected (QRCX)
17.80: D ?. ABS. encoder backup alarm
17.81: D ?. ABS. encoder battery alarm
17.85: D ?. ABS. encoder system error
17.92: D ?. ABS. cable disconnected
17.93: D ?. ABS. data overflow
17.94: D ?. ABS. Battery degradation
etc
Introduction
The YAMAHA YK-X series robots are SCARA type industrial robots developed
based on years of YAMAHA experience and achievements in the automation
field as well as efforts to streamline our in-house manufacturing systems.
The YK-X series robots have a two-joint manipulator consisting of an X-axis arm
and a Y-axis arm, and are further equipped with a vertical axis (Z-axis) and a
rotating axis (R-axis) at the tip of the manipulator. The YK-X series robots can be
used for a wide range of assembly applications such as installation and insertion
of various parts, application of sealant, and packing operations.
This instruction manual describes the safety measures, handling, adjustment and
maintenance of YK-X series robots for correct, safe and effective use. Be sure to
read this manual carefully before installing the robot. Even after you have read
this manual, keep it in a safe and convenient place for future reference.
This instruction manual should be used with the robot and considered an integral
part of it. When the robot is moved, transferred or sold, send this manual to the
new user along with the robot. Be sure to explain to the new user the need to read
through this manual.
This manual describes all models of the YK-X series except for the YK120X
series.
When you are using clean room models, dust/drip models or ceiling-mount mod-
els of the YK-X series robots, refer to their owner's manuals. For precautions and
operations common to standard models of the YK-X series, please refer to this
manual.
If there are any obscure points in handling these robot models or other custom
models, be sure to contact YAMAHA sales office or dealer.
For details on specific operation and programming of the robot, refer to the sepa-
rate "YAMAHA robot controller owner's manual".
NOTES
• The contents of this manual are subject to change without prior notice.
• Information furnished by YAMAHA in this manual is believed to be reliable.
However, if you find any part unclear or inaccurate in this manual, please
contact YAMAHA sales office or dealer.
CHAPTER 2 Functions
1 Robot Manipulator ......................................................... 2-1
2 Robot Controller ............................................................ 2-7 #
3 Robot initialization number list ....................................... 2-8 #
CHAPTER 3 Installation
1 Robot Installation Conditions ......................................... 3-1 #
1-1 Installation environments ......................................................... 3-1 #
1-2 Installation base ....................................................................... 3-3 #
CHAPTER 4 Adjustment
1 Overview ........................................................................ 4-1 #
2 Safety Precautions ........................................................ 4-1 #
3 Adjusting the origin ........................................................ 4-2 #
3-1 Absolute reset method ............................................................. 4-3 #
#
3-1-1 Sensor method (X-axis, Y-axis, and R-axis) ............................ 4-3
#
3-1-2 Mark method (X-axis, Y-axis, and R-axis) ................................ 4-4
#
3-1-3 Stroke end method (Z-axis) ..................................................... 4-4
3-2 Machine reference ................................................................... 4-5 #
3-3 Absolute reset procedures ....................................................... 4-6 #
#
3-3-1 Sensor method (X-axis, Y-axis, and R-axis) ............................ 4-6
#
3-3-2 Mark method (X-axis, Y-axis, and R-axis) ................................ 4-8
#
3-3-2-1 Absolute reset with servo on (re-reset) .................................. 4-9
#
3-3-2-2 Absolute reset with servo off (re-reset) ................................ 4-11
#
3-3-2-3 Absolute reset with servo on. (new reset) ............................ 4-13
#
3-3-2-4 Absolute reset with servo off. (new reset) ............................ 4-16
#
3-3-3 Stroke end method (Z-axis) ................................................... 4-24
3-4 Changing the origin position and adjusting the machine reference ... 4-25 #
#
3-4-1 Sensor method ....................................................................... 4-26
#
3-4-1-1 YK250X, YK350X, YK400X .................................................. 4-26
#
3-4-1-2 YK500X, YK600X, YK700X,YK800X, YK1000X .................. 4-34
3-4-1-3 YK550X ................................................................................ 4-44
#
3-4-2 Mark method .......................................................................... 4-50
#
3-4-3 Stroke end method ................................................................. 4-51
3-4-3-1 YK250X, YK350X, YK400X, YK500X, YK600X, YK700X,
YK800X, YK1000X, YK1200X .............................................. 4-51
3-4-3-2 YK550X ................................................................................ 4-55
CHAPTER 7 Specifications
1 Manipulator .................................................................... 7-1
1-1 Basic specification ................................................................... 7-1
1-2 External view and dimensions ................................................. 7-4
1-3 Robot inner wiring diagram .................................................... 7-24 #
1-4 Wiring table ............................................................................ 7-27 #
CHAPTER 1
1 Safety Information
Industrial robots are highly programmable, mechanical devices that provide a
large degree of freedom when performing various manipulative tasks. To ensure
correct and safe use of YAMAHA industrial robots, carefully read this manual
and make yourself well acquainted with the contents. FOLLOW THE WARN-
INGS, CAUTIONS AND INSTRUCTIONS INCLUDED IN THIS MANUAL.
Failure to take necessary safety measures or mishandling due to not following the
instructions in this manual may result in trouble or damage to the robot and in-
jury to personnel (robot operator or service personnel) including fatal accidents.
Warning information in this manual is shown classified into the following items.
DANGER
Failure to follow DANGER instructions will result in severe injury or death to the
robot operator, a bystander or a person inspecting or repairing the robot.
WARNING
Failure to follow WARNING instructions could result in severe injury or death to
the robot operator, a bystander or a person inspecting or repairing the robot.
! CAUTION
Failure to follow CAUTION instructions may result in injury to the robot opera-
tor, a bystander or a person inspecting or repairing the robot, or damage to the
robot and/or robot controller.
NOTE
Explains the key point in the operation in a simple and clear manner.
It is not possible to detail all safety items within the limited space of this manual.
So it is essential that the user have a full knowledge of basic safety rules and also
that the operator makes correct judgments on safety procedures during operation.
This manual and warning labels supplied with or affixed to the robot are written
in English. If the robot operator or service personnel does not understand Eng-
lish, do not permit him to handle the robot.
1-1
CHAPTER 1 Using the Robot Safely
DANGER
Serious injury or death will result from impact with moving robot.
• Keep outside of guard during operation.
• Lock out power before approaching robot.
WARNING
Moving parts can pinch or crush.
Keep hands away from robot arms.
DANGER WARNING
Serious injury or death
will result from impact Moving parts can
with moving robot. pinch or crush.
• Keep outside of guard
during operation. Keep hands away
• Lock out power before
approaching robot.
from robot arms.
1-2
CHAPTER 1 Using the Robot Safely
WARNING
Improper installation or operation can result in serious injury or death.
Read owner's manual and all warning labels before operation.
WARNING
Improper Installation or operation
can result in serious injury or
death.
Read owner's manual and all
warning labels before operation.
WARNING
• This robot was not designed for operation in environments where inflamma-
ble or explosive substances are present.
• Do not use the robot in environments containing inflammable gas, dust or
liquids. Explosions or fire could otherwise result.
WARNING
Avoid using the robot in locations subject to electromagnetic interference, elec-
trostatic discharge or radio frequency interference. Malfunction may otherwise
occur.
1-3
CHAPTER 1 Using the Robot Safely
(6) Use caution when releasing the Z-axis (vertical axis) brake.
WARNING
The Z-axis will slide down when the Z-axis brake is released, causing a hazard-
ous situation.
• Press the emergency stop button and prop up the Z-axis with a support stand
before releasing the brake.
• Use caution not to let your body get caught between the Z-axis and installa-
tion base when releasing the brake to perform direct teach.
WARNING
• End effectors must be designed and manufactured so that they cause no
hazards (for example, loosening of workpiece) even if power (electricity, air
pressure, etc.) is shut off or power fluctuations occur.
• If there is a possible danger that the object gripped by the end effector may
fly off or drop, then provide appropriate safety protection taking into account
the object size, weight, temperature and chemical properties.
WARNING
The Z-axis moves up when the power to the controller or PLC is turned off, the
program is reset, emergency stop is triggered, or air is supplied to the solenoid
valve for the Z-axis air cylinder.
• Do not let hands or fingers get caught and squeezed by moving parts of the
Z-axis.
• Keep the usual robot position in mind so that the Z-axis will not interfere with
obstacles during raising of the Z-axis, except in case of emergency stop.
(9) Use the following caution items when the Z-axis is interfering
with peripheral equipment. (2-axis robots with air driven Z-axis)
WARNING
When the Z-axis comes to a stop due to obstructions from peripheral equip-
ment, the Z-axis may move suddenly when the obstruction is removed, causing
injury such as pinched or crushed hands.
• Turn off the controller and reduce the air pressure before attempting to re-
move the obstruction.
• Before reducing the air pressure, place a support stand under the Z-axis
because it will drop under its own weight.
1-4
CHAPTER 1 Using the Robot Safely
(10) Use caution on Z-axis movement when air supply is stopped. (2-
axis robots with air-driven Z-axis)
WARNING
The Z-axis may suddenly drop when the air pressure to the Z-axis air cylinder
solenoid valve is reduced, creating a hazardous situation.
Turn off the controller and place a prop or support under the Z-axis before
cutting off the air supply.
WARNING
Air or parts may fly outwards if pneumatic equipment is disassembled or parts
replaced while air is still supplied.
• Do service work after first turning off the controller and reducing the air pres-
sure.
• Before reducing the air pressure, place a support stand under the Z-axis (2-
axis robots with air driven Z-axis) since it will drop under its own weight.
(12) Use the following caution items when removing the Z-axis mo-
tor.
WARNING
The Z-axis will drop when the Z-axis motor is removed, possibly resulting in
injury.
• Turn off the controller and set a support stand under the Z-axis before re-
moving the motor.
• Use caution not to allow hands or body to be squeezed or crushed by moving
parts on the Z-axis or between the Z-axis and the installation base.
WARNING
• When you need to touch the terminals or connectors on the outside of the
controller during inspection, always first turn off the controller power switch
and also the power source in order to prevent possible electrical shock.
• Never touch any internal parts of the controller.
For precautions on handling the controller, refer to the "YAMAHA robot control-
ler owner's manual".
1-5
CHAPTER 1 Using the Robot Safely
WARNING
If any part of the robot is damaged or any malfunction occurs, continuous op-
eration may be very dangerous. Please consult YAMAHA dealer for corrective
action.
(15) Use caution not to touch the X-axis motor cooling fan (YK550X)
and controller rear panel cooling fan.
WARNING
• Bodily injury may occur from coming into contact with the cooling fan while it
is rotating.
• When removing the fan cover for inspection, first turn off the controller and
make sure the fan has stopped.
(16) Use caution not to touch the high temperature motor or speed
reduction gear casing.
WARNING
The motor and speed reduction gear casing are extremely hot after automatic
operation, so burns may occur if these are touched.
Before touching these parts during inspections or servicing, turn off the control-
ler, wait for a while and check that the temperature has cooled.
WARNING
If warning labels are removed or difficult to see, necessary cautions may not be
taken, resulting in an accident.
• Do not remove, alter or stain the warning labels on the robot.
• Do not allow the warning labels to be hidden by the device installed to the
robot by the user.
• Provide proper lighting so that the symbols and instructions on the warning
labels can be clearly seen even from the outside of safeguards.
1-6
CHAPTER 1 Using the Robot Safely
WARNING
Be sure to ground the robot and controller to prevent electrical shock.
(19) Do not allow any object to enter the X-axis motor cooling fan.
(YK550X; See Fig. 2-6.)
WARNING
If an object such as a small workpiece which the end effector failed to pick up,
penetrates into the cooling fan for the X-axis motor, it may rebound and fly
away from the fan, possibly causing bodily injury or damage to the fan.
• Provide a proper protective wall which prevents workpieces or other objects
from entering the fan.
• When providing a protective wall, allow a space of at least 100mm between
the fan vent and the wall to ensure air flow and cooling effects.
! CAUTION
The robot must be operated with correct tolerable moment of inertia and accel-
eration coefficients according to the manipulator tip mass and moment of iner-
tia. If this is not observed, premature end to the life of the drive units, damage to
the robot parts or residual vibration during positioning may result.
(21) Do not use the robot for tasks requiring motor thrust.
! CAUTION
Avoid using the YK-X series robots for tasks which make use of motor thrust
(press-fitting, burr removal, etc.). These tasks may cause malfunctions of the
robot.
1-7
CHAPTER 1 Using the Robot Safely
1-8
CHAPTER 1 Using the Robot Safely
WARNING
Axis movement will not stop immediately after the servo power supply is shut
off by emergency stop or other safety functions.
WARNING
The Z-axis will slide down when the Z-axis brake is released, creating a haz-
ardous situation.
• Press the emergency stop button and prop the Z-axis with a support stand
before releasing the brake.
• Use caution not to let your body get caught between the Z-axis and installa-
tion base when releasing the brake to perform direct teach.
1-9
CHAPTER 1 Using the Robot Safely
1-10
CHAPTER 1 Using the Robot Safely
6 Trial Operation
After making installations, adjustments, inspections, maintenance or repairs to
the robot, make a trial run using the following procedures.
(1) If a safeguard enclosure has not yet been provided right after installation of
the robot, rope off or chain off around the movement area of the manipulator
in place of the safeguard enclosure, and observe the following points.
1. Use sturdy, stable posts which will not fall over easily.
2. The rope or chain should be easily visible by everyone around the robot.
3. Place a sign to keep the operator or other personnel from entering the
movement range of the manipulator.
(2) Check the following points before turning on the controller.
1. Is the robot securely and correctly installed?
2. Are the electrical connections to the robot correct?
3. Are items such as air pressure correctly supplied?
4. Is the robot correctly connected to peripheral equipment?
5. Have safety measures (safeguard enclosure, etc.) been taken?
6. Does the installation environment meet the specified standards.
(3) After the controller is turned on, check the following points from outside the
safeguard enclosure.
1. Does the robot start and stop as intended? Can the operation mode be
selected correctly?
2. Does each axis move as intended within the soft limits?
3. Does the end effector move as intended?
4. Are the signal transmissions to the end effector and peripheral equipment
correct?
5. Does emergency stop work?
6. Are the teaching and playback functions normal?
7. Are the safeguard enclosure and interlock working as intended?
8. Does the robot move correctly during automatic operation?
1-11
CHAPTER 1 Using the Robot Safely
For items 1) to 4), follow the precautions and procedure for each section. To
perform item 5), refer to the description in (2) below.
(2) Teaching
When performing teaching within the safeguard enclosure, comply with the
instructions listed below.
1) Check or perform the following points from outside the safeguard enclo-
sure.
1. Make sure that no hazards are present within the safeguard enclosure
by a visual check.
2. Check that the programming unit MPB operates correctly.
3. Check that no failures are found in the robot.
4. Check that emergency stop works correctly.
5. Select teaching mode and prohibit automatic operation.
2) Never enter the movement range of the manipulator while within the safe-
guard enclosure.
1-12
CHAPTER 1 Using the Robot Safely
8 Automatic Operation
Automatic operation described here includes all operations in AUTO mode.
1-13
CHAPTER 1 Using the Robot Safely
11 Warranty
The YAMAHA robots are designed and manufactured to be free from defects in
materials and workmanship. However, should any failure occur in the robot you
purchased, the YAMAHA warranty coverage is as follows.
Exceptions to the Warranty : This warranty will not apply in the following
cases:
• Fatigue arising due to the passage of time,
natural wear and tear occurring during opera-
tion (natural fading of painted or plated sur-
faces, deterioration of parts subject to wear)
• Minor natural phenomena which do not ef-
fect the capabilities of the robot (noise from
computers, motors, etc.).
Failure resulting from the following cases will not apply to warranty repair.
4) Use of any other than genuine parts and specified lubricant and grease.
1-14
CHAPTER 1 Using the Robot Safely
12 CE Marking
When the YAMAHA robots are exported to or used in EU (European Union)
countries, refer to the separate "YAMAHA robot controller owner's manual" or
"CE marking manual" for related information about CE marking.
1-15
MEMO
1-16
CHAPTER 2
Functions
1 Robot Manipulator
The YK-X series robots are available in 4-axis models having an X/Y-axis arm
(equivalent to human arm) and a Z/R-axis (equivalent to human wrist).
With these 4 axes, the YK-X series robots can move as shown in Fig. 2-1. By
attaching different types of end effector (gripper) to the end of the arm, a wide
range of tasks can be performed with high precision at high speeds.
The (+) and (-) signs show the direction of axis movement when the jog keys on
the programming unit are pressed (standard setting at the factory). Fig. 2-2 to Fig.
2-6 on the subsequent pages show part names and functions of each robot model.
X-axis arm
Y-axis
(+)
(–)
(–)
(–) (+)
R-axis
2-1
CHAPTER 2 Functions
Warning label 1
Warning label 2
Z-axis motor
R-axis motor
Z-axis spline
End effector attachment
Warning label 3
M4 ground terminal
Robot cable
Fig. 2-2 YK250X, YK350X, YK400X
2-2
CHAPTER 2 Functions
User tubing 1 (φ6 black) Eyebolt installation position X-axis movable mechanical stopper
Y-axis motor
Z-axis motor
R-axis motor
Y-axis arm
X-axis arm
Z-axis,R-axis pulley, belt
X-axis motor
End effector attachment
Warning label 3
Serial label
M4 ground terminal
D-sub connector for user wiring (No.1 to 20) Y-axis mechanical stopper Machine harness
R-axis motor
Z-axis motor
Y-axis motor
Y-axis arm
X-axis motor
End effector attachment
Warning label 3
Serial label
M4 ground terminal
2-4
CHAPTER 2 Functions
Ball screw
Machine harness
Warning label 1
(Same on opposite side)
Warning label 2 (Same on opposite side)
R-axis motor
Z-axis motor
Yaxis motor
X-axis arm
X-axis motor
Warning label 3
Serial label
M4 ground terminal
2-5
CHAPTER 2 Functions
Eyebolt installation position Window for X-axis origin adjustment (inside of cover)
mechanical stopper
machine harness
Ball screw
Y-axis arm
Z-axis motor, brake
Warning label 2
Y-axis motor R-axis motor
Warning label 3
Warning label1
User M4 tap
(Same on
opposite side)
R-axis origin sensor
Z-axis spline
X-axis motor
Robot cable
D-sub connector
for user wiring
Fan (No.1 to 20)
M4 ground terminal
2-6
CHAPTER 2 Functions
2 Robot Controller
The YK-X series robot comes with a robot controller (RCX40 or QRCX) accord-
ing to the particular order from the user.
For more details, refer to the separate "YAMAHA robot controller owner's
manual".
MOTOR
PWR MPB
OP.1 OP.3
RCX40
SRV
XM ERR
ROB
I/O
XY
YM
COM BATT
X
ROB
I/O Y
Z
ZR R
OP.2 OP.4
RGEN
ZM
STD.DIO
P
SAFETY N
RM ACIN
RCX40
YAMAHA
QRCX
POWER
CPU OK
SERVO
ALARM
QRCX
Fig. 2-7 Robot controller
2-7
CHAPTER 2 Functions
! CAUTION
Absolute reset must be performed after reinitializing the controller.
Before reinitializing the controller, read the descriptions in "3. Adjusting the ori-
gin" in Chapter 4 and make sure you thoroughly understand the procedure.
! CAUTION
When the controller is initialized, the "ARM LENGTH" and "OFFSET PULSE"
settings in the axis parameters will be erased, making the standard coordinate
settings invalid.
(For details on standard coordinates, see "5. Setting the Standard Coordinates"
in Chapter 4.)
If you do not want to change the origin position by initializing, make a note of
the "ARM LENGTH" and "OFFSET PULSE" settings before initializing, and re-
enter their settings after initialization is complete.
2-8
CHAPTER 3
Installation
2 Installation ..............................................................................3-5
2-1 Unpacking ........................................................................................ 3-5
2-2 Checking the product ....................................................................... 3-6
2-3 Moving the robot .............................................................................. 3-7
2-3-1 Moving the YK250X, YK350X, YK400X .......................................... 3-7
2-3-2 Moving the YK500X, YK600X, YK700X, YK800X, YK1000X,
YK1200X, YK550X .......................................................................... 3-8
2-4 Installing the robot........................................................................... 3-11
Working space Allow sufficient space margin to perform jobs (teaching, inspection,
repair, etc.)
For detailed information on how to install the robot controller, refer to the sepa-
rate "YAMAHA robot controller owner's manual".
WARNING
Avoid installing the robot in locations where the ambient conditions may ex-
ceed the allowable temperature or humidity, or in environments where water,
corrosive gases, metallic powder or dust are generated. Malfunction, failure or
short circuits may otherwise result.
WARNING
• This robot was not designed for operation in environments where inflamma-
ble or explosive substances are present.
• Do not use the robot in environments containing inflammable gas, dust or
liquids. Explosions or fire could otherwise result.
WARNING
Avoid using the robot in locations subject to electromagnetic interference, elec-
trostatic discharge or radio frequency interference. Malfunction may otherwise
occur.
3-1
CHAPTER 3 Installation
WARNING
Do not use the robot in locations subject to excessive vibration. Robot installa-
tion bolts may otherwise become loose causing the manipulator to fall over.
3-2
CHAPTER 3 Installation
Fxmax
Fzmax
Load
Mxmax
3-3
CHAPTER 3 Installation
WARNING
Do not place the robot on a moving installation base. Excessive loads will be
applied to the robot arm by movement of the installation base, resulting in dam-
age to the robot.
! CAUTION
The manipulator positioning might decrease if the installation surface precision
is insufficient.
! CAUTION
If the installation base is not sufficiently rigid and stable or a thin metallic plate
is attached to the installation base, vibration (resonance) may occur during
operation, causing detrimental effects on the manipulator work.
3-4
CHAPTER 3 Installation
2 Installation
2-1 Unpacking
WARNING
The robot and controller are heavy. Take sufficient care not to drop them during
moving or unpacking as this may damage the equipment or cause bodily injury.
! CAUTION
When moving the robot or controller by equipment such as a folk-lift that re-
quire a license, only properly qualified personnel may operate it. The equip-
ment and tools used for moving the robot should be serviced daily.
The YK-X series robot comes packed with a robot controller and accessories,
according to the order specifications. Using a carrying cart (dolly) or forklift,
move the package to near the installation base. Take sufficient care not to apply
shocks to the equipment when unpacking it.
YK250X, YK350X, YK400X
Robot manipulator
Case
Robot manipulator
3-5
CHAPTER 3 Installation
! CAUTION
If there is any damage due to transportation or insufficient parts, please notify
your YAMAHA sales office or dealer immediately.
Standard
STD. DIO
connector ( × 1)
Power plug ( × 1)
Terminator ( × 1)
Warning label ( × 1)
Owner's manual
D-sub connector/hood
( × 2)
Stoppers Eyebolts
(YK550X only; (×2 or ×3 for YK550X only)
RCX40controller or QRCXcontroller large×2, small×2)
Eyebolts are not supplied with the YK250X, YK350X and YK400X
Option
OP, DI connector
OP, DO connector
EXT, DIO connector
MPB programming unit Extension IO connector
3-6
CHAPTER 3 Installation
WARNING
Serious injury may occur if the robot falls and pins someone under it.
• Do not allow any part of your body to enter the area beneath the robot during
work.
• Always wear a helmet, safety shoes and gloves during work.
To check the mass of each robot, refer to "1-1 Basic specifications" in Chapter 7.
1) Fold the X and Y axis arms as shown in Fig. 3-4, and wind the robot cable
around the upper part of the pedestal, then fasten the robot cable with adhe-
sive tape so as not to cover the bolt installation holes.
2) Holding the support parts as shown in the figure with both hands, place the
robot on the installation base and secure it temporarily by tightening the bolts.
(For tightening torque to secure the robot firmly, see the next section, "2-4
Installing the robot".)
Support part
Robot cable
Support part
Bolt installation
hole
Fig. 3-4
3-7
CHAPTER 3 Installation
WARNING
Serious injury may occur if the robot falls and pins someone under it.
• Check that there are no cracks and corrosion on the eyebolt installation. If
found, do not use eyebolts to move the robot.
• Screw the eyebolts securely into the tapped holes until the bearing surface of
eyebolt makes tight contact with the bearing surface on the arm.
• Use a hoist and rope with carrying capacity strong enough to support the
robot weight.
• Make sure the rope stays securely on the hoist hook.
• Remove all loads attached to the robot manipulator end. If any load is still
attached, the robot may lose balance while being carried, and topple over
causing accidents.
! CAUTION
• When moving the robot by equipment such as cranes that require a license,
only properly qualified personnel may operate it.
• The equipment and tools used for moving the robot should be serviced daily.
To move a robot (for example, the YK500X) correctly and safely, follow the
procedure below. (See Fig. 3-5.) Use the same procedure to move other robots.
1) If the Z-axis is not at the origin position, perform return-to-origin from out-
side the safeguard enclosure. Then, turn off the controller and unplug the
robot cable from the controller. (The Z-axis is fixed at the origin position
prior to shipping.)
3) Fold the X and Y-axis arms as shown in the drawing, and clamp the Y axis
arm to the robot pedestal by using the stay and bolts that come with the robot.
If the arms cannot be folded in the carrying position due to the X-axis me-
chanical stoppers, then remove them. (When the robot is shipped, the me-
chanical stoppers are installed to provide the maximum movement range.)
4) Screw the two eyebolts securely into the tapped hole on the machined bear-
ing surface of the X-axis arm.
(Use three eyebolts for the YK550X.)
5) Wind the robot cable around the upper part of the robot pedestal so that it
does not hang up on the base mount, then fasten the cable end with adhesive
tape.
3-8
CHAPTER 3 Installation
6) Prepare two looped ropes with the same length to allow a good lifting bal-
ance, then pass each rope through each eyebolt and catch it on the hoist hook.
(3 looped ropes are needed for the YK550X.)
7) Slightly lift the hoist so that each rope has light tension to hold the robot. In
this state, remove the bolts securing the robot base to the pallet supplied or
installation base (if robot is to be moved to another installation base).
8) Using caution to keep the balance of the robot and avoid subjecting it to any
strong vibrations and shocks, operate the hoist carefully to move to the in-
stallation base. The angle between each rope and the arm surface should be
kept at 45 degrees or more.
9) Slightly lower the robot on the installation base and temporarily secure it by
tightening the bolts.
(For tightening torque to secure the robot firmly, see the next section, "2-4
Installing the robot".)
10) Remove the ropes, eyebolts and arm clamping stay, then reattach the cover
and the set screws on the X-axis arm. (Be sure to fit the set screws and the
cover in position to protect the tapped holes for eyebolts.) Keep the eyebolts,
arm clamping stay, bolts and pallet for future use in case the robot needs to be
moved or transported.
3-9
CHAPTER 3 Installation
Set screw
Eyebolt (2 pieces
supplied with the robot)
Hoist hook
Bearing surface for eyebolt
Rope
YK700X-YK1000X
45° or more
Bearing surface for eyebolt
YK1200X
Robot cable
Bolt (M12×20 : YK500X to YK1000X, YK550X Bearing surface for eyebolt
M16×25 : YK1200X)
Tightening toeque 71N•m (720kgf•cm)
3-10
CHAPTER 3 Installation
WARNING
When installing the robot, be sure to use the specified size and quantity of bolts
that match the depth of tapped holes in the installation base, and securely
tighten the bolts to the correct torque. If the bolts are not tightened correctly, the
robot might fall over during operation causing a serious accident.
Tightening torque
Robot Model Bolts Used Tightening torque
YK250X, YK350X ,YK400X M8 37N·m (380kgf · cm)
YK500X, YK600X,YK550X M10 71N·m (720kgf · cm)
YK700X, YK800X, YK1000X, YK1200X M12 128N·m (1310kgf · cm)
Installation base
3-11
CHAPTER 3 Installation
3 Protective Bonding
WARNING
Be sure to ground the robot and controller to prevent electrical shock.
WARNING
Turn off the controller before grounding the robot.
(Symbol 417-IEC-5019)
3) For details on protective bonding on the robot body to comply with CE mark-
ing, follow the instructions on protective bonding explained in the "YAMAHA
robot controller owner's manual" or "CE marking manual".
4) Use a ground cable with a conductor wire cross section of at least 2.0mm2
and a length within 1 meter.
3-12
CHAPTER 3 Installation
Ground symbol
M4 Ground terminal
3-13
CHAPTER 3 Installation
WARNING
• Before connecting the cables, check that there are no bends or breaks in the
connector pins of the robot cable and that the cables are not damaged. Bent
or broken pins or cable damage may cause malfunction of the robot.
• Ensure that the controller is off before connecting the robot cable to the
controller.
WARNING
In the RCX40 and QRCX controller, the MOTOR connectors XM and ZM, and
YM and RM each have identical shapes. In addition, the PI connectors XY and
ZR have identical shapes. Do not confuse these connectors when making con-
nections. Wrong connections may result in malfunction and hazardous situa-
tions.
WARNING
• If the connector installation is inadequate or if there are contact failures in the
pins, the robot may malfunction causing a hazardous situation. Reconfirm
that each connector is securely installed before turning on the controller.
• To attach the PI connector securely, tighten the screws supplied with the
robot.
• Take caution not to apply an excessive load to the connectors due to stress
or tension on the cables.
WARNING
Lay out the cables so that they do not obstruct the movement of the manipula-
tor. Determine the robot work area in which the robot cables will not interfere
with the load or workpiece picked up by the manipulator. (See "1-2 External
view and dimensions" in Chapter 7.) If the robot cables interfere with the mov-
able parts of the robot, the cables may be damaged causing malfunction and
hazardous situations.
WARNING
Lay out the robot cables so as to keep the operator or any other person from
tripping on them. Bodily injury may result if someone trips on the cables.
3-14
CHAPTER 3 Installation
XM XY M1 XM
YM XY M2 YM
ZM ZR M1 ZM
RM ZR M2 RM
ROB I/O
Robot cable XY PI 1
XY
ROB I/O
PI 2
ZR
ZR
3-15
CHAPTER 3 Installation
WARNING
Always turn off the controller and shut off air supply before attempting wiring
and piping work. If air or power is supplied during this work, the manipulator
may move erroneously causing a hazardous situation.
1) The YK-X series robots are equipped with user wires and air tubes in the
machine harness. The table below shows the number of wires and air tubes
available for each robot model.
Robot model User wiring User tubing
YK250X, YK350X, YK400X 10wires φ4, 3tubes
YK500X, YK600X, YK700X, YK800X, YK1000X, YK1200X 20wires φ6, 3tubes
YK550X 20wires φ6, 2tubes
(Robot models for custom specifications may have different wiring or tub-
ing.)
The specifications of the user wires and air tubes are shown below. Always
observe the specifications.
User Wiring
Rated voltage 30V
Allowable current 1.5A
Nominal cross-section area of conductor 0.2mm2
Shield Yes
User Tubing
Maximum pressure 0.58MPa (6Kgf/cm2)
Outer diameter × inner diameter φ4mm×φ2.5mm
φ6mm×φ4mm
Fluid Dry clean air not containing deteriorated
compressor oil; filtration 40µm or less
2) A D-sub connector for user wiring and a bulkhead union for user tubing are
provided one each on the arm side and pedestal side. Refer to "1-2 External
view and dimensions" in Chapter 7 for the locations.
3-16
CHAPTER 3 Installation
1 1 Brown
2 2 Red
3 3 Orange
4 4 Blue
5 5 Violet
User signal line IO IO
6 6 Grey
(Arm side) (Base side)
7 7 White
8 8 Black
9 9 Brown
10 10 Red
11 11 Orange
12 12 Blue
13 13 Violet
14 14 Grey
Shield 15 15 Green
3-17
CHAPTER 3 Installation
4) As shown in Fig. 3-9, solder the user cable wires to the D-sub connector
(supplied with the robot). Reattach the hood to the D-sub connector after
soldering, then plug it into the user wiring connector.
The connector pinouts as viewed from the solder side are shown below.
Hood
Soldering
Cable to be
prepared by user
D-sub connector
8 7 6 5 4 3 2 1 1 2 3 4 5 6 7 8
15 14 13 12 11 10 9 9 10 11 12 13 14 15
13 12 11 10 9 8 7 6 5 4 3 2 1 1 2 3 4 5 6 7 8 9 10 11 12 13
25 24 23 22 21 20 19 18 17 16 15 14 14 15 16 17 18 19 20 21 22 23 24 25
Fig. 3-9
WARNING
The user cable wires should have a shield wire. Connect it to the same No. pin
in the D-sub connector on the robot side, which also connects to the shield
wire. If this task is omitted, noise may cause malfunction of the robot.
WARNING
Securely attach the D-sub connector (supplied with the robot) into the D-sub
connector on the robot side, by tightening the screws on the connector hood. If
this connector comes loose or comes off, malfunction may result.
WARNING
Avoid fastening the user cable or tube with the machine harness, as this may
lead to harness breakage and malfunction.
3-18
CHAPTER 3 Installation
WARNING
Make sure that the user cable attached to the D-sub connector for user wiring
and the tube attached to the bulkhead union for user tubing will not interfere
with the robot movement, entangle around the robot or flap around during op-
eration. Wiring and tubing might then be damaged causing malfunction of the
robot.
WARNING
Lay out the user cable attached to the D-sub connector for user wiring and the
tube attached to the bulkhead union for user tubing so that they do not obstruct
the movement of the operator or any other persons. Bodily injury may result if
anyone trips on the cable or air tube.
! CAUTION
The D-sub connector supplied with the robot should be connected to the arm
side by pin contact, and to the pedestal side by socket contact. Use caution at
these points when soldering.
! CAUTION
Be sure to use the D-sub connector and hood which are supplied with the ro-
bot. Using other types may result in contact failure.
5) To check the operation and signal transmission between the end effector and
the controller or peripheral equipment after making connections, refer to "6.
Trial operation" in Chapter 1.
3-19
CHAPTER 3 Installation
2) The R-axis tolerable moment of inertia and the acceleration coefficient ver-
sus R-axis moment of inertia for each robot model are shown in Fig. 3-10 to
Fig. 3-78 on the subsequent pages. The symbols AX, AY, and AR in each figure
respectively indicate the acceleration coefficients of the X-axis, Y-axis and
R-axis. The symbol IR (JR) is the moment of inertia of the load around the R-
axis and m is the tip mass.
Example: YK250X
Assume that the mass of the load installed to the R-axis is 1.5kg and the
moment of inertia around the R-axis is 0.02kgm2 (0.2kgf·cm·sec2). When the
tip mass parameter is set to 2kg, the robot can be operated by reducing the
X, Y and R-axis acceleration coefficients to 60%, as can be seen from Fig. 3-
11.
Be sure to select an optimum tip mass and acceleration coefficient param-
eters that meet the mass of the load and moment of inertia before using the
robot.
To make settings for the tip mass and acceleration coefficient, refer to the
separate "YAMAHA robot controller owner's manual".
3) Methods for calculating the moment of inertia of the load are shown in Sec-
tion 6-2, however, it is not easy to precisely figure out these values.
If a calculated value smaller than the actual moment of inertia is set, residual
vibrations may occur. If this happens, reduce the acceleration coefficient pa-
rameter even further.
! CAUTION
The robot must be operated with correct tolerable moment of inertia and accel-
eration coefficients according to the manipulator tip mass and moment of iner-
tia. If this is not observed, premature end to the life of the drive units, damage to
the robot parts or residual vibration during positioning may result.
3-20
CHAPTER 3 Installation
! CAUTION
Depending on the Z-axis position, vibration may occur when the X, Y or R-axis
moves. If this happens, reduce the X, Y or R-axis acceleration to an appropri-
ate level.
! CAUTION
If the moment of inertia is too large, vibration may occur on the Z-axis depend-
ing on its operation position. If this happens, reduce the Z-axis acceleration to
an appropriate level.
3-21
CHAPTER 3 Installation
80
60
40
20
0
0.01 0.02 0.03 0.04 0.05 Ir (kgm2)
0 0.1 0.2 0.3 0.4 0.5 Jr (kgf • cm • sec2)
80
60
40
20
80
60
40
20
3-22
CHAPTER 3 Installation
80
60
40
20
0
0.01 0.02 0.03 0.04 0.05 Ir (kgm2)
0 0.1 0.2 0.3 0.4 0.5 Jr (kgf • cm • sec2)
80
60
40
20
80
60
40
20
3-23
CHAPTER 3 Installation
80
60
40
20
80
60
40
20
0
0.01 0.02 0.03 0.04 0.05 Ir (kgm2)
0 0.1 0.2 0.3 0.4 0.5 Jr (kgf • cm • sec2)
80
60
40
20
3-24
CHAPTER 3 Installation
80
60
40
20
80
60
40
20
80
60
40
20
3-25
CHAPTER 3 Installation
80
60
40
20
80
60
40
20
80
60
40
20
3-26
CHAPTER 3 Installation
80
60
40
20
80
60
40
20
3-27
CHAPTER 3 Installation
80
60
40
20
80
60
40
20
80
60
40
20
3-28
CHAPTER 3 Installation
80
60
40
20
80
60
40
20
80
60
40
20
3-29
CHAPTER 3 Installation
80
60
40
20
80
60
40
20
3-30
CHAPTER 3 Installation
80
60
40
20
80
60
40
20
0
0.1 0.2 0.3 Ir (kgm2)
0 1.0 2.0 3.0 Jr (kgf • cm • sec2)
80
60
40
20
3-31
CHAPTER 3 Installation
80
60
40
20
0
0.1 0.2 0.3 Ir (kgm2)
0 1.0 2.0 3.0 Jr (kgf • cm • sec2)
80
60
40
20
80
60
40
20
0
0.1 0.2 0.3 Ir (kgm2)
0 1.0 2.0 3.0 Jr (kgf • cm • sec2)
3-32
CHAPTER 3 Installation
80
60
40
20
0
0.1 0.2 0.3 Ir (kgm2)
0 1.0 2.0 3.0 Jr (kgf • cm • sec2)
80
60
40
20
0
0.1 0.2 0.3 Ir (kgm2)
0 1.0 2.0 3.0 Jr (kgf • cm • sec2)
80
60
40
20
0
0.1 0.2 0.3 Ir (kgm2)
0 1.0 2.0 3.0 Jr (kgf • cm • sec2)
3-33
CHAPTER 3 Installation
80
60
40
20
0
0.1 0.2 0.3 Ir (kgm2)
0 1.0 2.0 3.0 Jr (kgf • cm • sec2)
80
60
40
20
0
0.1 0.2 0.3 Ir (kgm2)
0 1.0 2.0 3.0 Jr (kgf • cm • sec2)
80
60
40
20
3-34
CHAPTER 3 Installation
80
60
40
20
0
0.1 0.2 0.3 Ir (kgm2)
0 1.0 2.0 3.0 Jr (kgf • cm • sec2)
80
60
40
20
0
0.1 0.2 0.3 Ir (kgm2)
0 1.0 2.0 3.0 Jr (kgf • cm • sec2)
80
60
40
20
0
0.1 0.2 0.3 Ir (kgm2)
0 1.0 2.0 3.0 Jr (kgf • cm • sec2)
3-35
CHAPTER 3 Installation
80
60
40
20
0
0.1 0.2 0.3 Ir (kgm2)
0 1.0 2.0 3.0 Jr (kgf • cm • sec2)
80
60
40
20
0
0.1 0.2 0.3 Ir (kgm2)
0 1.0 2.0 3.0 Jr (kgf • cm • sec2)
80
60
40
20
0
0.1 0.2 0.3 Ir (kgm2)
0 1.0 2.0 3.0 Jr (kgf • cm • sec2)
3-36
CHAPTER 3 Installation
80
60
40
20
0
0.1 0.2 0.3 Ir (kgm2)
0 1.0 2.0 3.0 Jr (kgf • cm • sec2)
80
60
40
20
0
0.1 0.2 0.3 Ir (kgm2)
0 1.0 2.0 3.0 Jr (kgf • cm • sec2)
80
60
40
20
3-37
CHAPTER 3 Installation
80
60
40
20
0
0.1 0.2 0.3 Ir (kgm2)
0 1.0 2.0 3.0 Jr (kgf • cm • sec2)
80
60
40
20
0
0.1 0.2 0.3 Ir (kgm2)
0 1.0 2.0 3.0 Jr (kgf • cm • sec2)
80
60
40
20
0
0.1 0.2 0.3 Ir (kgm2)
0 1.0 2.0 3.0 Jr (kgf • cm • sec2)
3-38
CHAPTER 3 Installation
80
60
40
20
0
0.1 0.2 0.3 Ir (kgm2)
0 1.0 2.0 3.0 Jr (kgf • cm • sec2)
80
60
40
20
0
0.1 0.2 0.3 Ir (kgm2)
0 1.0 2.0 3.0 Jr (kgf • cm • sec2)
80
60
40
20
0
0.1 0.2 0.3 Ir (kgm2)
0 1.0 2.0 3.0 Jr (kgf • cm • sec2)
3-39
CHAPTER 3 Installation
80 80
60 60
40 40
20 20
0 0
0.5 1.0 1.5 2.0 2.5 IR (kgm2) 0.5 1.0 1.5 2.0 2.5 IR (kgm2)
0 5 10 15 20 25 JR (kgf • cm • sec2) 0 5 10 15 20 25 JR (kgf • cm • sec2)
80 80
60 60
40 40
20 20
0 0
0.5 1.0 1.5 2.0 2.5 IR (kgm2) 0.5 1.0 1.5 2.0 2.5 IR (kgm2)
0 5 10 15 20 25 JR (kgf • cm • sec2) 0 5 10 15 20 25 JR (kgf • cm • sec2)
80 80
60 60
40 40
20 20
0 0
0.5 1.0 1.5 2.0 2.5 IR (kgm2) 0.5 1.0 1.5 2.0 2.5 IR (kgm2)
0 5 10 15 20 25 JR (kgf • cm • sec2) 0 5 10 15 20 25 JR (kgf • cm • sec2)
3-40
CHAPTER 3 Installation
80 80
60 60
40 40
20 20
0 0
0.5 1.0 1.5 2.0 2.5 IR (kgm2) 0.5 1.0 1.5 2.0 2.5 IR (kgm2)
0 5 10 15 20 25 JR (kgf • cm • sec2) 0 5 10 15 20 25 JR (kgf • cm • sec2)
80 80
60 60
40 40
20 20
0 0
0.5 1.0 1.5 2.0 2.5 IR (kgm2) 0.5 1.0 1.5 2.0 2.5 IR (kgm2)
0 5 10 15 20 25 JR (kgf • cm • sec2) 0 5 10 15 20 25 JR (kgf • cm • sec2)
80 80
60 60
40 40
20 20
0 0
0.5 1.0 1.5 2.0 2.5 IR (kgm2) 0.5 1.0 1.5 2.0 2.5 IR (kgm2)
0 5 10 15 20 25 JR (kgf • cm • sec2) 0 5 10 15 20 25 JR (kgf • cm • sec2)
3-41
CHAPTER 3 Installation
80 80
60 60
40 40
20 20
0 0
0.5 1.0 1.5 2.0 2.5 IR (kgm2) 0.5 1.0 1.5 2.0 2.5 IR (kgm2)
0 5 10 15 20 25 JR (kgf • cm • sec2) 0 5 10 15 20 25 JR (kgf • cm • sec2)
80 80
60 60
40 40
20 20
0 0
0.5 1.0 1.5 2.0 2.5 IR (kgm2) 0.5 1.0 1.5 2.0 2.5 IR (kgm2)
0 5 10 15 20 25 JR (kgf • cm • sec2) 0 5 10 15 20 25 JR (kgf • cm • sec2)
80 80
60 60
40 40
20 20
0 0
0.5 1.0 1.5 2.0 2.5 IR (kgm2) 0.5 1.0 1.5 2.0 2.5 IR (kgm2)
0 5 10 15 20 25 JR (kgf • cm • sec2) 0 5 10 15 20 25 JR (kgf • cm • sec2)
3-42
CHAPTER 3 Installation
80
60
40
20
0
0.04 0.08 0.1 0.12 IR (Kgm2)
0.0 0.4 0.8 1.0 1.2 JR (Kgf • cm • sec2)
80
60
40
20
0
0.04 0.08 0.1 0.12 IR (Kgm2)
0.0 0.4 0.8 1.0 1.2 JR (Kgf • cm • sec2)
80
60
40
20
0
0.04 0.08 0.1 0.12 IR (Kgm2)
0.0 0.4 0.8 1.0 1.2 JR (Kgf • cm • sec2)
3-43
CHAPTER 3 Installation
! CAUTION
If the acceleration on the X, Y or R axis is too high compared to the moment of
inertia of the load, feedback error 2 or over-current error may occur. If this
happens, reduce the acceleration.
80
60
40
20
0
0.04 0.05 0.08 0.1 0.12 IR (Kgm2)
0.0 0.4 0.5 0.8 1.0 1.2 JR (Kgf • cm • sec2)
80
60
40
20
0
0.04 0.05 0.08 0.1 0.12 IR (Kgm2)
0.0 0.4 0.5 0.8 1.0 1.2 JR (Kgf • cm • sec2)
3-44
CHAPTER 3 Installation
80
60
40
20
0
0.04 0.05 0.08 0.1 0.12 IR (Kgm2)
0.0 0.4 0.5 0.8 1.0 1.2 JR (Kgf • cm • sec2)
80
60
40
20
0
0.04 0.05 0.08 0.1 0.12 IR (Kgm2)
0.0 0.4 0.5 0.8 1.0 1.2 JR (Kgf • cm • sec2)
80
60
40
20
0
0.04 0.05 0.08 0.1 0.12 IR (Kgm2)
0.0 0.4 0.5 0.8 1.0 1.2 JR (Kgf • cm • sec2)
3-45
CHAPTER 3 Installation
Fig. 3-80
3-46
CHAPTER 3 Installation
Fig. 3-81
4) Moment of inertia for prism
The equation for the moment of inertia for a prism that has a rotation center
as shown in Fig. 3-82 is given as follows.
ρ abc(a 2 +b 2 ) m(a2 +b 2 )
I= = (kgm2)
12 12
ρ abc(a 2 +b 2 ) W(a2 +b 2 )
J= = (kgf · cm · sec2)
12g 12g
... (Eq. 3.4)
c 1/2a
b
a
ρ : Density (kg/m3, kg/cm3)
g : Gravitational acceleration (cm/sec2)
m : Mass of prism (kg)
W : Weight of prism (kgf)
Fig. 3-82
3-47
CHAPTER 3 Installation
5) When the object's center line is offset from the rotation center.
The equation for the moment of inertia, when the center of the cylinder is
offset by the distance "x" from the rotation center as shown in Fig. 3-83, is
given as follows.
ρπD 4 h ρπD 2 hx2 2
I= + = mD + mx2 (kgm2)
32 4 8 Center line
ρπD h
4
ρπD hx
2 2
J= + Rotation center
32g 4g
2 2
= WD + Wx (kgf · cm · sec2)
8g g h
... (Eq. 3.5)
In the same manner, the moment of inertia of a cylinder as shown in Fig. 3-84
is given by
ρπ D 2h D2 h2 ρπ D 2 h x 2 m D2 h2
I= ( + )+ = ( + ) + mx2 (kgm2)
16 4 3 4 4 4 3
ρπ D 2 h D2 h2 ρπ D 2h x 2
J= ( + )+
16g 4 3 4g Cneter line
2 2 2
W D h Wx 2
= ( + ) + (kgf · cm · sec )
4g 4 3 g
... (Eq. 3.6) D
Fig. 3-84
In the same manner, the moment of inertia of a prism as shown in Fig. 3-85 is
given by
ρabc(a2 + b 2 ) m(a2 +b 2 )
I= + ρabcx2= + mx2 (kgm2)
12 12 Center line
ρabc(a 2 + b2 ) ρabcx2
J= +
12g g
W(a 2 + b2 ) 2
= + Wx (kgf · cm · sec2)
12g g c
x
... (Eq. 3.7) b
a
3-48
CHAPTER 3 Installation
2cm
Stay
2cm
2cm
1cm
4cm 10cm
1cm
6cm
Chuck
Workpiece
4cm
2cm
Fig. 3-86
2cm
5cm
2cm
12cm
Fig. 3-87
The moment of inertia of the stay (Js) is then calculated from Eq. 3-7.
0.37 × 52
Js = 0.37 × (12 +2 ) +
2 2
= 0.014 (kgf · cm · sec2)
12 × 980 980
3-49
CHAPTER 3 Installation
10cm R-axis
When the chuck form resem- 2cm
10cm R-axis
When the workpiece form
resembles that shown in Fig.
3-89, the weight of the
workpiece (Ww) is
ρπD2h 0.0078π × 22 × 4
Ww = = 4cm
4 4
= 0.098 (kgf)
4) Total weight
3-50
CHAPTER 3 Installation
WARNING
Before attaching the end effector, be sure to turn off the controller.
The manipulator part to which an end effector is attached must have adequate
strength and rigidity, as well as gripping force to prevent positioning errors. Table
3-1 shows the maximum load that can be applied to the end effector attachment
of each robot model. Recommended methods for attaching end effectors are shown
in Table 3-2 and Fig. 3-92. Refer to Fig. 3-90 for details on the end effector
attachment of each robot model. (For the YK550X, refer to "1-2 External view
and dimensions" in Chapter 7.)
When checking end effector operation, refer to "6 Trial Operation" in Chapter 1.
φ5 +0.2
0 (Hole for attaching user tool or
R-axis rotation during direct teaching)
Z-axis mechanical stopper
36
φ12 0
-0.018
M8×1.25, depth 15
φ7 +0.2
0 (Hole for attaching user tool or
R-axis rotation during direct teaching)
Z-axis mechanical stopper
φ18 0
-0.018
M12×1.75, depth 20
3-51
CHAPTER 3 Installation
φ8 +0.2
0 (Hole for attaching user tool or
R-axis rotation during direct teaching)
Z-axis mechanical stopper
50.5
O-ring groove for clean room models
45(φ22 range)
0
φ22 -0.021
M12×1.75, depth 20
φ10 +0.2
0
(Hole for attaching user tool or
R-axis rotation during direct teaching)
45
φ25 -0.01
-0.02
φ39
M16×2 depth25
! CAUTION
The horizontal hole provided in the spline is for attaching a user tool or R-axis
rotation during direct teaching.
Do not insert a pin or rod into this hole in order to stop a user tool from rotating.
Doing so may damage the spline.
When inserting a rod into this hole to rotate the R-axis, use a round rod with a
diameter slightly smaller than the diameter of each hole. Avoid using a square
rod because the spline might be damaged by the edge of the rod.
3-52
CHAPTER 3 Installation
Table 3-1
FXYmax FZmax FRmax MRmax Mmax
Robot Model N kgf N kgf N kgf Nm kgfm Nm kgfm
YK250X 46 5 40 4 121 12 6 0.6 5 0.5
YK350X 46 5 40 4 121 12 6 0.6 5 0.5
YK400X 46 5 40 4 121 12 6 0.6 5 0.5
YK500X 115 12 89 9 253 26 12 1.3 10 1.0
YK600X 115 12 89 9 253 26 12 1.3 10 1.0
YK700X 376 38 178 18 464 47 47 4.8 22 2.3
YK800X 376 38 159 16 464 47 47 4.8 20 2.0
YK1000X 341 35 159 16 464 47 43 4.4 20 2.0
YK1200X 441 45 39 4 1215 124 98 10.0 4.9 0.5
YK550X 300 31 135 14 295 30 18 1.8 19 1.9
End effector
Stay
FRmax Mmax
MRmax
FxYmax
Fzmax
3-53
CHAPTER 3 Installation
Table 3-2
Number of Tightening torque
Bolts Used Hole diameter(mm)
Robot Model bolts Nm kgf·cm
+0.018
YK250X M4 or lager 2 or more 4.5 46 12 0
+0.018
YK350X M4 or lager 2 or more 4.5 46 12 0
+0.018
YK400X M4 or lager 2 or more 4.5 46 12 0
+0.018
YK500X M6 or lager 2 or more 15.3 156 18 0
+0.018
YK600X M6 or lager 2 or more 15.3 156 18 0
+0.021
YK700X M8 or lager 2 or more 37.0 380 22 0
+0.021
YK800X M8 or lager 2 or more 37.0 380 22 0
+0.021
YK1000X M8 or lager 2 or more 37.0 380 22 0
YK1200X M10 or lager 2 or more 74.0 760 25 ±0.01
+0.018
YK550X M6 or lager 2 or more 15.3 156 16 0
Hole diameter
Bolt
Slot
Spline shaft
Tapped hole
Fig. 3-92
3-54
CHAPTER 3 Installation
WARNING
The end effector attachment must have adequate strength to withstand the
loads listed in Table 3-1. If too weak, the attachment may break during robot
operation and fragments fly off causing accidents or injuries.
WARNING
The end effector attachment must have sufficient rigidity versus the loads listed
in Table 3-1. If this rigidity is inadequate, the end effector may vibrate during
robot operation causing bad effects on the manipulator operation.
WARNING
• When the end effector is attached by slot clamping, always observe the con-
ditions listed in Table 3-2. If these are ignored, the end effector may come
loose and fly off during robot operation, resulting in an accident or injury.
• In cases where other attachment methods are used, be sure that the end
effector will not come off when the loads listed in Table 3-1 are applied.
WARNING
• The tapped hole (see Figs. 3-90 and 3-92) provided on the lower part of the
end effector attachment should be used only for preventing the end effector
from coming loose.
• Do not fasten the end effector just by using this tapped hole. If the end effector
is fastened only with this tapped hole, it may come loose from the attachment
during robot operation and fly off resulting in accidents or injuries.
! CAUTION
Do not attempt to secure the user tool to the spline shaft by using the tapped
hole (see Figs. 3-90 and 3-92) at the lower part of the end effector attachment,
which will apply an axial force to the user tool positioning circlip (retaining ring).
Trying to secure the tool in this way will damage the retaining ring.
3-55
CHAPTER 3 Installation
ARmax
Amax AXYmax
Azmax
WARNING
The gripping force of the end effector must have a sufficient extra margin of
strength to prevent the workpiece from coming loose and flying off during robot
operation.
If the gripping force is too weak, the workpiece may come loose and fly off
causing accidents or injuries.
3-56
CHAPTER 3 Installation
WARNING
Always turn off the controller before changing the movement range with me-
chanical stoppers.
! CAUTION
When the mechanical stoppers are installed, the soft limits must be set to a
point inside the mechanical stopper positions. (Refer to "4 Setting the Soft Lim-
its" in Chapter 4.)
! CAUTION
When installing the mechanical stoppers, use caution not to allow the mechanical
stoppers to make contact with the urethane damper (see Fig. 3-97 to 3-98). If
these make contact, the urethane damper might come off.
3-57
CHAPTER 3 Installation
3) Place a sign indicating the robot is being adjusted, to keep others from touch-
ing the controller switch.
8) Check that no one is inside the safeguard enclosure when turning on the
controller.
Table 3-4
Robot Model Bolt size Tightening torque(kgf · cm) Tightening torque(N · m)
YK500X,YK600X M6 156 15.3
YK700X,YK800X,YK1000X M8 380 37.2
YK1200X M10 720 70.6
3-58
CHAPTER 3 Installation
122°
92 °
°
62
°
32
2°
Y-axis Mechanical stopper(fixation)
93°
°
63
°
33
3°
Y-axis Mechanical stopper(fixation) Tapped hole for stopper installation X-axis Mechanical stopper
3-59
CHAPTER 3 Installation
128°
103°
78 °
°
53
°
28
3°
3-60
7-2 YK550X
To change the X-axis mechanical stopper positions, use the procedure below while
referring to Fig. 3-97.
1) Turn the robot X-axis arm so that it faces the machine front.
3) The mechanical stoppers are not installed at the time of shipment, but the
robot has fixed stoppers cast integrally with the arm. These are used for the
maximum working envelope. To narrow the movement range, install the
mechanical stoppers (supplied with the robot) securely in the desired positions
A to C. Use a slotted screwdriver to tighten the stopper all the way into the
tapped holes.
For example, when the mechanical stoppers are installed in position A in Fig.
3-97, the X-axis arm is allowed to turn though an angle of 65 degrees from
the front of the arm to the mechanical stopper.
3-61
CHAPTER 3 Installation
93°
65
°
Installation position of
X-axis mechanical stoppers
35
(Remove the cover.) A
°
B
5°
C
B
A
Urethane damper
(When installing the mechanical
stoppers, use caution not to allow
the mechanical stoppers to make
contact with the urethane dampers.)
X-axis arm
Stopper
3-62
CHAPTER 3 Installation
1) Turn the robot X and Y-axis arms so that they are nearly straight.
2) The mechanical stoppers are not installed at the time of shipment, but the
robot has fixed stoppers cast integrally with the arm. These are used for the
maximum working envelope. To narrow the movement range, install the
mechanical stoppers (supplied with the robot) securely in the desired positions
A to E. Use a slotted screwdriver to tighten the stopper all the way into the
tapped holes.
For example, when the mechanical stoppers are installed in position A in Fig.
3-98, the Y-axis arm is allowed to turn though an angle of 121 degrees from
the front of the arm to the mechanical stopper.
Urethane damper
(When installing the mechanical
stoppers, use caution not to allow D C
B
the mechanical stoppers to make E
contact with the urethane dampers.) A
E A
D B
C
5°
34
°
Y-axis mechanical
stopper position
63
°
92°
121°
148°
Stopper
3-63
CHAPTER 3 Installation
1) X and Y axes
1. Do not attempt operation outside the working envelope. On the YK-X
series, the origin can be set at any position. The working envelope de-
scribed in this manual is an area with the robot frontal reference.
2. Interference positions where a load may touch the robot within the work-
ing envelope and their radii are shown in the figure. Here, "a", "b" and "c"
are the respective interference positions with the base flange, base rear
panel, and base. Use caution not to allow the robot load to interfere with
any part of the robot.
3. Interference positions where a load might touch the robot when the robot
strikes the X-axis or Y-axis mechanical stoppers set for the maximum
working envelope and their radii are shown at the mechanical stopper po-
sitions. Here, "a", "b" and "c" are the respective interference positions
with the base flange, base rear panel, and base.
2) Z-axis
Do not attempt work outside the working envelope. In particular, do not at-
tempt work in the area between the working envelope and mechanical stop-
per position. Mechanical stoppers are installed at both the upper and lower
ends of the movement range.
WARNING
The robot cable, user wiring or tubing may be damaged if the robot load inter-
feres with them resulting in hazardous robot malfunctions. Do not operate at
points where the load may interfere with the robot cable, user wiring or tubing.
3) R-axis
The R-axis has no mechanical stoppers.
! CAUTION
Since the R-axis has no mechanical stoppers, make certain that the end effec-
tor wiring and tubing do not become entangled during operation.
3-64
CHAPTER 3 Installation
1. When the robot strikes the X-axis or Y-axis mechanical stopper or another
object, or when the R-axis collides with an object, speed reduction gears
are locked while being meshed if the collision impact is large. If this hap-
pens, please contact our sales office or dealer.
2. When the robot strikes the Z-axis upper mechanical stopper excessively,
the urethane damper may be splayed beyond the retaining ring. In this
case, return the urethane damper to its original state. (All models except
for YK550X)
3-65
MEMO
3-66
CHAPTER 4
Adjustment
1 Overview .................................................................................4-1
2 Safety Precautions .................................................................4-1
3 Adjusting the origin .................................................................4-2
3-1 Absolute reset method ..................................................................... 4-3
3-1-1 Sensor method (X-axis, Y-axis, and R-axis) .................................... 4-3
3-1-2 Mark method (X-axis, Y-axis, and R-axis) ....................................... 4-4
3-1-3 Stroke end method (Z-axis) ............................................................. 4-4
3-2 Machine reference ........................................................................... 4-5
3-3 Absolute reset procedures ............................................................... 4-6
3-3-1 Sensor method (X-axis, Y-axis, and R-axis) .................................... 4-6
3-3-2 Mark method (X-axis, Y-axis, and R-axis) ....................................... 4-8
3-3-2-1 Absolute reset with servo on (re-reset) ....................................... 4-9
3-3-2-2 Absolute reset with servo off (re-reset) ..................................... 4-11
3-3-2-3 Absolute reset with servo on. (new reset) ................................. 4-13
3-3-2-4 Absolute reset with servo off. (new reset) ................................. 4-16
3-3-3 Stroke end method (Z-axis) ........................................................... 4-24
3-4 Changing the origin position and adjusting the machine reference .... 4-25
3-4-1 Sensor method .............................................................................. 4-26
3-4-1-1 YK250X, YK350X, YK400X ....................................................... 4-26
3-4-1-2 YK500X, YK600X, YK700X,YK800X, YK1000X ........................ 4-34
3-4-1-3 YK550X ..................................................................................... 4-44
3-4-2 Mark method ................................................................................. 4-50
3-4-3 Stroke end method ........................................................................ 4-51
3-4-3-1 YK250X, YK350X, YK400X, YK500X, YK600X, YK700X,
YK800X, YK1000X, YK1200X ................................................... 4-51
3-4-3-2 YK550X ..................................................................................... 4-55
1 Overview
YAMAHA robots have been completely adjusted at the factory or by the sales
representative before shipment, including the origin position adjustment. If the
operating conditions are changed and the robot must be adjusted, then follow the
procedures described in this chapter.
2 Safety Precautions
(1) Read and understand the contents of this chapter completely before attempt-
ing to adjust the robot.
(2) Place a conspicuous sign indicating the robot is being adjusted, to prevent
others from touching the controller switch, programming unit or operation
panel.
(3) If a safeguard enclosure has not yet been provided right after installation of
the robot, rope off or chain off the movement area around the manipulator in
place of a safeguard enclosure, and observe the following points.
qUse stable posts which will not fall over easily.
wThe rope or chain should be easily visible by everyone around the robot.
ePlace a conspicuous sign prohibiting the operator or other personnel from
entering the movement area of the manipulator.
(4) To check operation after adjustment, refer to "6. Trial Operation" in Chapter 1.
4-1
CHAPTER 4 Adjustment
! CAUTION
If any of the above cases occur after installing the robot, absolute reset must be
performed again. To perform absolute reset, move the robot arms back to their
origin positions where the robot does not interfere with peripheral equipment
after the setup is complete.
! CAUTION
After performing absolute reset, move the robot to a known point to check
whether the origin position is correctly set. When doing this check, move the
robot at the slowest possible speed.
! CAUTION
The standard coordinate and point data must be reset when the origin position
is changed.
! CAUTION
Make point data setting after changing the origin position.
After changing the origin position, do not use the previous point data.
4-2
CHAPTER 4 Adjustment
There are three absolute reset methods for the YK-X series: the sensor method,
mark method, and stroke end method.
The X-axis, Y-axis, and R-axis use the sensor method as the initial setting, while
the Z-axis uses the stroke end method.
WARNING
Serious injury might occur from physical contact with the robot during opera-
tion.
Never enter within the robot movement range during absolute reset.
! CAUTION
The origin cannot be detected in any axis which is not positioned on the plus
side from the origin (See Fig. 4-2.) before starting the return-to-origin opera-
tion. (Factory setting at shipment.)
In this case, press the STOP key to interrupt the return-to-origin operation,
move the target axis to the plus side of the origin, and reperform the origin
return operation.
If the return-to-origin operation is not interrupted, the robot will continue the
operation and may collide with the mechanical stopper or a peripheral device.
Since a mechanical stopper is not provided in the R-axis, the wiring and piping
installed on the end effecter may be wound up by the operation.
4-3
CHAPTER 4 Adjustment
(1) Move the robot in step jog while the servo is on.
---- Select this method when the mark (sticker, slit, or similar) indicating
the origin position can be seen from outside the robot movement range.
(2) Move the robot manually while the servo is off.
---- Select this method when the mark (sticker, slit, or similar) indicating
the origin position cannot be seen from outside the robot movement range.
! CAUTION
Use the teaching pendant (MPB) or the RS-232C port when using the mark
method for absolute reset. You cannot use dedicated inputs to perform abso-
lute reset.
! CAUTION
The deviation between the origin position marks must be within a specified
range (repeatability tolerance) when performing absolute reset at the same
positions as the previous absolute reset. (See Fig. 4-4.)
A position deviation (positional shift) will occur if absolute reset is performed at
a position outside the repeatability tolerance or at a position different from the
previous absolute reset position.
Use the supplied origin position stickers to put a mark on the origin positions of
the X-axis, Y-axis and R-axis, so that you can perform absolute reset at the
origin positions within the tolerance range.
Origin position repeatability (tolerance) values for each robot axis are shown in
Table 4-1.
WARNING
Serious injury might occur from physical contact with the robot during opera-
tion.
Never enter within the robot movement range during absolute reset.
4-4
CHAPTER 4 Adjustment
! CAUTION
The machine reference must be adjusted within a specified range to keep the
repeatability precision of the absolute reset position. (The machine reference is
factory-adjusted prior to shipping.)
If the origin position is changed, the machine reference must be readjusted. For
information on how to adjust the machine reference, refer to "3-4 Changing the
origin position and adjusting the machine reference" in Chapter 4.
When the temperature of the robot joint sections is high immediately after the
robot has been operated, the machine reference value might be outside the
specified range (40 to 60%). When checking or adjusting the machine refer-
ence value, always make sure that the temperature of the robot joint sections
has returned to room temperature.
Recommended machine reference value: 40 to 60%
Machine reference
Origin signal detection
ON
Resolver
A B
M4= 66
M1 M2 M3 M4 M5
WARNING
Serious injury might occur from physical contact with the robot during opera-
tion.
Never enter within the robot movement range during absolute reset.
The operation procedure using the MPB is described next. (Press the ESC key on
the MPB if you want to return to the preceding step.)
See the "YAMAHA robot controller owner's manual" for information on operat-
ing the robot controller.
1) Check that no one is inside the safeguard enclosure and then turn on the
controller.
2) Place a sign indicating the robot is being adjusted, to keep others from touch-
ing the controller switch or operation panel.
5) Select the axis for absolute reset. (X-axis: M1, Y-axis: M2, Z-axis: M3, R-
axis: M4)
To perform absolute reset on all axes, select "ALL" with the F11 (LOWER+F1)
key.
! CAUTION
The Z-axis of the stroke end method first rises during the absolute reset of all
axes (default setting). Be careful that your fingers do not get pinched or crushed
by any sudden movement.
6) Check that the absolute reset axis must be positioned at the plus side of the
origin. (See Fig. 4-2.)
If it is not at the plus side, then press the jog key to move the target axis to the
plus side.
7) Since the message "Reset ABS encoder OK?" is displayed, check that there
are not any obstacles in the robot movement range, and press the F4 key
(YES).
4-6
CHAPTER 4 Adjustment
8) After the absolute reset is completed, check that the machine reference value
displayed on the MPB is between 40 and 60 (recommended range).
If the machine reference value is outside the recommended range, then the
next absolute reset may not be properly performed.
In this case, refer to "3-4 Changing the origin position and adjusting the ma-
chine reference", and make the necessary adjustments.
Return-to-origin is
impossible from this area.
Return-to-origin direction
Fig. 4-2
4-7
CHAPTER 4 Adjustment
4-8
CHAPTER 4 Adjustment
WARNING
Serious injury might occur from physical contact with the robot during opera-
tion.
Never enter within the robot movement range during absolute reset.
The operation procedure using the MPB is described next. (Press the ESC key on
the MPB if you want to return to the preceding step.)
See the "YAMAHA robot controller owner's manual" for information on operat-
ing the robot controller.
1) Check that no one is inside the safeguard enclosure and then turn on the
controller.
2) Place a sign indicating the robot is being adjusted, to keep others from touch-
ing the controller switch or operation panel.
3) While holding the MPB, move to a position where the slit for the origin
position sticker can be seen. Never enter within the robot movement range at
this time.
6) Select the axis for absolute reset. (X-axis: M1, Y-axis: M2, Z-axis: M3, R-
axis: M4)
To perform absolute reset on all axes, select "ALL" with the F11 (LOWER+F1)
key.
! CAUTION
The Z-axis of the stroke end method first rises during the absolute reset of all
axes (default setting). Be careful that your fingers do not get pinched or crushed
by any sudden movement.
4-9
CHAPTER 4 Adjustment
! CAUTION
There are several dispersed positions where absolute reset can be performed.
All robot stop positions can be used for absolute reset when the robot was
moved with the F1 or F2 key.
Press the F1 or F2 key again before performing the absolute reset, move the
axis left or right, and check that the origin position marks align with each other.
(See Fig. 4-4.)
A position deviation (position shift) occurs if absolute reset is performed at a
position different from the previous absolute reset position.
2. When the robot has been moved to a position for absolute reset, check that
the figure of the selected axis displayed on the MPB screen is within 26
from 74 (usually 50) and press the ENTER key.
3. A message "Reset ABS encoder OK?" appears so press the F4 (YES) key
if this position is okay for reset.
If "ALL" was selected in 6), then the message "Reset ABS encoder OK?"
appears once again before the Z-axis rises.
Check that there are no hazards even if the Z-axis rises and press the F4
(YES) key.
(2) Z axis
1. The message "Reset ABS encoder OK?" appears so check that there are
no obstacles in the robot movement area and press the F4 (YES) key.
2. After absolute reset is complete, check that the machine reference value
shown on the MPB is between 26 and 74.
If the machine reference value is outside these limits, then the absolute
reset may not have been performed correctly. If the absolute reset is incor-
rect, adjust the Z-axis setting while referring to "Chapter 4, 3-4 Changing
the origin position and adjusting the machine reference".
4-10
CHAPTER 4 Adjustment
1) Check that no one is inside the safeguard enclosure and then press the emer-
gency stop button. Next turn on the controller while in servo-off.
2) Place a sign indicating the robot is being adjusted, to keep others from touch-
ing the controller switch.
6) Select the axis for absolute reset. (X-axis: M1, Y-axis: M2, Z-axis: M3, R
axis: M4)
To perform absolute reset on all axes, select "ALL" with the F11 (LOWER+F1)
key.
! CAUTION
The Z-axis (M3) uses the stroke end method to detect the origin position by
having the axis making contact with a mechanical stopper at the end of the
stroke. (default setting)
This means that the servo must be turned on to perform Z-axis absolute reset.
See "3-3-2-1 Absolute reset with servo on (re-reset)" for information on per-
forming absolute reset on the Z-axis.
7) Move the robot manually to a position where the origin position marks are
aligned with each other.
! CAUTION
The deviation between the origin position marks must be within a specified
range (repeatability tolerance) when performing an absolute reset at the same
position as the previous absolute reset. (See Fig. 4-4)
A position deviation (positional shift) will occur if the absolute reset is performed
at a position outside the repeatability tolerance or at a position different from
the previous absolute reset position.
When performing the absolute reset make sure that the deviation (positional
shift) between the origin position marks is within the allowed tolerance for origin
position repeatability.
Origin position repeatability (tolerance) values for each robot axis are shown in
Table 4-1.
4-11
CHAPTER 4 Adjustment
8) After moving the robot to a position for absolute reset, check that the figure
of the selected axis displayed on the MPB screen is within 26 to 74 and press
the ENTER key.
! CAUTION
There are several dispersed positions where absolute reset can be performed.
Move the robot a little bit at a time while viewing the MPB screen so that the
origin position marks match each other. Then press the ENTER key at a posi-
tion where the selected axis figure is between 26 and 74 on the MPB screen.
! CAUTION
If the selected axis does not show a figure between 26 and 74, then an error
message, "ABS.reset position error" appears during the next step and absolute
reset is disabled.
9) A message "Reset ABS encoder OK?" appears, so press the F4 (YES) key if
okay to reset at that position.
! CAUTION
If "ALL" was selected in 6) then the X-axis, Y-axis or R-axis can be reset in
servo-off. However the servo must be on when performing absolute reset of the
Z-axis. See "3-3-2-1 Absolute reset with servo on (re-reset)" for information on
how to perform Z-axis absolute reset.
11) Check that no one is inside the safeguard enclosure and then release the emer-
gency stop button on the controller.
4-12
CHAPTER 4 Adjustment
WARNING
Serious injury might occur from physical contact with the robot during opera-
tion.
Never enter within the robot movement range during absolute reset.
The operation procedure using the MPB is described next. (Press the ESC key on
the MPB if you want to return to the preceding step.)
See the "YAMAHA robot controller owner's manual" for information on operat-
ing the robot controller.
1) Check that no one is inside the safeguard enclosure and then turn on the
controller.
2) Place a sign indicating the robot is being adjusted, to keep others from touch-
ing the controller switch or operation panel.
3) Move the robot to the arm position where the absolute reset will be newly
performed, and shift your own position while holding the MPB so you can
see the joint area. Do not enter within the robot movement range.
6) Select the axis for absolute reset. (X-axis: M1, Y-axis: M2, Z-axis: M3, R-
axis: M4)
To perform absolute reset on all axes, select "ALL" with the F11 (LOWER+F1)
key.
! CAUTION
The Z-axis rises during absolute reset of all axes (default setting) so don't let
fingers get pinched or crushed by sudden movement.
4-13
CHAPTER 4 Adjustment
! CAUTION
There are several dispersed positions where absolute reset can be performed.
All robot stop positions can be used for absolute reset when the robot was
moved with the F1 or F2 key.
2. When the robot has been moved to a position for absolute reset, check that
the figure of the selected axis displayed on the MPB screen is within 26 to
74 (usually 50) and press the ENTER key.
3. A message "Reset ABS encoder OK?" appears so press the F4 (YES) key
if this position is okay for reset.
If "ALL" was selected in 6), then the message "Reset ABS encoder OK?"
appears once again before the Z-axis rises.
Check that there are no hazards even if the Z-axis rises and press the F4
(YES) key.
(2) Z-axis
1. The message "Reset ABS encoder OK?" appears so check that there are
no obstacles in the robot movement area and press the F4 (YES) key.
2. After absolute reset is complete, check that the machine reference value
shown on the MPB is between 26 and 74.
If the machine reference value is outside these limits, then the absolute
reset may not have been performed correctly. If the absolute reset is incor-
rect, adjust the Z-axis setting while referring to "Chapter 4, 3-4 Changing
the origin position and adjusting the machine reference".
8) After absolute reset is complete, move all robot axes to their "0" pulse posi-
tions. To move axes to their "0" pulse positions, see Chapter 4, "Point trace
function" in the "YAMAHA robot controller owner's manual".
! CAUTION
Before affixing the origin position stickers, be sure to move all robot axes back
to their "0" pulse positions. Omitting this step may mean that the next absolute
reset might be incorrect.
4-14
CHAPTER 4 Adjustment
9) After moving all the axes back to their "0" pulse positions, press the emer-
gency stop button and affix the supplied origin position stickers to the upper
and lower areas of the X-axis, Y-axis, and R-axis. Use these marked positions
to perform an absolute reset if it is needed in the future. (See Fig. 4-5 to Fig.
4-8.)
Use alcohol, etc. to remove any grease or oil from the surface where you will
affix the stickers. After the surface dries attach the stickers securely.
The YK550X does not have a relatively rotating part where the R-axis origin
position sticker is attached. We recommend using the sensor method for
detection the R-axis origin.
! CAUTION
The deviation between the origin position marks must be within a specified
range (repeatability tolerance) when performing the absolute reset at the same
position as the previous absolute reset. (See Fig. 4-4)
When affixing an origin position sticker, align it precisely with the upper and
lower stickers of the joint area so that the absolute reset position can be easily
checked the next time an absolute reset is performed.
! CAUTION
Be careful not to let the robot joints move while attaching the origin stickers.
When the servo is off, the robot joints may sometimes move due to tension in
the harness from the arm position. If this is the case, the origin should be set to
another position where the joints will not move.
11) Check that no one is inside the safeguard enclosure and then release the emer-
gency stop button on the controller.
4-15
CHAPTER 4 Adjustment
1) Check that no one is inside the safeguard enclosure and then press the emer-
gency stop button. Next turn on the controller while in servo-off.
2) Place a sign indicating the robot is being adjusted, to keep others from touch-
ing the controller switch or operation panel.
6) Select the axis for absolute reset. (X-axis: M1, Y-axis: M2, Z-axis: M3, R-
axis: M4)
To perform absolute reset on all axes, select "ALL" with the F11 (LOWER+F1)
key.
! CAUTION
The Z-axis (M3) uses the stroke end method to detect the origin position by
having the axis making contact with a mechanical stopper at the end of the
stroke. (default setting)
This means that the servo must be turned on to perform Z-axis absolute reset.
See "3-3-2-3 Absolute reset with servo on (new reset)" for information on per-
forming absolute reset on the Z-axis.
7) Move the robot manually to the position for performing absolute reset.
8) After moving the robot to a position for absolute reset, check that the figure
of the selected axis displayed on the MPB screen is within 26 to 74 and press
the ENTER key.
! CAUTION
There are several dispersed positions where absolute reset can be performed.
Move the robot a little bit at a time while viewing the MPB screen, and press the
ENTER key at a position where the figure of the selected axis is between 26 to
74 on the MPB screen.
4-16
CHAPTER 4 Adjustment
! CAUTION
If the selected axis does not show a figure between 26 and 74, then an error
message, "ABS.reset position error" appears during the next step and absolute
reset is disabled.
9) A message "Reset ABS encoder OK?" appears, so press the F4 (YES) key if
okay to reset at that position.
! CAUTION
If "ALL" was selected in 6) then the X-axis, Y-axis or R-axis can be reset in
servo-off. However the servo must be on when performing absolute reset of the
Z-axis. See "3-3-2-3 Absolute reset with servo on (new reset)" for information
on performing Z-axis absolute reset.
10) After absolute reset is complete, set the robot to servo-on and move all robot
axes to their "0" pulse positions. To move axes to their "0" pulse positions,
see Chapter 4, "Point trace function" in the "YAMAHA robot controller own-
er's manual".
! CAUTION
Before affixing the origin position stickers, be sure to move all robot axes back
to their "0" pulse positions. Omitting this step may mean that the next absolute
reset might be incorrect.
11) After moving all the axes back to their "0" pulse positions, press the emer-
gency stop button and affix the supplied origin position stickers to the upper
and lower areas of the X-axis, Y-axis, and R-axis. Use these marked positions
to perform an absolute reset if it is needed in the future. (See Fig. 4-5 to Fig.
4-8.)
Use alcohol, etc. to remove any grease or oil from the surface where you will
affix the stickers. After the surface dries attach the stickers securely.
! CAUTION
The deviation between the origin position marks must be within a specified
range (repeatability tolerance) when performing the absolute reset at the same
position as the previous absolute reset. (See Fig. 4-4)
When affixing an origin position sticker, align it precisely with the upper and
lower stickers of the joint area so that the absolute reset position can be easily
checked the next time an absolute reset is performed.
4-17
CHAPTER 4 Adjustment
! CAUTION
Be careful not to let the robot joints move while attaching the origin stickers.
When the servo is off, the robot joints may sometimes move due to tension in
the harness from the arm position. If this is the case, the origin should be set to
another position where the joints will not move.
13) Check that no one is inside the safeguard enclosure and then release the emer-
gency stop button on the controller.
4-18
CHAPTER 4 Adjustment
YK500X, YK600X
Axis Origin position repeatability tolerance (° ) Origin position repeatability tolerance (mm)
X-axis ±0.56 ±0.58
Y-axis ±0.56 ±0.47
R-axis ±0.90 ±0.65
YK700X, YK800X
Axis Origin position repeatability tolerance (° ) Origin position repeatability tolerance (mm)
X-axis ±0.56 ±0.76
Y-axis ±0.56 ±0.62
R-axis ±0.90 ±0.73
YK1000X
Axis Origin position repeatability tolerance (° ) Origin position repeatability tolerance (mm)
X-axis ±0.45 ±0.62
Y-axis ±0.56 ±0.62
R-axis ±0.90 ±0.73
YK1200X
Axis Origin position repeatability tolerance (° ) Origin position repeatability tolerance (mm)
X-axis ±0.37 ±0.64
Y-axis ±0.43 ±0.58
R-axis ±0.90 ±0.89
Repeatability tolerance
Slit
OK
Origin position sticker
Repeatability tolerance
Slit
OK
Origin position sticker
Repeatability tolerance
Slit
NG
Origin position sticker
Repeatability tolerance
Slit
NG
4-19
CHAPTER 4 Adjustment
Fig. 4-5 Origin position mark setting example YK250X, YK350X, YK400X
4-20
CHAPTER 4 Adjustment
4-21
CHAPTER 4 Adjustment
Fig. 4-7 Origin position mark setting example YK700X, YK800X, YK1000X
4-22
CHAPTER 4 Adjustment
Slit
Details of part A
4-23
CHAPTER 4 Adjustment
WARNING
Serious injury might occur from physical contact with the robot during opera-
tion.
Never enter within the robot movement range during absolute reset.
The operation procedure using the MPB is described next. (Press the ESC key on
the MPB if you want to return to the preceding step.)
See the "YAMAHA robot controller owner's manual" for information on operat-
ing the robot controller.
1) Check that no one is inside the safeguard enclosure and then turn on the
controller.
2) Place a sign indicating the robot is being adjusted, to keep others from touch-
ing the controller switch or operation panel.
5) Select M3 (Z-axis).
6) Since the message "Reset ABS encoder OK?" is displayed, check that there
are not any obstacles in the robot movement range, and press the F4 key
(YES).
7) After the absolute reset is completed, check that the machine reference value
displayed on the MPB is within the absolute reset tolerance range (26 to 74).
If the machine reference value is outside the absolute reset tolerance range,
then the next absolute reset may not be properly performed.
In this case, refer to "Chapter 4, 3-4 Changing the origin position and adjust-
ing the machine reference" and make the necessary adjustments.
4-24
CHAPTER 4 Adjustment
! CAUTION
If the origin position has been changed, then the absolute reset must be per-
formed, the machine reference must be adjusted, and the standard coordinate
and point data must be reset.
! CAUTION
If any machine reference is adjusted, the origin position may change.
Before the adjustment, mark off the reference mark at the current origin posi-
tion on the main body of the robot.
After the machine reference is adjusted, be sure to check that the origin posi-
tion has not deviated.
If the origin position changes after the machine reference has been adjusted,
then the standard coordinate and point data must be reset.
4-25
CHAPTER 4 Adjustment
2) Check that no one is inside the safeguard enclosure and then turn on the
controller.
4) If any machine reference value displayed on the MPB is not in the range
between 40 and 60 (recommended range) after the absolute reset has been
completed, then proceed with the following adjustment procedure.
5) Place a sign indicating that the robot is being adjusted in order to keep others
from operating the controller or operation panel.
7) Mark off the reference mark at the current origin position on the X-axis joint
area of the robot.
At this time, be careful to prevent the origin position from deviating since the
X-axis arm is touched.
8) Use the hex wrench to loosen two setscrews which fasten the dog ring of the
X-axis joint area. (See Fig. 4-9.)
! CAUTION
It is sufficient to loosen them. It is not necessary to completely remove them.
9) Refer to Fig. 4-9 and Table 4-2 and turn the dog ring to the minimum extent.
11) Go out of the safeguard enclosure, and check that no one is inside the safe-
guard enclosure. Then turn on the controller.
12) Perform the absolute reset from outside the safeguard enclosure.
4-26
CHAPTER 4 Adjustment
13) After the absolute reset is completed, read the machine reference value dis-
played on the MPB.
14) If the machine reference value is in the range between 40 and 60 (recom-
mended range), then the machine reference has been completely adjusted.
If it is outside the recommended range, then repeat the procedure that starts
in 5) to readjust it.
4-27
CHAPTER 4 Adjustment
! CAUTION
If the origin position has been changed, then the absolute reset must be per-
formed, the machine reference must be adjusted, and the standard coordinate
and point data must be reset.
2) Check that no one is inside the safeguard enclosure and then turn on the
controller.
4) Place a sign indicating that the robot is being adjusted in order to keep others
from operating the controller or operation panel.
6) Use the hex wrench to loosen two setscrews which fasten the dog ring of the
X-axis joint area. (See Fig. 4-9.)
! CAUTION
It is sufficient to loosen them. It is not necessary to completely remove them.
7) Turn the dog ring to move the sensor detection area (dog) on the dog ring to
the desired origin position.
9) Go out of the safeguard enclosure, and check that no one is inside the safe-
guard enclosure. Then turn on the controller.
10) Perform the absolute reset from outside the safeguard enclosure.
11) After the absolute reset is completed, read the machine reference value dis-
played on the MPB.
12) If the machine reference value is in the range between 40 and 60 (recom-
mended range), then the origin position has been completely changed.
If it is outside the recommended value, then adjust the machine reference by
referring to "1-1 Adjusting the X-axis machine reference".
4-28
CHAPTER 4 Adjustment
2) Check that no one is inside the safeguard enclosure and then turn on the
controller.
4) If any machine reference value displayed on the MPB is not in the range
between 40 and 60 (recommended range) after the absolute reset has been
completed, then proceed with the following adjustment procedure.
5) Place a sign indicating that the robot is being adjusted in order to keep others
from operating the controller or operation panel.
7) Mark off the reference mark at the current origin position on the Y-axis joint
area of the robot.
At this time, be careful to prevent the origin position from deviating since the
Y-axis arm is touched.
8) Use the hex wrench to loosen two setscrews which fasten the dog ring of the
Y-axis joint area. (See Fig. 4-9.)
! CAUTION
It is sufficient to loosen them. It is not necessary to completely remove them.
9) Refer to Fig. 4-9 and Table 4-2 and turn the dog ring to the minimum extent.
11) Go out of the safeguard enclosure, and check that no one is inside the safe-
guard enclosure. Then turn on the controller.
12) Perform the absolute reset from outside the safeguard enclosure.
13) After the absolute reset is completed, read the machine reference value dis-
played on the MPB.
14) If the machine reference value is in the range between 40 and 60 (recom-
mended range), then the machine reference has been completely adjusted.
If it is outside the recommended range, then repeat the procedure that starts
in 5) to readjust it.
4-29
CHAPTER 4 Adjustment
! CAUTION
If the origin position has been changed, then the absolute reset must be per-
formed, the machine reference must be adjusted, and the standard coordinate
and point data must be reset.
2) Check that no one is inside the safeguard enclosure and then turn on the
controller.
4) Place a sign indicating that the robot is being adjusted in order to keep others
from operating the controller or operation panel.
6) Use the hex wrench to loosen two setscrews which fasten the dog ring of the
Y-axis joint area. (See Fig. 4-9.)
! CAUTION
It is sufficient to loosen them. It is not necessary to completely remove them.
7) Turn the dog ring to move the sensor detection area (dog) on the dog ring to
the desired origin position.
9) Go out of the safeguard enclosure, and check that no one is inside the safe-
guard enclosure. Then turn on the controller.
10) Perform the absolute reset from outside the safeguard enclosure.
11) After the absolute reset is completed, read the machine reference value dis-
played on the MPB.
12) If the machine reference value is in the range between 40 and 60 (recom-
mended range), then the origin position has been completely changed.
If it is outside the recommended value, then adjust the machine reference by
referring to "2-1 Adjusting the Y-axis machine reference".
4-30
CHAPTER 4 Adjustment
2) Check that no one is inside the safeguard enclosure and then turn on the
controller.
4) If any machine reference value displayed on the MPB is not in the range
between 40 and 60 (recommended range) after the absolute reset has been
completed, then proceed with the following adjustment procedure.
5) Place a sign indicating that the robot is being adjusted in order to keep others
from operating the controller or operation panel.
7) Mark off the reference mark at the current origin position on the R-axis area
of the robot.
At this time, be careful not to touch the tool at the tip of the robot arm so that
the origin position does not shift.
8) Use the hex wrench to loosen the two setscrews which fasten the dog ring on
the R-axis area. (See Fig. 4-9.)
! CAUTION
It is sufficient to loosen them. It is not necessary to completely remove them.
9) Refer to Fig. 4-9 and Table 4-2 and turn the dog ring to the minimum extent.
11) Go out of the safeguard enclosure, and check that no one is inside the safe-
guard enclosure. Then turn on the controller.
12) Perform the absolute reset from outside the safeguard enclosure.
13) After the absolute reset is completed, read the machine reference value dis-
played on the MPB.
14) If the machine reference value is in the range between 40 and 60 (recom-
mended range), then the machine reference has been completely adjusted.
If it is outside the recommended range, then repeat the procedure that starts
in 5) to readjust it.
4-31
CHAPTER 4 Adjustment
! CAUTION
If the origin position has been changed, then the absolute reset must be per-
formed, the machine reference must be adjusted, and point data must be reset.
2) Check that no one is inside the safeguard enclosure and then turn on the
controller.
4) Place a sign indicating that the robot is being adjusted in order to keep others
from operating the controller or operation panel.
6) Use the hex wrench to loosen the two setscrews which fasten the dog ring on
the R-axis area. (See Fig. 4-9.)
! CAUTION
It is sufficient to loosen them. It is not necessary to completely remove them.
7) Turn the dog ring to move the sensor detection area (dog) on the dog ring to
the desired origin position.
9) Go out of the safeguard enclosure, and check that no one is inside the safe-
guard enclosure. Then turn on the controller.
10) Perform the absolute reset from outside the safeguard enclosure.
11) After the absolute reset is completed, read the machine reference value dis-
played on the MPB.
12) If the machine reference value is in the range between 40 and 60 (recom-
mended range), then the origin position has been completely changed.
If it is outside the recommended value, then adjust the machine reference by
referring to "3-1 Adjusting the R-axis machine reference".
4-32
CHAPTER 4 Adjustment
X 1.88
q Y 1.54
R 1.38
Set screw (One each on opposite sides)
* Machine reference < 40% : Movement in direction q
Machine reference > 60% : Movement in direction w
Set screw (One each on opposite sides)
q w
Fig. 4-9
4-33
CHAPTER 4 Adjustment
2) Check that no one is inside the safeguard enclosure and then turn on the
controller.
4) If any machine reference value displayed on the MPB is not in the range
between 40 and 60 (recommended range) after the absolute reset has been
completed, then proceed with the following adjustment procedure.
5) Place a sign indicating that the robot is being adjusted in order to keep others
from operating the controller or operation panel.
7) Mark off the reference mark at the current origin position on the X-axis joint
area of the robot.
At this time, be careful to prevent the origin position from deviating since the
X-axis arm is touched.
8) Use the hex wrench to loosen the two M4 bolts which fasten the dog plate to
the X-axis joint area. (See Fig. 4-10.)
! CAUTION
It is sufficient to loosen the M4 bolts. It is not necessary to completely remove
them.
9) Refer to Fig. 4-10 and Table 4-3 and turn the dog ring to the minimum extent.
11) Go out of the safeguard enclosure, and check that no one is inside the safe-
guard enclosure. Then turn on the controller.
12) Perform the absolute reset from outside the safeguard enclosure.
13) After the absolute reset is completed, read the machine reference value dis-
played on the MPB.
4-34
CHAPTER 4 Adjustment
14) If the machine reference value is in the range between 40 and 60 (recom-
mended range), then the machine reference has been completely adjusted.
If it is outside the recommended range, then repeat the procedure that starts
in 5) to readjust it.
4-35
CHAPTER 4 Adjustment
! CAUTION
If the origin position has been changed, then the absolute reset must be per-
formed, the machine reference must be adjusted, and the standard coordinate
and point data must be reset.
2) Check that no one is inside the safeguard enclosure and then turn on the
controller.
4) Place a sign indicating that the robot is being adjusted in order to keep others
from operating the controller or operation panel.
6) Use the hex wrench to loosen the two M4 bolts which fasten the dog plate to
the X-axis joint area. (See Fig. 4-10.)
7) Move the dog plate to position the sensor detection area (dog) on the dog
plate at the desired origin position.
! CAUTION
The upper and lower parts of the dog plate are symmetric. Move the dog plate
to position it at the desired origin position.
9) Go out of the safeguard enclosure, and check that no one is inside the safe-
guard enclosure. Then turn on the controller.
10) Perform the absolute reset from outside the safeguard enclosure.
11) After the absolute reset is completed, read the machine reference value dis-
played on the MPB.
4-36
CHAPTER 4 Adjustment
2) Check that no one is inside the safeguard enclosure and then turn on the
controller.
4) If any machine reference value displayed on the MPB is not in the range
between 40 and 60 (recommended range) after the absolute reset has been
completed, then proceed with the following adjustment procedure.
5) Place a sign indicating that the robot is being adjusted in order to keep others
from operating the controller or operation panel.
7) Mark off the reference mark at the current origin position on the Y-axis joint
area of the robot.
At this time, be careful to prevent the origin position from deviating since the
Y-axis arm is touched.
8) Use the hex wrench to loosen two setscrews which fasten the dog ring of the
Y-axis joint area. (See Fig. 4-10.)
! CAUTION
The collar is placed between the setscrew and Y-axis arm.
It is sufficient to loosen the setscrew. It is not necessary to completely remove
it.
9) Refer to Fig. 4-10 and Table 4-3 and turn the dog ring to the minimum extent.
! CAUTION
Depending on the origin position, the dog ring may not be able to be fastened
with the two setscrews.
In this case, fasten the dog ring with one setscrew.
11) Go out of the safeguard enclosure, and check that no one is inside the safe-
guard enclosure. Then turn on the controller.
4-37
CHAPTER 4 Adjustment
12) Perform the absolute reset from outside the safeguard enclosure.
13) After the absolute reset is completed, read the machine reference value dis-
played on the MPB.
14) If the machine reference value is in the range between 40 and 60 (recom-
mended range), then the machine reference has been completely adjusted.
If it is outside the recommended range, then repeat the procedure that starts
in 5) to readjust it.
4-38
CHAPTER 4 Adjustment
! CAUTION
If the origin position has been changed, then the absolute reset must be per-
formed, the machine reference must be adjusted, and the standard coordinate
and point data must be reset.
2) Check that no one is inside the safeguard enclosure and then turn on the
controller.
4) Place a sign indicating that the robot is being adjusted in order to keep others
from operating the controller or operation panel.
6) Use the hex wrench to loosen two setscrews which fasten the dog ring of the
Y-axis joint area. (See Fig. 4-10.)
! CAUTION
The collar is placed between the setscrew and Y-axis arm.
It is sufficient to loosen the setscrew. It is not necessary to completely remove
it.
7) Turn the dog ring to move the sensor detection area (dog) on the dog ring to
the desired origin position.
! CAUTION
Depending on the origin position, the dog ring may not be able to be fastened
with the two setscrews.
In this case, fasten the dog ring with one setscrew.
9) Go out of the safeguard enclosure, and check that no one is inside the safe-
guard enclosure. Then turn on the controller.
10) Perform the absolute reset from outside the safeguard enclosure.
4-39
CHAPTER 4 Adjustment
11) After the absolute reset is completed, read the machine reference value dis-
played on the MPB.
4-40
CHAPTER 4 Adjustment
2) Check that no one is inside the safeguard enclosure and then turn on the
controller.
4) If any machine reference value displayed on the MPB is not in the range
between 40 and 60 (recommended range) after the absolute reset has been
completed, then proceed with the following adjustment procedure.
5) Place a sign indicating that the robot is being adjusted in order to keep others
from operating the controller or operation panel.
7) Mark off the reference mark at the current origin position on the R-axis area
of the robot.
At this time, be careful not to touch the tool at the tip of the robot arm so that
the origin position does not shift.
8) Use the hex wrench to loosen the two M4 bolts which fasten the dog ring on
the R-axis area. (See Fig. 4-10.)
! CAUTION
It is sufficient to loosen the M4 bolts. It is not necessary to completely remove
them.
9) Refer to Fig. 4-10 and Table 4-3 and turn the dog ring to the minimum extent.
11) Go out of the safeguard enclosure, and check that no one is inside the safe-
guard enclosure. Then turn on the controller.
12) Perform the absolute reset from outside the safeguard enclosure.
13) After the absolute reset is completed, read the machine reference value dis-
played on the MPB.
14) If the machine reference value is in the range between 40 and 60 (recom-
mended range), then the machine reference has been completely adjusted.
If it is outside the recommended range, then repeat the procedure that starts
in 5) to readjust it.
4-41
CHAPTER 4 Adjustment
4-42
CHAPTER 4 Adjustment
w
q
w
q
w
q
Table 4-3
Movement amount (mm) for 100% of machine reference
Y 1.17 1.48
R 1.58 1.71
* Machine reference < 40% : Movement in direction q
Machine reference > 60% : Movement in direction w
Y-axis dog
X-axis dog
R-axis origin sensor
M4 bolts (2 places)
Fig. 4-10
4-43
CHAPTER 4 Adjustment
3-4-1-3 YK550X
1 Changing the X-axis origin position and adjusting the machine
reference value
2) Check that no one is inside the safeguard enclosure, and then turn on the
controller.
6) Place a sign indicating the robot is being adjusted, to keep others from
operating the controller switch.
8) Remove the cover on the left side of the robot base (pedestal) as viewed from
the front and pry off the rubber cap with a slotted screwdriver. The X-axis
origin dog and its mounting screw can be seen through the circular adjustment
window. (See Fig. 4-11.)
9) Use the 2mm hex wrench to loosen the set screw of the X-axis origin dog
(but, do not remove it).
10) With the 2mm hex wrench still inserted into the set screw, move the X-axis
arm by hand to the desired origin position.
11) Move the X-axis origin dog so that the set screw is positioned in the center of
the adjustment window.
At this position the X-axis origin sensor is aligned with the origin dog.
4-44
CHAPTER 4 Adjustment
Set screw
Rear cover
Right
Left
Adjustment window
Rubber cap
13) Go outside the safeguard enclosure, check that no one is inside the safeguard
enclosure, and turn on the controller. Then perform absolute reset and check
the X-axis origin position when return-to-origin is complete.
14) Check the machine reference value displayed on the MPB. When it is within
the allowable range (between 40 and 60%), the X-axis origin adjustment is
now complete. If the machine reference value is outside the allowable range,
make a note of the machine reference value and make adjustment with the
following procedure.
17) Loosen the set screw and move the X-axis origin dog as indicated in NOTE
below. Retighten the set screw, then repeat the above procedure from step 13)
until the X-axis machine reference value is set within the allowable range.
NOTE
Move the origin dog as follows:
X-axis machine reference value < 40% : Turn to the left.
X-axis machine reference value > 60% : Turn to the right.
As an approximate guide, a 1.2mm movement equals 100%.
18) After adjustment is complete, turn off the controller. Then enter the safeguard
enclosure, refit the rubber cap by tapping it with a plastic hammer, and reattach
the cover.
4-45
CHAPTER 4 Adjustment
2) Check that no one is inside the safeguard enclosure, and then turn on the
controller.
6) Place a sign indicating the robot is being adjusted, to keep others from
operating the controller switch.
8) Remove the M16 set screw located on the Y-axis arm joint with the 8mm hex
wrench. The Y-axis origin dog and set screw can be seen through the adjustment
window. (See Fig. 4-12)
9) Use the 2mm hex wrench to loosen the set screw of the Y-axis origin dog
(but, do not remove it).
10) With the 2mm hex wrench still inserted into the set screw, move the Y-axis
arm by hand to the desired origin position.
11) Move the Y-axis origin dog so that the set screw is positioned in the center of
the adjustment window.
At this position the Y-axis origin sensor is aligned with the origin dog.
4-46
CHAPTER 4 Adjustment
Set screw
Left Right
Adjustment window
13) Go outside the safeguard enclosure, check that no one is inside the safeguard
enclosure, and turn on the controller. Then perform absolute reset and check
the Y-axis origin position when return-to-origin is complete.
14) Check the machine reference value displayed on the MPB. When it is within
the allowable range (between 40 and 60%), the Y-axis origin adjustment is
now complete. If the machine reference value is outside the allowable range,
make a note of the machine reference value and make adjustment with the
following procedure.
17) Loosen the set screw and move the Y-axis origin dog as indicated in NOTE
below. Retighten the set screw, then repeat the above procedure from step 13)
until the Y-axis machine reference value is set within the allowable range.
NOTE
Move the origin dog as follows:
Y-axis machine reference value < 40% : Turn to the right.
Y-axis machine reference value > 60% : Turn to the left.
As an approximate guide, a 0.8mm movement equals 100%.
18) After adjustment is complete, turn off the controller, then enter the safeguard
enclosure and reattach the M16 set screw by tightening it.
4-47
CHAPTER 4 Adjustment
The R-axis origin position is fixed and cannot be changed. The R-axis machine
reference value is preadjusted before shipment and does not deviate from the
allowable range (40 to 60%) during normal operation. However, if for some reason
the machine reference value goes outside the allowable range, adjust as needed
with the procedure below.
! CAUTION
The origin position may shift if the origin sensor is moved too far.
2) Check that no one is inside the safeguard enclosure, and then turn on the
controller.
6) Place a sign indicating the robot is being adjusted, to keep others from
operating the controller switch.
8) Remove the cover on the Y-axis arm. (See Fig. 4-21.) Place the cover on the
robot pedestal side with the machine harness still connected.
The R-axis origin sensor and dog can be seen at the location shown in Figure
4-13.
R-axis origin sensor
9) Put a mark on the current position of the R-axis origin sensor, then loosen the
bolts (M4, 1 piece) securing the installation plate of the R-axis origin sensor.
(See Fig. 4-14.)
M4 Bolt
NOTE
Move the origin sensor as follows:
R-axis machine reference value < 40% : Move to the right.
R-axis machine reference value > 60% : Move to the left.
As an approximate guide, a 0.8mm movement equals 100%. (1.3mm/100% for
high-speed R-axis specifications)
12) Go outside the safeguard enclosure, check that no one is inside the safeguard
enclosure, and turn on the controller. Then perform absolute reset and check
the R-axis machine reference value when return-to-origin is complete.
13) Repeat the above steps until the R-axis machine reference value is set within
the allowable range.
14) After adjustment is complete, turn off the controller, then enter the safeguard
enclosure and reattach the cover to the Y-axis arm.
4-49
CHAPTER 4 Adjustment
! CAUTION
If the origin position has been changed, then the absolute reset must be per-
formed and the standard coordinate and point data must be reset.
! CAUTION
Mark off the reference mark at the position where the absolute reset is perf-
ormed so that the absolute reset position can be easily checked the next time
an absolute reset is performed.
Unless it can be precisely checked, then the repeatability of the absolute reset
position cannot be assured.
Refer to "Chapter 4, 3-3 Absolute reset procedures" for information about the
absolute reset.
4-50
CHAPTER 4 Adjustment
WARNING
Injury can occur if hands or fingers are squeezed between the drive pulley and
belt. Always turn off the controller and use caution when handling these parts.
! CAUTION
The positional shift will occur after adjusting the machine reference value, so
point data settings are required again.
2) Place a sign indicating the robot is being adjusted, to keep others from oper-
ating the controller or operation panel.
6) Remove the Y-axis upper cover and under cover (YK500X to YK1000X).
To remove the covers, see "7 Removing the Robot Covers" in Chapter 4.
Place the upper cover on the robot base (pedestal) side with the machine
harness still connected.
7) Prop the spline or end effector with a support stand to prevent the Z-axis
from dropping.
4-51
CHAPTER 4 Adjustment
8) Remove the bolts securing the Z-axis motor (See Figs. 4-15 to 4-18) and then
remove the Z-axis motor.
WARNING
If the Z-axis motor comes off the Z-axis belt, the Z-axis drops causing a hazard-
ous situation. Be sure to prop the Z-axis with a support stand.
9) Adjust the distance (L) between the Z-axis mechanical stopper and the axis
end so it is set to the value shown in Table 4-4. Then tighten the four bolts to
reassemble the Z-axis motor. (See Fig. 4-19, Fig4-20.) At this point, do not
allow the spline shaft position to shift from the correct height.
10) After reassembling the Z-axis motor, adjust the timing belt tension.
To adjust the timing belt tension, see "8 Adjusting the Timing Belt Tension"
in Chapter 4.
11) Reattach the Y-axis upper cover and under cover (YK500X to YK1000X).
To attach the covers, see "7 Removing the Robot Covers" in Chapter 4.
13) Check that no one is inside the safeguard enclosure, and then turn on the
controller.
4-52
CHAPTER 4 Adjustment
! CAUTION
The adjustment machine reference value is displayed with the procedure
below.
Always check the adjustment machine reference value when the machine
reference is adjusted.
4-53
CHAPTER 4 Adjustment
Z-axis motor
Z-axis motor installation bolt M3×6
Z-axis motor
Z-axis motor installation bolt M5×14
Z-axis motor
Z-axis motor installation bolt M5×12
Z-axis motor
4-54
CHAPTER 4 Adjustment
3-4-3-2 YK550X
1) Prepare the necessary tools.
• Hex wrench set
• Phillips screwdriver
• Support stand
• Ruler
2) Check that no one is inside the safeguard enclosure, and then turn on the
controller.
6) Place a sign indicating the robot is being adjusted, to keep others from
operating the controller switch.
8) Remove the screws (7 pieces) securing the upper cover on the Y-axis arm and
remove the cover. Place the cover on the robot pedestal side with the machine
harness still connected. Also remove the Y-axis arm under covers.
9) Before removing the Z-axis motor, use a support stand to prop the spline or
end effector to prevent it from dropping along the Z-axis. Then, remove the
four M4 bolts on the Z-axis motor underplate, but do not remove the bolts
securing the Z-axis motor. It is unnecessary to remove the Z-axis motor
underplate from the arm
4-55
CHAPTER 4 Adjustment
M4 bolt plate
Y-axis arm
Z-axis spline
Under cover
Stand
Fig. 4-21
4-56
CHAPTER 4 Adjustment
10) Adjust the height of the support stand so that the distance between the urethane
damper and the upper face of the ball screw nut is 12mm as shown in Fig. 4-
22. Then, fit the Z-axis belt on the Z-axis motor pulley.
11) Lightly tighten the bolts to temporarily fasten the Z-axis motor underplate
until it has no play in the vertical direction.
12) Viewing from the bottom of the Y-axis arm, check that the belt is properly
engaged with the Z-axis motor pulley and ball screw pulley.
13) Pull the Z-axis motor in the direction of arrow and align the scribed lines (on
both sides of the X-axis motor underplate) with the reference scribed lines.
While maintaining this position, tighten the four M4 bolts to 4.5Nm (46kgf·cm)
to secure the Z-axis motor underplate.
! CAUTION
If the scribed lines on the Z-axis motor underplate do not reach the reference
scribed lines, the belt teeth may slip on the pulley. If they exceed the reference
scribe lines on the arm, the Z-axis drive unit may wear out quickly. Align the
scribed lines exactly.
14) Go outside the safeguard enclosure, check that no one is inside the safeguard
enclosure, and turn on the controller. Then perform absolute reset.
15) Check that the Z-axis machine reference value is within the allowable range
(40 to 60%).
16) After adjustment is complete, turn off the controller, then enter the safeguard
enclosure and reattach the covers to the Y-axis arm.
4-57
CHAPTER 4 Adjustment
Pull
Urethane damper
12
Ball screw nut
M4 bolt
Y-axis arm
Spline Pulley
Pulley
Z-axis belt
Stand
Fig. 4-22
4-58
CHAPTER 4 Adjustment
1) Check that no one is inside the safeguard enclosure, and then turn on the
controller.
2) Press the emergency stop button on the MPB to set emergency stop.
Refer to the "YAMAHA robot controller owner's manual" for further details
on emergency stop and canceling emergency stop.
3) Place a sign indicating the robot is being adjusted, to keep others from oper-
ating the controller or operation panel.
5) Move the X-axis and Y-axis arms by hand to the mechanical stopper posi-
tions or to the point where interference with the peripheral equipment oc-
curs, and note the X-axis and Y-axis plus (+) and minus (-) direction pulses
displayed on the MPB.
6) Check that no one is inside the safeguard enclosure, then cancel emergency
stop from outside the safeguard enclosure.
7) Set the soft limits to within the figure for the X-axis and Y-axis encoder pulses
that you noted above in step 5). This software limit setting must be made
from outside the safeguard enclosure.
Refer to the "YAMAHA robot controller owner's manual" for further details
on soft limit settings.
4-59
CHAPTER 4 Adjustment
! CAUTION
The origin position factory-adjusted at shipment is not completely aligned with
the front face position of the robot.
When introducing the robot, be sure to set the soft limits with the number of
pulses from the origin position (0 pulse position).
4-60
CHAPTER 4 Adjustment
! CAUTION
Overloads may occur if the soft limit is almost near the encoder pulse at the
mechanical stopper and the operating point is used at the edge of the move-
ment range. Set the soft limit to the inner side of the mechanical stopper with an
ample safety margin.
(4) Relation between the X, Y and R-axis movement angle, the Z-axis
movement distance and the number of pulses
The tables below are for calculating resolver pulses with respect to the X, Y
and R-axis movement angles and to the Z-axis movement distance for each
robot. Use these figures as a guide to set the soft limits.
X, Y and R-axis speed reduction ratio and Z-axis ball screw lead for each robot
Robot model X-axis Y-axis Z-axis R-axis
YK250X, YK350X, YK400X 50 50 12mm 50
YK500X, YK600X 80 80 20mm 50
YK700X, YK800X 80 80 20mm 50
YK1000X 100 80 20mm 50
YK1200X 121 105 10mm 50
YK550X 50 50 30mm 50
YK550X with high-speed R-axis specifications 50 50 30mm 30
4-61
CHAPTER 4 Adjustment
! CAUTION
If the standard coordinate settings are incorrect, the acceleration cannot be
optimized to match the arm position. This results in too short a service life,
damage to the drive unit, or residual vibration during positioning. In addition,
the cartesian coordinate accuracy will be impaired.
Setting the standard coordinates enables the following operations and functions.
1. Optimizes acceleration according to arm position during automatic op
eration.
2. Allows moving robot arm tip at right angles.
3. Allows using shift coordinates.
4. Enables commands such as linear interpolation and arm switching.
The procedure for setting standard coordinates and cautions are shown below.
1) Check that no one is inside the safeguard enclosure, and then turn on the
controller.
3) Place a sign indicating the robot is being adjusted, to keep others from oper-
ating the controller or operation panel.
4) Enter the safeguard enclosure while holding the MPB. Stay outside the robot
movement range at this time.
5) Make the standard coordinate settings while referring to methods for "Set-
ting the Standard Coordinates" as explained in the "YAMAHA robot control-
ler owner's manual". Never enter within the robot movement range.
6) When the standard coordinate settings are complete, check the following points
from outside the safeguard enclosure.
1. Check that the robot arm tip can move at right angles in MANUAL opera-
tion (cartesian coordinates).
2. Check that the values nearly equal to the X-axis and Y-axis arm lengths
are entered in "Arm length" of the axis parameters.
If the above points are not satisfied, the standard coordinate settings are in-
correct, so make the standard coordinate settings again.
4-62
CHAPTER 4 Adjustment
1) Check that no one is inside the safeguard enclosure, and then turn on the
controller.
2) Move the robot to the 0 pulse position.
To move the axes to their "0" pulse positions, see "Chapter 4 Point trace
function" in the "YAMAHA robot controller owner's manual".
3) Turn off the controller.
4) Place a sign indicating the robot is being adjusted, to keep others from oper-
ating the controller switch.
5) Enter the safeguard enclosure.
6) Being careful not to move the origin positions, attach stickers at conspicuous
points on matching sides of components such as the robot arm of each axis,
base (robot pedestal) and end effector. Affix stickers nearby showing the axis
name and direction of movement. Use a cloth moistened with alcohol to re-
move grease from the surface where you will affix the stickers. After the
surface is dry, affix the stickers securely. (See Fig. 4-24)
WARNING
Affix the origin position stickers precisely on the origin positions. Align the direc-
tion of movement stickers with the jog direction and affix them correctly. Affix
each axis name sticker on the correct axis. Affixing the sticker at a wrong loca-
tion may cause faulty operation and hazardous situations.
A B
X Y
YK500X, YK600X
Z R
(a) Origin position stickers (b) Direction of movement and
axis name stickers
Fig. 4-23
4-63
CHAPTER 4 Adjustment
-
R z
- +
+
- +
Y
- +
X
End effector
4-64
CHAPTER 4 Adjustment
3) Place a sign indicating the robot is being adjusted, to keep others from oper-
ating the controller switch.
4-65
CHAPTER 4 Adjustment
wM4×6
qM4×6
rM3×10
tM3×16
Fig. 4-25
4-66
CHAPTER 4 Adjustment
eM4×6
yM3×50
Base rear cover 2 wM4×6
uM4×6
Fig. 4-26
4-67
CHAPTER 4 Adjustment
eM4×6
yM4×50
uM4×6
Fig. 4-27
4-68
CHAPTER 4 Adjustment
rM4×6
y M4×6
uM4×6
Y-axis arm side cover
qM4×6
Base rear cover 1
Base front cover
Fig. 4-28
4-69
CHAPTER 4 Adjustment
WARNING
The motor and speed reduction gear casing are extremely hot after automatic
operation, so burns may occur if these are touched. Before touching these
parts, turn off the controller, wait for a while and check that the temperature has
cooled.
WARNING
Injury can occur if hands or fingers are squeezed between the drive pulley and
belt. Always turn off the controller and use caution when handling these parts.
! CAUTION
Since a positional shift occurs after adjusting the belt tension, it is necessary to
make absolute reset, standard coordinate setting and point data setting again.
Push-pull scale
Slack
Load
Push-pull scale
25
55
Nut
Stay Hole
Nut
10
15
4-70
CHAPTER 4 Adjustment
WARNING
If the Z-axis pulley comes off the Z-axis belt, the Z-axis drops causing a hazard-
ous situation. Turn off the controller and be sure to prop the Z-axis with a sup-
port stand before beginning adjustment.
Adjust the Z-axis and R-axis timing belts of the YK250X, YK350X and YK400X
with the procedure below.
1) Prepare the necessary tools.
• Push-pull scale
• Stay (See Fig. 4-30. This stay should be prepared by the user.)
• Hex wrench set
• Phillips-head screwdriver
• Scale
2) Turn off the controller.
3) Place a sign indicating the robot is being adjusted, to keep others from oper-
ating the controller switch.
4) Enter the safeguard enclosure.
5) Remove the Y-axis upper cover.
Refer to "7 Removing the Robot Covers" in Chapter 4 for removing the cover.
Place the upper cover on the robot base (pedestal) side with the machine
harness still connected.
6) Prop the spline or end effector with a support stand to prevent the Z-axis
from dropping (when adjusting the Z-axis belt tension).
7) Adjust the belt tension by two people as follows.
Using the push-pull scale, one person applies a load perpendicular to the
middle of the belt. The other person checks the slack of the belt. (See Fig. 4-
29 and Fig. 4-30.)
8) The correct load to be applied to the belt of each robot model and the result-
ing slack are shown in Tables 4-7 and 4-7. When the load producing the
specified slack is within this range, no adjustment is required. If not, adjust
the tension with the following procedure.
(1) Z-axis belt adjustment
1. Loosen the bolt q shown in Fig. 4-31.
2. If the load producing the slack specified in Table 4-9 (step 7) above) is
smaller than the specified range, move the Z-axis motor in the direc-
tion increasing the tension. If the load is greater than this, move it in the
direction reducing the tension. Then, retighten the bolt.
3. Recheck the belt tension using the same procedure in step 7). When the
load applied to produce the specified slack is within the specified range
of Table 4-9, the adjustment is okay. If not, repeat the above procedure
from steps 1 to 3.
4-71
CHAPTER 4 Adjustment
Z-axis motor
Z-axis belt
R-axis belt
R-axis motor
1M3×6 2M3×6
4-72
CHAPTER 4 Adjustment
WARNING
If the Z-axis pulley comes off the Z-axis belt, the Z-axis drops causing a hazard-
ous situation. Turn off the controller and be sure to prop the Z-axis with a sup-
port stand before beginning adjustment.
Adjust the Z-axis and R-axis timing belts of the YK500X and YK600X with the
procedure below.
1) Prepare the necessary tools.
• Push-pull scale
• Stay (See Fig. 4-30. This stay should be prepared by the user.)
• Hex wrench set
• Phillips-head screwdriver
• Scale
2) Turn off the controller.
3) Place a sign indicating the robot is being adjusted, to keep others from oper-
ating the controller switch.
4) Enter the safeguard enclosure.
5) Remove the Y-axis upper and under covers.
Refer to "7 Removing the Robot Covers" in Chapter 4 for removing the cov-
ers.
Place the upper cover on the robot base (pedestal) side with the machine
harness still connected.
6) Prop the spline or end effector with a support stand to prevent the Z-axis
from dropping (when adjusting the Z-axis belt tension).
7) Adjust the belt tension by two people as follows.
Using the push-pull scale, one person applies a load perpendicular to the
middle of the belt. The other person checks the slack of the belt. (See Figs. 4-
29 and 4-30.)
8) The correct load to be applied to the belt of each robot model and the result-
ing slack are shown in Tables 4-9 and 4-10. When the load producing the
specified slack is within this range, no adjustment is required. If not, adjust
the tension with the following procedure.
4-73
CHAPTER 4 Adjustment
2M4×10 1M5×14
Z-axis belt
4-74
CHAPTER 4 Adjustment
WARNING
If the Z-axis pulley comes off the Z-axis belt, the Z-axis drops causing a hazard-
ous situation. Turn off the controller and be sure to prop the Z-axis with a sup-
port stand before beginning adjustment.
Adjust the Z-axis and R-axis timing belts of the YK700X, YK800X and YK1000X
with the procedure below.
1) Prepare the necessary tools.
• Push-pull scale
• Stay (See Fig. 4-30. This stay should be prepared by the user.)
• Hex wrench set
• Phillips-head screwdriver
• Scale
2) Turn off the controller.
3) Place a sign indicating the robot is being adjusted, to keep others from oper-
ating the controller switch.
4) Enter the safeguard enclosure.
5) Remove the Y-axis upper and under covers.
Refer to "7 Removing the Robot Covers" in Chapter 4 for removing the cov-
ers.
Place the upper cover on the robot base (pedestal) side with the machine
harness still connected.
6) Prop the spline or end effector with a support stand to prevent the Z-axis
from dropping (when adjusting the Z-axis belt tension).
7) Adjust the belt tension by two people as follows.
Using the push-pull scale, one person applies a load perpendicular to the
middle of the belt. The other person checks the slack of the belt. (See Figs. 4-
29 and 4-30.)
8) The correct load to be applied to the belt of each robot model and the result-
ing slack are shown in Tables 4-9 and 4-10. When the load producing the
specified slack is within this range, no adjustment is required. If not, adjust
the tension with the following procedure.
(1) Z-axis belt adjustment
1. Loosen the bolt q shown in Fig. 4-33.
2. If the load producing the slack specified in Table 4-9 (step 7) above) is
smaller than the specified range, move the Z-axis motor in the direction
increasing the tension. If the load is greater than this, move it in the direc-
tion reducing the tension. Then, retighten the bolt.
3. Recheck the belt tension using the same procedure in step 7). When the
load applied to produce the specified slack is within the specified range of
Table 4-9, the adjustment is okay. If not, repeat the above procedure from
steps 1 to 3.
4-75
CHAPTER 4 Adjustment
Z-axis belt
4-76
CHAPTER 4 Adjustment
WARNING
If the Z-axis pulley comes off the Z-axis belt, the Z-axis drops causing a hazard-
ous situation. Turn off the controller and be sure to prop the Z-axis with a sup-
port stand before beginning adjustment.
Adjust the Z-axis and R-axis timing belts of the YK1200X with the procedure
below.
1) Prepare the necessary tools.
• Push-pull scale
• Stay (See Fig. 4-30. This stay should be prepared by the user.)
• Hex wrench set
• Phillips-head screwdriver
• Scale
2) Turn off the controller.
3) Place a sign indicating the robot is being adjusted, to keep others from oper-
ating the controller switch.
4) Enter the safeguard enclosure.
5) Remove the Y-axis arm front cover and side cover.
Refer to "7 Removing the Robot Covers" in Chapter 4 for removing the covers.
6) Remove the bolts (M4×10L, 4 pieces) and then remove the harness clamp
stay from the Y-axis arm. (See Fig. 4-34.)
7) Prop the spline or end effector with a support stand to prevent the Z-axis
from dropping (when adjusting the Z-axis belt tension).
8) Adjust the belt tension by two people as follows.
Using the push-pull scale, one person applies a load perpendicular to the
middle of the belt. The other person checks the slack of the belt. (See Figs. 4-
29 and 4-30.)
9) The correct load to be applied to the belt of each robot model and the result-
ing slack are shown in Tables 4-9 and 4-10. When the load producing the
specified slack is within this range, no adjustment is required. If not, adjust
the tension with the following procedure.
(1) Z-axis belt adjustment
1. Loosen the bolt q shown in Fig. 4-34.
2. If the load producing the slack specified in Table 4-9 (step 7) above) is
smaller than the specified range, move the Z-axis motor in the direction
increasing the tension. If the load is greater than this, move it in the direc-
tion reducing the tension. Then, retighten the bolt.
3. Recheck the belt tension using the same procedure in step 7). When the
load applied to produce the specified slack is within the specified range of
Table 4-9, the adjustment is okay. If not, repeat the above procedure from
steps 1 to 3.
4-77
CHAPTER 4 Adjustment
10) After adjustment is complete, tighten the bolt q or w to the torque specified
in Table 4-11.
11) Reattach the harness clamp stay to the Y-axis arm. (See Fig. 4-34.)
Be careful not to allow the R-axis belt to make contact with the harness clamp
stay and harness.
12) Reattach the Y-axis arm front cover and side cover.
Refer to "7 Removing the Robot Covers" in Chapter 4 for attaching the cov-
ers.
13) Go outside the safeguard enclosure.
14) Check that no one is inside the safeguard enclosure, and then turn on the
controller.
M4×10
R-axis belt harness clamp stay Z-axis motor
R-axis motor qM6×20
wM6×20
Z-axis belt
4-78
CHAPTER 4 Adjustment
Robot model Load(N) Load(kgf) Slack (mm) (Ref.) Belt vibration frequency(Hz)
YK250X,YK350X 2.7 to 2.9 0.28 to 0.30 0.7 430 to 453
YK400X 2.8 to 3.1 0.29 to 0.32 1.4 215 to 226
YK500X, YK600X 9.5 to 10.1 0.97 to 1.03 1.6 213 to 225
YK700X, YK800X 10.3 to 10.9 1.05 to 1.11 2.8 121 to 127
YK1000X 10.9 to 11.5 1.11 to 1.17 4.4 76 to 80
YK1200X 11.7 to 12.6 1.19 to 1.29 5.9 66 to 70
Robot model Load(N) Load(kgf) Slack (mm) (Ref.) Belt vibration frequency(Hz)
YK250X,YK350X 1.9 to 2.3 0.19 to 0.23 2.1 159 to 185
YK400X 1.9 to 2.3 0.19 to 0.13 2.8 118 to 137
YK500X, YK600X 3.1 to 3.8 0.32 to 0.39 1.9 182 to 194
YK700X, YK800X 3.6 to 7.6 0.64 to 0.78 2.7 97 to 115
YK1000X 6.7 to 8.0 0.68 to 0.82 4.3 61 to 72
YK1200X 6.8 to 8.1 0.69 to 0.83 6.0 54 to 64
Robot model Axis Bolt size Tightening torque (kgf•cm) Tightening torque (N•m)
YK250X,YK350X,YK400X Z M3 20 2.0
R M3 20 2.0
YK500X, YK600X Z M5 92 9.0
R M4 46 4.5
YK700X, YK800X,YK1000X Z M5 92 9.0
R M4 46 4.5
YK1200X Z
M6 156 15.3
R
4-79
CHAPTER 4 Adjustment
WARNING
If the Z-axis pulley comes off the Z-axis belt, the Z-axis drops causing a
hazardous situation. Turn off the controller and be sure to prop the Z-axis with
a support stand before beginning adjustment.
3) Place a sign indicating the robot is being adjusted, to keep others from
operating the controller switch.
5) Remove the screws (7 pieces) shown in Fig. 4-35 and remove the upper cover.
Place the upper cover on the robot pedestal side with the machine harness
still connected.
Also remove the under cover.
6) Check whether the edge of the Z-axis motor flange is aligned with the scribed
lines (on both sides of plate) shown in Fig. 4-36. When exactly aligned, no
adjustment is required. If not aligned, make adjustment as follows.
7) Prop the spline or end effector with a support stand to prevent the Z-axis
from dropping.(See Fig. 4-36.)
8) Slightly loosen the four M4 bolts on the plate under the Z-axis motor as long
as no backlash occurs between the plate and the Y-axis arm.
9) Check from the bottom of the Y-axis arm that the belt is properly engaged
with the Z-axis motor pulley and ball screw pulley.
4-80
CHAPTER 4 Adjustment
10) Pull the Z-axis motor in the direction of arrow and align the scribed lines (on
both sides of the X-axis motor underplate) with the reference scribed lines.
While maintaining this position, tighten the four M4 bolts to 4.5Nm (46kgf·cm)
to secure the Z-axis motor underplate.
! CAUTION
If the scribed lines on the Z-axis motor underplate do not reach the reference
scribed lines, the belt teeth may slip on the pulley. If they exceed the reference
scribe lines on the arm, the Z-axis drive unit may wear out quickly. Align the
scribed lines exactly.
Screw
Under cover
Fig. 4-35
4-81
CHAPTER 4 Adjustment
Z-axis motor
Ball screw
Spline Scribed line
R-axis speed
reduction gear unit
plate
Y-axis arm
Scribed line
Spline Pulley
Z-axis belt
R-axis belt
Stand
4-82
CHAPTER 4 Adjustment
3) Place a sign indicating the robot is being adjusted, to keep others from
operating the controller switch.
5) Remove the screws (7 pieces) shown in Fig. 4-35 and remove the upper cover.
Place the upper cover on the robot pedestal side with the machine harness
still connected.
Also remove the under cover.
6) Check whether the edge of the R-axis speed reduction gear unit is aligned
with the scribed line shown in Fig. 4-36. When exactly aligned, no adjustment
is required. If not aligned, make adjustment as follows
7) Slightly loosen the four M4 bolts securing the R-axis speed reduction gear
unit as long as no backlash occurs between the unit and the Y-axis arm.
! CAUTION
For high-speed R-axis specifications, an O-ring is fitted between the arm and
the plate under the bolts. This O-ring might come off if the gap between the arm
and plate becomes large. Looses the bolts so that the gap does not become
large.
8) Check from the top and bottom of the Y-axis arm that the belt is properly
engaged with the pulleys on the speed reduction gear unit and spline.
9) Utilizing the tension adjust bolt, pull speed reduction gear unit in the reverse
direction of arrow and then move it back. When the unit flange edge is exactly
aligned with the scribed line, tighten the four M4 bolts to secure the unit. The
tightening torque should be 4.5Nm (46kgf·cm). Slightly tighten the tension
adjust bolt.
! CAUTION
If the flange edge of the speed reduction gear unit does not reach the scribed
line, the belt may slip on the pulleys. If it exceeds the scribed line, the belt is too
tight causing the drive parts to wear prematurely. Align the flange edge exactly
with the scribed line.
4-83
MEMO
4-84
CHAPTER 5
Periodic Inspecition
1 Overview .................................................................................5-1
2 Precautions .............................................................................5-2
3 Daily Inspection ......................................................................5-3
4 Six-Month Inspection ..............................................................5-5
5 Replacing the Harmonic Drive ................................................5-8
5-1 Replacement period ......................................................................... 5-8
5-2 Basic replacement procedure for harmonic drive and precautions .... 5-10
5-2-1 YK250X, YK350X, YK400X ........................................................... 5-12
5-2-2 YK500X, YK600X .......................................................................... 5-29
5-2-3 YK700X, YK800X, YK1000X ......................................................... 5-44
5-2-4 YK1200X ....................................................................................... 5-60
5-2-5 YK550X with high-speed R-axis specifications: R-axis ................. 5-65
1 Overview
Daily and periodic inspection of the YAMAHA robot is essential in order to en-
sure safe and efficient operation. This chapter describes the periodic inspection
items and procedures for the YAMAHA YK-X series robots.
Make sure that you thoroughly understand details of the inspection and follow
the procedures and precautions explained in this chapter.
5-1
CHAPTER 5 Periodic Inspection
2 Precautions
(1) Periodic inspection must be performed by or in the presence of personnel
who have received the Robot Training given by YAMAHA or YAMAHA
dealers.
(2) Do not attempt any inspection, adjustment, repair and parts replacement not
described in this manual. This work requires specialized technical knowl-
edge and skill, and may also involve work hazards.
(3) When inspection is required inside the safeguard enclosure, always turn off
the controller and also the external switch board.
(4) If the inspection or maintenance procedure calls for operation of the robot,
stay outside the safeguard enclosure.
(5) Place a sign indicating the robot is being inspected, to keep others from oper-
ating the controller switch, programming unit or operation panel.
(7) To check the operation after inspection, refer to "6 Trial operation" in Chapter 1.
WARNING
• When you need to touch the terminals or connectors on the outside of the
controller during inspection, always first turn off the controller power switch
and also the power source in order to prevent possible electrical shock.
• Never touch any internal parts of the controller.
For precautions on handling the controller, refer to the "YAMAHA robot control-
ler owner's manual".
5-2
CHAPTER 5 Periodic Inspection
3 Daily Inspection
The following is an inspection list that must be performed every day before and
after operating the robot.
(1) Inspection to be performed with the controller turned off
1) Turn off the controller.
2) Place a sign indicating the robot is being inspected, to keep others from
operating the controller switch.
3) Enter the safeguard enclosure and check the following points.
Checkpoint Procedure
Machine harness Check for scratches, dents and excessive bend and kinks.
Robot cable (If the machine harness or robot cable is damaged, contact YAMAHA
User cable and wiring dealer.)
Robot exterior Check for damage. (If a damage is found, contact YAMAHA dealer.)
Checkpoint Procedure
Emergency stop device Press the emergency stop button to check if it works.
Check for abnormal movement and excessive vibration and noise. (If
Robot movement
any abnormal symptom is found, contact YAMAHA dealer.)
Check if the brake works to stop the Z-axis from dropping more than
Z-axis brake operation *1 3mm from the stationary point. (If any abnormal operation is found,
contact YAMAHA dealer.)
*1 Visually check the Z-axis movement when you press the emergency stop
button from outside the safeguard enclosure and also when you turn off the
controller.
5-3
CHAPTER 5 Periodic Inspection
5-4
CHAPTER 5 Periodic Inspection
4 Six-Month Inspection
Take the following precautions when performing 6-month inspection.
WARNING
Injury can occur if hands or fingers are squeezed between the drive pulley and
belt. Always turn off the controller and use caution when handling these parts.
WARNING
The Z-axis will slide down when the Z-axis brake is released, causing a hazard-
ous situation. Do not release the brake when lubricating the Z-axis parts.
When lubricating the ball screw, spline shaft and linear busing shaft, observe the
following precautions.
WARNING
Precautions when handling grease:
• Inflammation may occur if this gets in the eyes.
Before handling the grease, wear your safety goggles to ensure the grease
will not come in contact with the eyes.
• Inflammation may occur if the grease comes into contact with skin. Be sure
to wear protective gloves to prevent contact with skin.
• Do not take orally or eat. (Eating will cause diarrhea and vomiting.)
• Hands and fingers might be cut when opening the container, so use protec-
tive gloves.
• Keep out of the reach of children.
• Do not heat the grease or place near an open flame since this could lead to
sparks and fires.
Emergency Treatment:
• If this grease gets in the eyes, wash liberally with pure water for about 15
minutes and consult a physician for treatment.
• If this grease comes in contact with the skin, wash away completely with
soap and water.
• If taken internally, do not induce vomiting but promptly consult a physician for
treatment.
WARNING
Disposing of grease and the container:
• Proper disposal is compulsory under federal, state and local regulations. Take
appropriate measures in compliance with legal regulations.
• Do not pressurize the empty container. Pressurizing may cause the con-
tainer to rupture.
• Do not attempt to weld, heat up, drill holes or cut this container. This might
cause the container to explode and the remaining materials inside it to ignite.
! CAUTION
Unless grease specified by YAMAHA is used, the service life of the ball screw,
ball spline and linear bushing shaft will shorten.
5-5
CHAPTER 5 Periodic Inspection
2) Place a sign showing that the robot is being inspected, to keep others from
operating the controller switch.
5-6
CHAPTER 5 Periodic Inspection
WARNING
The robot controller must be installed outside the safeguard enclosure, to pre-
vent a hazardous situation in which you or anyone enter the safeguard enclo-
sure to inspect the controller while it is turned on.
WARNING
• Bodily injury may occur from coming into contact with the fan while it is rotat-
ing.
• When removing the fan cover for inspection, first turn off the controller and
make sure the fan has stopped.
1) Check that no one is inside the safeguard enclosure, and then turn on the
controller.
2) Place a sign indicating the robot is being inspected, to keep others from
operating the controller, programming unit or operation panel.
3) Check the following points from outside the safeguard enclosure (except
checkpoint marked *1).
Checkpoint Procedure
*1 After pressing the emergency stop button, enter the safeguard enclosure and
make checks. Place a sign indicating the robot is being inspected, to keep
others from operating the controller, programming unit or operation panel.
(3) Adjustment and parts replacement
1) After inspection, if you notice any adjustment or parts replacement is
needed, first turn off the controller and then enter the safeguard enclosure
to perform the necessary work. After adjustment or replacement is fin-
ished, again review the checkpoints outlined in (1) and (2) above.
5-7
CHAPTER 5 Periodic Inspection
For example, when the robot is used under the following conditions, the replacement
period for the X-axis harmonic drive of the YK500X can be calculated as follows.
n : 10
θ : 0.25
N : 80
h : 24 hours per day
D : 240 days per year
Replacement period = 8.4×108/(n×60×h×D×N×θ)
= 8.4×108/(10×60×24×240×80×0.25)
= 12.2 years
5-8
CHAPTER 5 Periodic Inspection
5-9
CHAPTER 5 Periodic Inspection
WARNING
The motor and speed reduction gear casing are extremely hot after automatic
operation, so burns may occur if these are touched. Before touching these
parts, turn off the controller, wait for a while and check that the temperature has
cooled.
WARNING
Precautions when handling harmonic grease, cleaning oil:
• Inflammation may occur if they get in the eyes.
Before handling them, wear your safety goggles to ensure they will not come
in contact with the eyes.
• Inflammation may occur if they come into contact with skin. Be sure to wear
protective gloves to prevent contact with skin.
• Do not take orally or eat. (Eating will cause diarrhea and vomiting.)
• Hands and fingers might be cut when opening the container, so use protec-
tive gloves.
• Keep out of the reach of children.
• Do not heat them or place near an open flame since this could lead to sparks
and fires.
Emergency Treatment:
• If they get in the eyes, wash liberally with pure water for about 15 minutes
and consult a physician for treatment.
• If they come in contact with the skin, wash away completely with soap and
water.
• If taken internally, do not induce vomiting but promptly consult a physician for
treatment.
WARNING
Disposing of harmonic grease, cleaning oil and the container:
• Proper disposal is compulsory under federal, state and local regulations. Take
appropriate measures in compliance with legal regulations.
• Do not pressurize the empty container. Pressurizing may cause the con-
tainer to rupture.
• Do not attempt to weld, heat up, drill holes or cut this container. This might
cause the container to explode and the remaining materials inside it to ignite.
WARNING
When removing the wave generator from the motor shaft or reinstalling it back
onto the motor shaft, use caution to avoid as much as possible, applying a
thrust load to the motor shaft. If a load is applied, the resolver may be damaged
resulting in a hazardous situation of the robot trouble.
5-10
CHAPTER 5 Periodic Inspection
! CAUTION
The harmonic drive service life may shorten if the grease recommended by
YAMAHA is not used.
Recommended grease
Use the following harmonic drive grease.
4B No.2 (made by Harmonic Drive Systems Inc.)
! CAUTION
Harmonic drive
• Do not apply strong shocks or impacts to these parts such as with a hammer.
Also, do not scratch, scar or dent these parts by dropping, etc. Such actions
will damage the harmonic drive.
• The specified performance cannot be maintained if any part of the harmonic
drive is used in a damaged state. This damage or wear may also lead to
trouble with the harmonic drive.
! CAUTION
Since a positional shift occurs after replacing the harmonic drive, it is neces-
sary to make absolute reset, standard coordinate setting and point data setting
again.
5-11
CHAPTER 5 Periodic Inspection
1. X-axis
1) Prepare the following tools and items.
• Harmonic grease 4B No.2
• Waste cloth (rag)
• Phillips-head screwdriver
• Hex wrench set
• Screw Lock (thread sealant)
• Ratchet handle
• Hexagonal socket set
• Extension bar
• Torque-limiting wrench
• Replacement parts (See table below.)
Replacement parts
Parts name Type No. YAMAHA Parts No. Note
Harmonic drive SHF-20-50 KN3-M2110-001
S71(JIS) KN3-M2159-000 Top of harmonic drive
O-ring Rubber wire diameter 1.50mm × Ring inner diameter 49.00mm KN3-M2143-000 For motor
Rubber wire diameter 0.99mm × Ring inner diameter 53.28mm KN3-M2144-000 Supplied with harmonic drive
3) Place a sign indicating that the robot is being inspected, to keep others from
operating the controller switch.
WARNING
When you remove the X-axis arm installation bolts (M3×40L, 8 pieces) in the
next step, the X-axis arm may come off causing a hazardous situation. Be es-
pecially careful to keep the arm from falling when a heavy tool is attached to the
arm tip.
5-12
CHAPTER 5 Periodic Inspection
6) Remove the X-axis arm installation bolts (M3×40L, 8 pieces). (See Fig. 5-1.)
M3×40
M6×14
Fig. 5-1
! CAUTION
An O-ring is fitted to the X-axis arm, so be careful not to let it drop into the
peripheral unit. (See Fig. 5-2.)
O-ring
(S71 : KN3-M2159-000)
Fig. 5-2
7) Disconnect the connectors on the X-axis motor power cable XM and resolver
cable XP.
5-13
CHAPTER 5 Periodic Inspection
8) Remove the base assembly bolts (M6×14L, 6 pieces) to separate base 1 and
base 2. (See Fig. 5-1 and Fig. 5-3.)
M6×14 Base 1
M5×12
Base 2
Fig. 5-3
9) Remove the bolts (M5×12L, 4 pieces) securing the motor and remove the
motor from base 1. (See Fig. 5-4.)
M5×12
Fig. 5-4
! CAUTION
An O-ring is fitted to the motor, so be careful not to let it drop into the peripheral
unit.
5-14
CHAPTER 5 Periodic Inspection
10) Remove the wave generator from the motor shaft. The wave generator is
secured with an M3 set screw. (See Fig. 5-6.)
11) Remove the X-axis harmonic drive installation bolts (M3×20L, 16 pieces)
M3×20
Fig. 5-5
12) Remove the X-axis harmonic drive from the top of base 1.
! CAUTION
An O-ring is fitted to the X-axis harmonic drive, so be careful not to let it drop
into the peripheral unit.
13) Fit an O-ring (supplied with the harmonic drive) coated with harmonic grease
into the O-ring groove on the new harmonic drive.
Apply small amounts of "Screw Lock" to the bolts (M3×20L, 16 pieces) and
tighten them to secure the harmonic drive from the backside of the base. (See
Fig. 5-5.)
! CAUTION
Do not allow the O-ring to get caught out of the groove during reassembly. A
trouble will occur if the robot is operated with the O-ring left caught out of the
groove.
5-15
CHAPTER 5 Periodic Inspection
14) Apply harmonic grease to the new wave generator and flexible spline.
See Fig. 5-6 for applying grease properly.
Fit O-ring (supplied) into this groove
Harmonic drive willl be damaged if O-ring is caught out of groove.
O-ring : KN3-M2144-000
M3 set screw
Apply grease to entire oldham coupling.
O-ring : KN3-M2143-000
Wave generator
Apply grease to sufficiently fill in the ball space.
Apply grease to the thickness equal to the ball diameter.
Circular spline
Never remove these temporarily tightened bolts.
The axis will otherwise deviate from center.
Fig. 5-6
15) Fit the wave generator onto the motor shaft and fully insert it against the motor.
Then, apply small amounts of "Screw Lock" to the M3 set screw (1 piece) you
removed earlier and tighten it to secure the wave generator. (See Fig. 5-6.)
16) Fit a new O-ring to the motor and secure the motor to base 1 with the bolts
(M5×12L, 4 pieces) you removed earlier. (See Fig. 5-4.)
! CAUTION
Do not allow the O-ring to get caught out of the groove during reassembly. A
trouble will occur if the robot is operated with the O-ring left caught out of the
groove.
17) Fasten base 1 to base 2 with the bolts (M6×14L, 6 pieces) you removed ear-
lier. (See Fig. 5-3.)
18) Reattach the connectors on the X-axis motor power cable XM and resolver
cable XP.
19) Fit a new O-ring into the O-ring groove on the X-axis arm and place the arm
on the harmonic drive. Then, apply small amounts of "Screw Lock" to the
bolts (M3×40L, 8 pieces) you removed earlier and tighten them uniformly to
secure the X-axis arm to the base. (See Fig. 5-1 and Fig. 5-2.)
! CAUTION
Do not allow the O-ring to get caught out of the groove during reassembly. A
trouble will occur if the robot is operated with the O-ring left caught out of the
groove.
5-16
CHAPTER 5 Periodic Inspection
20) Reattach the base (robot pedestal) front and rear covers.
22) Check that no one is inside the safeguard enclosure, and then turn on the
controller.
! CAUTION
After the Harmonic drive is replaced, an absolute reset must be performed, and
the standard coordinate and point data must be reset. Refer to "Chapter 4 Ad-
justment" to adjust it.
5-17
CHAPTER 5 Periodic Inspection
2. Y-axis
1) Prepare the following tools and items.
• Harmonic grease 4B No.2
• Waste cloth (rag)
• Phillips-head screwdriver
• Hex wrench set
• Screw Lock (thread sealant)
• Torque-limiting wrench
• Replacement parts (See table below.)
Replacement parts
Parts name Type No. YAMAHA Parts No. Note
Harmonic drive SHF-17-50 KN3-M2510-002
S63(JIS) KN3-M2519-000 Lower part of harmonic drive
O-ring Rubber wire diameter 1.00mm × Ring inner diameter 29.50mm KN3-M257K-000 For motor
Rubber wire diameter 0.80mm × Ring inner diameter 45.40mm KN3-M257L-000 Supplied with harmonic drive
3) Place a sign indicating that the robot is being inspected, to keep others from
operating the controller switch.
5) Remove the Y-axis arm upper cover. Place the cover on the robot base (ped-
estal) side with the machine harness still connected.
Refer to "7 Removing the Robot Covers" in Chapter 4 for removing the covers.
WARNING
When you remove the Y-axis arm installation bolts (M3×20L, 8 pieces) in the
next step, the Y-axis arm may come off causing a hazardous situation. Be es-
pecially careful to keep the arm from falling when a heavy tool is attached to the
arm tip.
5-18
CHAPTER 5 Periodic Inspection
6) Remove the Y-axis arm installation bolts (M3×20L, 8 pieces). (See Fig. 5-7.)
M3×20
Fig. 5-7
7) Remove the Y-axis arm and place it where it will not obstruct the work.
! CAUTION
An O-ring is fitted to the upper surface of the harmonic drive, so be careful not to
let it drop into the peripheral unit.
8) Remove the wave generator from the motor shaft. The wave generator is
secured with an M3 set screws (2 pieces). (See Fig. 5-10.)
Fig. 5-8
10) Remove the Y-axis dog ring from the Y-axis Harmonic drive. The dog ring is
fastened with M4 setscrews (2 pieces).
5-19
CHAPTER 5 Periodic Inspection
! CAUTION
The dog ring is used for reassembly. Store it where the work will not be dis-
turbed.
The dog ring is provided with the setscrews. Be careful to avoid losing them.
11) Remove the Y-axis harmonic drive from the top of the X-axis arm.
! CAUTION
An O-ring is fitted to the X-axis harmonic drive, so be careful not to let it drop
into the peripheral unit. (See Fig. 5-9.)
O-ring
(S63 : KN3-M2519-000)
Fig. 5-9
12) Remove the four bolts temporarily tightened to the new harmonic drive.
! CAUTION
Remove only the four bolts shown in Fig. 5-10 at this point. Never remove the
bolts on the opposite side. If they are removed, the harmonic drive axis may
deviate from the center causing a trouble.
13) Fit a new O-ring coated with harmonic grease into the O-ring groove on the
X-axis arm. (See Fig. 5-9.)
14) Place the new harmonic drive on the X-axis arm, and secure it with the bolts
(M3×40L, 6 pieces). Apply small amounts of "Screw Lock" to the bolts and
tighten uniformly them to secure the harmonic drive from the backside. (See
Fig. 5-8.)
! CAUTION
Do not allow the O-ring to get caught out of the groove during reassembly. A
trouble will occur if the robot is operated with the O-ring left caught out of the
groove.
5-20
CHAPTER 5 Periodic Inspection
16) Fit an O-ring (supplied with the harmonic drive) coated with harmonic grease
into the O-ring groove on the new harmonic drive
17) Apply harmonic grease to the new wave generator and flexible spline.
See Fig. 5-10 for applying grease properly.
18) Fit the wave generator onto the motor shaft and fully insert it against the
motor. Then, apply small amounts of "Screw Lock" to the M3 set screw (2
piece) you removed earlier and tighten it to secure the wave generator. (See
Fig. 5-10.)
Circular spline
O-ring : KN3-M257K-000
Y-axis arm
Apply grease to sufficiently fill in the ball space.
Never remove these temporarily tightened bolts.
The axis will otherwise deviate from center. M3 set screw
Fig. 5-10
19) Secure the Y-axis arm to the harmonic drive with the bolts (M3×20L, 8 pieces)
you removed earlier. Apply small amounts of "Screw Lock" to the bolts and
tighten them uniformly to secure the Y-axis arm. (See Fig. 5-7.)
! CAUTION
Do not allow the O-ring to get caught out of the groove during reassembly. A
trouble will occur if the robot is operated with the O-ring left caught out of the
groove.
When reassembling the harmonic drive, be careful to keep the circular spline
from coming off. If it comes off, the harmonic drive axis will deviate from the
center causing a trouble.
5-21
CHAPTER 5 Periodic Inspection
22) Check that no one is inside the safeguard enclosure, and then turn on the
controller.
! CAUTION
After the Harmonic drive is replaced, an absolute reset must be performed, and
the standard coordinate and point data must be reset. Refer to "Chapter 4 Ad-
justment" to adjust it.
5-22
CHAPTER 5 Periodic Inspection
3. R-axis
1) Prepare the following tools and items.
• Harmonic grease 4B No.2
• Waste cloth (rag)
• Phillips-head screwdriver
• Hex wrench set
• Screw Lock (thread sealant)
• Torque-limiting wrench
• Adjustable wrench or spanner
• Replacement parts (See table below.)
Replacement parts
Parts name Type No. YAMAHA Parts No. Note
Harmonic drive SHF-14-50 KN3-M1821-001
S53(JIS) KN3-M1895-000 Lower part of harmonic drive
O-ring Rubber wire diameter 0.80mm × Ring inner diameter 23.70mm KN3-M181H-000 For wave generator
Rubber wire diameter 0.60mm × Ring inner diameter 37.10mm KN5-M181G-000 Supplied with harmonic drive
Edge seal VR18A KN3-M1886-000
3) Place a sign indicating that the robot is being inspected, to keep others from
operating the controller switch.
5) Remove the Y-axis arm upper cover. Place the cover on the robot base (ped-
estal) side with the machine harness still connected.
Refer to "7 Removing the Robot Covers" in Chapter 4 for removing the covers.
6) Remove the bolts (M4×8L, 4 pieces) securing the bearing to the upper end of
the spline and remove the spline mount plate, spline and bearing from the
holder. (See Fig. 5-11.)
M4×8
Bearing
Holder
Spline shaft
Fig. 5-11
5-23
CHAPTER 5 Periodic Inspection
WARNING
The Z-axis will slide down when the U-nut is removed in the next step, causing
a hazardous situation. Prop the Z-axis with a support stand before loosening
the U-nut.
7) While placing a steel rod or similar tool through the 5mm diameter hole at
the lower part of the spline, loosen the U-nut at the top of the spline with the
wrench, and remove the bearing. (See Fig. 5-12.)
Use a round steel rod with a diameter slightly smaller than 5mm. Avoid using
a square rod because the spline might be damaged by the edge of the rod.
After removing the bearing, refit the U-nut to the top of the spline shaft to
keep the spline shaft from falling out.
U-nut
Spline shaft
Spline nut
Fig. 5-12
8) Remove the button bolts (M3×20L, 6 pieces) on the underside of the Y-axis
arm and remove the plate fastening the spline and the harmonic drive. (See
Fig. 5-13.)
M3×20, Button bolt
Fastening plate
Not necessary to remove these
bolts in through-holes (2 pieces)
Fig. 5-13
5-24
CHAPTER 5 Periodic Inspection
! CAUTION
An O-ring is fitted to the fastening plate, so be careful not to let it drop into the
peripheral unit. (See Fig. 5-14.)
O-ring (S53 : KN3-M1895-000)
Fig. 5-14
9) Remove the R-axis dog ring from the R-axis Harmonic drive. The dog ring is
fastened with M4 setscrews (2 pieces).
! CAUTION
The dog ring is used for reassembly. Store it where the work will not be dis-
turbed.
The dog ring is provided with the setscrews. Be careful to avoid losing them.
10) Remove the bolts (M3×6L, 3 pieces) securing the R-axis motor plate at the
top of the Y-axis arm. (See Fig. 5-15.)
M3×18 M3×6
M4 set screw
Fig. 5-15
5-25
CHAPTER 5 Periodic Inspection
11) Loosen the pulley set screw (M4, 2 pieces) and remove the pulley from the
wave generator. (See Fig. 5-15.)
12) Remove the harmonic drive installation bolts (M3×18L, 8 pieces) and pull
out the harmonic drive from the bottom of the Y-axis arm. (See Fig. 5-15.)
! CAUTION
An O-ring is fitted to the harmonic drive, so be careful not to let it drop into the
peripheral unit.
13) Remove the retaining ring for the wave generator and pull out the wave gen-
erator from the bottom of the Y-axis arm. (See Fig. 5-16.)
14) Apply harmonic grease to the new wave generator. See Fig. 5-16 for apply-
ing grease properly.
15) Fit a new O-ring into the O-ring groove on the wave generator. (See Fig. 5-16.)
Apply grease to sufficiently fill in the ball space. Fit a new O-ring into the O-ring groove on the wave generator.
O-ring : KN3-M181H-000
Fit O-ring (supplied) into this groove
Harmonic drive will be damaged if O-ring is Apply grease to entire oldham coupling.
caught out of groove.
O-ring : KN5-M181G-000
Apply grease to the thickness equal to the ball diameter.
Remove the temporarily tightened bolts when assembling
Keep the circular spline from coming off when assembling
Circular spline
Fig. 5-16
16) Insert the new wave generator into the Y-axis arm from the bottom, and se-
cure it with the retaining ring. The chamfered side of the retaining ring should
face downwards.
! CAUTION
Do not allow the O-ring to get caught out of the groove during reassembly. A
trouble will occur if the robot is operated with the O-ring left caught out of the
groove.
5-26
CHAPTER 5 Periodic Inspection
18) Remove the four bolts temporarily tightened to the new harmonic drive.
! CAUTION
Remove only the four bolts shown in Fig. 5-16 at this point. Never remove the
bolts on the opposite side. If they are removed, the harmonic drive axis may
deviate from the center causing a trouble.
19) Fit an O-ring (supplied with the harmonic drive) coated with harmonic grease
into the O-ring groove on the new harmonic drive.
Apply small amounts of "Screw Lock" to the bolts (M3×18L, 8 pieces) and
tighten them to secure the harmonic drive to the Y-axis arm from the top of
the Y-axis arm.
! CAUTION
Do not allow the O-ring to get caught out of the groove during reassembly. A
trouble will occur if the robot is operated with the O-ring left caught out of the
groove.
When reassembling the harmonic drive, be careful to keep the circular spline
from coming off. If it comes off, the harmonic drive axis will deviate from the
center causing a trouble.
20) Apply small amounts of "Screw Lock" to the M4 set screws (2 pieces) and
tighten them to secure the pulley to the wave generator.
21) Check that the timing belt is fitted on the wave generator pulley and motor
pulley, and then secure the motor plate. (See Fig. 5-15.)
! CAUTION
It is necessary to apply correct tension to the timing belt during reassembly.
Refer to "8 Adjusting the Timing Belt Tension" in Chapter 4.
23) Next, secure the fastening plate to the harmonic drive with the button bolts
(M3×20L, 6 pieces) coated with small amounts of "Screw Lock". (See Fig.
5-17.) At this point, be careful to keep the spline shaft from coming off the
spline nut.
! CAUTION
The harmonic drive service life may shorten if the edge seal effect is insuffi-
cient, so carefully reassemble the parts.
5-27
CHAPTER 5 Periodic Inspection
Edge seal
O-ring : KN3-M1895-000
Fastening plate
Spline nut
Spline shaft
Fig. 5-17
24) Insert the spline into the holder, fit the bearing onto the spline and tighten the
U-nut to secure the bearing. (Utilize the φ5 through-hole when tightening the
U-nut like you did to loosen it.) (See Fig. 5-11 and Fig. 5-12.)
25) Attach the bearing mount plate to the holder and fasten them with the bolts
you removed earlier (M4×8L, 4 pieces).
28) Check that no one is inside the safeguard enclosure, and then turn on the
controller.
! CAUTION
After the Harmonic drive is replaced, the absolute reset must be performed,
and the point data must be reset. Refer to "Chapter 4 Adjustment" to adjust it.
5-28
CHAPTER 5 Periodic Inspection
1. X-axis
1) Prepare the following tools and items.
• Harmonic grease 4B No.2
• Waste cloth (rag)
• Phillips-head screwdriver
• Hex wrench set
• Screw Lock (thread sealant)
• Ratchet handle
• Hexagonal socket set
• Extension bar
• Torque-limiting wrench
• Replacement parts (See table below.)
Replacement parts
Parts name Type No. YAMAHA Parts No. Note
Harmonic drive SHF-25-80 KN4-M2110-001
S90(JIS) KN4-M2143-000 Top of harmonic drive
Rubber wire diameter 1.78mm × Ring inner diameter 85.00mm KN4-M2159-000 Base (robot pedestal)
O-ring
Rubber wire diameter 1.78mm × Ring inner diameter 69.57mm KN5-M2143-000 Motor
Rubber wire diameter 1.30mm × Ring inner diameter 66.50mm KN5-M257L-000 Supplied with harmonic drive
3) Place a sign indicating that the robot is being inspected, to keep others from
operating the controller switch.
5) Remove the base (robot pedestal) front and rear covers and the X-axis arm
upper cover.
Refer to "7 Removing the Robot Covers" in Chapter 4 for removing the cov-
ers.
6) Disconnect the connectors on the X-axis motor power cable XM and resolver
cable XP.
5-29
CHAPTER 5 Periodic Inspection
7) Remove the bolts (M6×20L, 4 pieces) securing the motor holder by using the
ratchet handle, M6 hexagonal socket, socket adapter and extension bar. (See
Fig. 5-18.)
M6×14
M6×20
Fig. 5-18
8) With the motor still attached to the motor holder, pull out the motor by sway-
ing it gently right and left. If it is difficult to remove the motor holder, slowly
rotate the X-axis arm and again try removing the motor holder.
! CAUTION
Carefully remove the motor holder so as not to let hands or fingers get pinched
between the motor holder and the base.
An O-ring is fitted to the motor holder, so be careful not to let it drop into the
peripheral unit.
9) Remove the bolts (M6×14L, 4 pieces) securing the motor and remove the
motor from the motor holder. (See Fig. 5-18.)
! CAUTION
An O-ring is fitted to the motor, so be careful not to let it drop into the peripheral
unit.
10) Remove the wave generator from the motor shaft. The wave generator is
secured with an M4 set screw and keyway. (See Fig. 5-22.)
! CAUTION
A spacer is inserted between the wave generator and the motor, so be careful
not to lose it.
5-30
CHAPTER 5 Periodic Inspection
WARNING
When you remove the X-axis arm installation bolts (M4×40L, 8 pieces) in the
next step, the X-axis arm may come off causing a hazardous situation. Be es-
pecially careful to keep the arm from falling when a heavy tool is attached to the
arm tip.
WARNING
Removing the X-axis arm is dangerous for just one person. Always use two or
more people, or remove the Y-axis arm in advance.
Refer to "2. Y-axis" of "5-2-2" for removing the Y-axis arm.
11) Remove the X-axis arm installation bolts (M4×40L, 8 pieces). (See Fig. 5-
19.)
M4×40
Fig. 5-19
12) Remove the X-axis arm and place it where it will not obstruct the work.
! CAUTION
An O-ring is fitted to the X-axis arm, so be careful not to let it drop into the
peripheral unit. (See Fig. 5-20.)
O-ring
(S90 : KN4-M2143-000)
Fig. 5-20
5-31
CHAPTER 5 Periodic Inspection
13) Remove the bolts (M4×20L, 12 pieces) securing the X-axis harmonic drive.
(See Fig. 5-21.)
M4×20
Fig. 5-21
14) Remove the X-axis harmonic drive from the top of the base.
! CAUTION
An O-ring is fitted to the X-axis harmonic drive, so be careful not to let it drop
into the base or peripheral unit.
15) Fit an O-ring (supplied with the harmonic drive) coated with harmonic grease
into the O-ring groove on the new harmonic drive. (See Fig. 5-22.)
Apply small amounts of "Screw Lock" to the bolts (M4×20L, 12 pieces) and
tighten them to secure the harmonic drive from the backside of the base. (See
Fig. 5-21.)
! CAUTION
Do not allow the O-ring to get caught out of the groove during reassembly. A
trouble will occur if the robot is operated with the O-ring left caught out of the
groove.
16) Apply harmonic grease to the new wave generator and flexible spline.
See Fig. 5-22 for applying grease properly.
17) Fit a new O-ring into the O-ring groove on the X-axis arm (see Fig. 5-20) and
secure it to the harmonic drive. Then apply small amounts of "Screw Lock"
to the bolts (M4×40L, 8 pieces) you removed earlier and tighten them
uniformly to secure the X-axis arm. (See Fig. 5-19.)
! CAUTION
Do not allow the O-ring to get caught out of the groove during reassembly. A
trouble will occur if the robot is operated with the O-ring left caught out of the
groove.
5-32
CHAPTER 5 Periodic Inspection
18) Fit the spacer and wave generator onto the motor shaft, and fully insert them
against the motor. Then, apply small amounts of "Screw Lock" to the M4 set
screw (1 piece) you removed earlier and tighten it to secure the wave genera-
tor onto the motor shaft. (See Fig. 5-22.)
Fit O-ring (supplied) into this groove
Harmonic drive will be damaged if O-ring is caught out of groove.
O-ring : KN5-M257L-000
Apply grease to entire oldham coupling.
O-ring : KN5-M2143-000
M4 set screw
Spacer
Wave generator
Apply grease to sufficiently fill in the ball space.
Apply grease to the thickness equal to the ball diameter.
Circular spline
Never remove these temporarily tightened bolts.
The axis will otherwise deviate from center.
Fig. 5-22
19) Fit the O-ring to the motor and secure the motor to the motor holder with the
bolts (M6×14L, 4 pieces) you removed earlier. (See Fig. 5-18 and Fig. 5-22.)
! CAUTION
Do not allow the O-ring to get caught out of the groove during reassembly. A
trouble will occur if the robot is operated with the O-ring left caught out of the
groove.
20) Fit a new O-ring coated with harmonic grease into the O-ring groove on the
motor holder and tighten the bolts (M6×20L, 4 pieces) you removed earlier
to temporarily secure the motor holder to the base. (See Fig. 5-18.)
! CAUTION
Do not allow the O-ring to get caught out of the groove during reassembly. A
trouble will occur if the robot is operated with the O-ring left caught out of the
groove.
21) Uniformly tighten the four bolts (M6×20L) temporarily fastened in the pre-
vious step while moving the X-axis by hand slowly left and right through
45°. If any jamming or catching is felt while moving the axis at this time,
then reassemble from the beginning.
22) Reattach the connectors on the X-axis motor power cable XM and resolver
cable XP.
23) Reattach the base (robot pedestal) front and rear covers and the X-axis arm
upper cover.
5-33
CHAPTER 5 Periodic Inspection
25) Check that no one is inside the safeguard enclosure, and then turn on the
controller.
! CAUTION
After the Harmonic drive is replaced, an absolute reset must be performed, and
the standard coordinate and point data must be reset. Refer to "Chapter 4 Ad-
justment" to adjust it.
5-34
CHAPTER 5 Periodic Inspection
2. Y-axis
1) Prepare the following tools and items.
• Harmonic grease 4B No.2
• Waste cloth (rag)
• Phillips-head screwdriver
• Hex wrench set
• Screw Lock (thread sealant)
• Torque-limiting wrench
• Replacement parts (See table below.)
Replacement parts
Parts name Type No. YAMAHA Parts No. Note
Harmonic drive SHF-20-80 KN4-M2510-001
Rubber wire diameter 1.78mm × Ring inner diameter 72.75mm KN4-M257K-000 Lower part of harmonic drive
O-ring Rubber wire diameter 1.50mm × Ring inner diameter 49.00mm KN3-M2143-000 For motor
Rubber wire diameter 0.99mm × Ring inner diameter 53.28mm KN3-M2144-000 Supplied with harmonic drive
3) Place a sign indicating that the robot is being inspected, to keep others from
operating the controller switch.
5) Remove the Y-axis arm upper cover. Place the cover on the robot base (ped-
estal) side with the machine harness still connected.
Refer to "7 Removing the Robot Covers" in Chapter 4 for removing the cov-
ers.
6) Disconnect the connectors on the Y-axis motor power cable YM and resolver
cable YP.
7) Remove the Y-axis motor installation bolts (M5×14L, 4 pieces) and then re-
move the Y-axis motor by swaying it gently right and left. (See Fig. 5-23.)
M5×14
Fig. 5-23
! CAUTION
An O-ring is fitted to the motor, so be careful not to let it drop into the peripheral
unit.
5-35
CHAPTER 5 Periodic Inspection
8) Remove the wave generator from the motor shaft. The wave generator is
secured with an M4 set screws. (See Fig. 5-27.)
WARNING
When you remove the Y-axis arm installation bolts (M3×20L, 12 pieces) in the
next step, the Y-axis arm may come off causing a hazardous situation. Be es-
pecially careful to keep the arm from falling when a heavy tool is attached to the
arm tip.
9) Remove the Y-axis arm installation bolts (M3×20L, 12 pieces). (See Fig. 5-
24.)
M3×20
Fig. 5-24
10) Remove the Y-axis arm and place it where it will not obstruct the work.
! CAUTION
An O-ring is fitted to the upper surface of the harmonic drive, so be careful not
to let it drop into the peripheral unit.
11) Remove the Y-axis harmonic drive installation bolts (M3×40L, 8 pieces) from
the bottom of the arm. (See Fig. 5-25.)
M3×40
Fig. 5-25
12) Remove the Y-axis harmonic drive from the top of the X-axis arm.
5-36
CHAPTER 5 Periodic Inspection
! CAUTION
An O-ring is fitted to the upper surface of the X-axis, so be careful not to let it
drop into the peripheral unit. (See Fig. 5-26.)
O-ring
(KN4-M257K-000)
Fig. 5-26
13) Fit a new O-ring coated with harmonic grease into the O-ring groove on the
X-axis arm. (See Fig. 5-26.)
14) Place the new harmonic drive on the X-axis arm, and secure it with the bolts
(M3×40L, 8 pieces) you removed earlier. Apply small amounts of "Screw
Lock" to the bolts and tighten them uniformly to secure the harmonic drive
from the backside. (See Fig. 5-25.)
! CAUTION
Do not allow the O-ring to get caught out of the groove during reassembly. A
trouble will occur if the robot is operated with the O-ring left caught out of the
groove.
15) Fit an O-ring (supplied with the harmonic drive) coated with harmonic grease
into the O-ring groove on the new harmonic drive. (See Fig. 5-27.)
16) Secure the Y-axis arm to the harmonic drive with the bolts (M3×20L, 12
pieces) you removed earlier. Apply small amounts of "Screw Lock" to the
bolts and tighten them uniformly to secure the Y-axis arm. (See Fig. 5-24.)
! CAUTION
Do not allow the O-ring to get caught out of the groove during reassembly. A
trouble will occur if the robot is operated with the O-ring left caught out of the
groove.
5-37
CHAPTER 5 Periodic Inspection
17) Apply harmonic grease to the new wave generator and flexible spline.
See Fig. 5-27 for applying grease properly.
18) Fit the wave generator onto the motor shaft, and fully insert it against the
motor. Then, apply small amounts of "Screw Lock" to the M4 set screw (1
piece) you removed earlier and tighten it to secure the wave generator. (See
Fig. 5-27.)
Fit O-ring (supplied) into this groove
Harmonic drive will be damaged if O-ring is caught out of groove.
O-ring : KN3-M2144-000
M4 set screw
Apply grease to entire oldham coupling.
O-ring : KN3-M2143-000
Wave generator
Apply grease to sufficiently fill in the ball space.
Apply grease to the thickness equal to the ball diameter.
Circular spline
Never remove these temporarily tightened bolts.
The axis will otherwise deviate from center.
Fig. 5-27
19) Fit a new O-ring to the motor and tighten the bolts (M5×14L, 4 pieces) you
removed earlier to temporarily secure the motor to the Y-axis arm. (See Fig.
5-23 and Fig. 5-27.)
! CAUTION
Do not allow the O-ring to get caught out of the groove during reassembly. A
trouble will occur if the robot is operated with the O-ring left caught out of groove.
20) Uniformly tighten the four bolts (M5×12L) temporarily fastened in the pre-
vious step while moving the Y-axis by hand slowly left and right through 45°.
If any jamming or catching is felt while moving the axis at this time, then
reassemble from the beginning.
21) Reattach the connectors on the Y-axis motor power cable YM and resolver
cable YP.
24) Check that no one is inside the safeguard enclosure, and then turn on the
controller.
! CAUTION
After the Harmonic drive is replaced, an absolute reset must be performed, and
the standard coordinate and point data must be reset. Refer to "Chapter 4 Ad-
justment" to adjust it.
5-38
CHAPTER 5 Periodic Inspection
3. R-axis
1) Prepare the following tools and items.
• Harmonic grease 4B No.2
• Waste cloth (rag)
• Phillips-head screwdriver
• Hex wrench set
• Screw Lock (thread sealant)
• Torque-limiting wrench
• Hook wrench
• Replacement parts (See table below.)
Replacement parts
Parts name Type No. YAMAHA Parts No. Note
Harmonic drive SHF-17-50 KN4-M1821-000
Rubber wire diameter 1.78mm × Ring inner diameter 63.22mm KN4-M1896-000 Lower part of harmonic drive
O-ring
Rubber wire diameter 0.80mm × Ring inner diameter 45.40mm KN3-M257L-000 Supplied with harmonic drive
Edge seal VR22A KN4-M1886-000
WARNING
The Z-axis will slide down when the spline mounting bolts (M5×16L, 4 pieces)
are removed in the next step, causing a hazardous situation. Prop the Z-axis
with a support stand before loosening these bolts.
6) Remove the bolts (M5×16L, 4 pieces) securing the bearing to the upper end
of the spline and remove the spline and bearing from the holder. (See Fig. 5-
28.)
Holder
Bearing
M5×16
Spline shaft
Fig. 5-28
5-39
CHAPTER 5 Periodic Inspection
7) While placing a steel rod or similar tool through the 7mm diameter hole at
the lower part of the spline, loosen the U-nut at the top of the spline with the
wrench, and remove the bearing and bearing mount plate. (See Fig. 5-29.)
Use a round steel rod with a diameter slightly smaller than 7mm. Avoid using
a square rod because the spline might be damaged by the edge of the rod.
At this point, be careful to keep the spline shaft from coming off the spline
nut.
U-nut
Spline nut
Spline shaft
Fig. 5-29
8) Remove the bolts (M4×10L, 2 pieces) on the lower side of the Y-axis arm,
and remove the R-axis dog ring from the fastening plate.
9) Remove the bolts (M3×25L, 8 pieces) on the underside of the Y-axis arm and
remove the plate fastening the spline and the harmonic drive. (See Fig. 5-30.)
M3×25
Fastening plate
Fig. 5-30
5-40
CHAPTER 5 Periodic Inspection
! CAUTION
An O-ring is fitted to the fastening plate, so be careful not to let it drop into the
peripheral unit. (See Fig. 5-31.)
O-ring : KN4-M1896-000
Fig. 5-31
10) Remove the bolts (M4×10L, 4 pieces) securing the R-axis motor plate at the
top of the Y-axis arm. (See Fig. 5-32.)
11) Loosen the pulley set screw (M4, 2 pieces) and remove the pulley from the
wave generator. (See Fig. 5-32.)
12) Remove the harmonic drive installation bolts (M3×16L, 9 pieces) and pull
out the harmonic drive from the bottom of the Y-axis arm. (See Fig. 5-32.)
M3×16
M4 set screw
M4×10
Pulley
Fig. 5-32
! CAUTION
An O-ring is fitted to the harmonic drive, so be careful not to let it drop into the
peripheral unit.
13) Remove the retaining ring for the wave generator and pull out the wave gen-
erator from the bottom of the Y-axis arm.
5-41
CHAPTER 5 Periodic Inspection
14) Apply harmonic grease to the new wave generator. See Fig. 5-33 for apply-
ing grease properly.
Wave generator Retaining ring groove
Fig. 5-33
15) Insert the new wave generator into the Y-axis arm from the bottom, and se-
cure it with the retaining ring. The chamfered side of the retaining ring should
face downwards.
17) Remove the four bolts temporarily tightened to the new harmonic drive.
! CAUTION
Remove only the four bolts shown in Fig. 5-33 at this point. Never remove the
bolts on the opposite side. If they are removed, the harmonic drive axis may
deviate from the center causing a trouble.
18) Fit an O-ring (supplied with the harmonic drive) coated with harmonic grease
into the O-ring groove on the new harmonic drive. (See Fig. 5-33.)
Apply small amounts of "Screw Lock" to the bolts (M3×16L, 9 pieces) and
tighten them to secure the harmonic drive to the Y-axis arm from the top of
the Y-axis arm. (See Fig. 5-32.)
! CAUTION
Do not allow the O-ring to get caught out of the groove during reassembly. A
trouble will occur if the robot is operated with the O-ring left caught out of the
groove.
When reassembling the harmonic drive, be careful to keep the circular spline
from coming off. If it comes off, the harmonic drive axis will deviate from the
center causing a trouble.
19) Apply small amounts of "Screw Lock" to the M4 set screws (2 pieces) and
tighten them to secure the pulley to the wave generator. (See Fig. 5-32.)
20) Fit the timing belt onto the wave generator pulley and motor pulley, and then
secure the motor plate. (See Fig. 5-32.)
5-42
CHAPTER 5 Periodic Inspection
! CAUTION
It is necessary to apply correct tension to the timing belt during reassembly.
Refer to "8 Adjusting the Timing Belt Tension" in Chapter 4.
21) Fit a new O-ring into the O-ring groove on the fastening plate and also re-
place the edge seal with new one. Then secure the fastening plate to the har-
monic drive with the bolts (M3×25L, 8 pieces) coated with small amounts of
"Screw Lock". (See Fig. 5-30 and Fig. 5-34.) At this point, be careful to keep
the spline shaft from coming off the spline nut.
! CAUTION
The harmonic drive service life may shorten if the edge seal effect is insuffi-
cient, so carefully reassemble the parts.
22) Tighten the bolts (M4×10L, 2 pieces) to secure the dog ring to the fastening
plate.
23) Insert the bearing mount plate and bearing onto the spline from the top, and
tighten the U-nut to secure the bearing. (Utilize the φ7 through-hole when
tightening the U-nut like you did to loosen it.) (See Fig. 5-29.)
24) Insert the spline and bearing through the holder and secure them with the
bolts you removed earlier (M5×16L, 4 pieces). (See Fig. 5-28.)
27) Check that no one is inside the safeguard enclosure, and then turn on the
controller.
! CAUTION
After the Harmonic drive is replaced, the absolute reset must be performed,
and the point data must be reset. Refer to "Chapter 4 Adjustment" to adjust it.
Edge seal
O-ring : KN4-M1896-000
Fastening plate
Spline nut
Spline shaft
Fig. 5-34
5-43
CHAPTER 5 Periodic Inspection
1. X-axis
1) Prepare the following tools and items.
• Harmonic grease 4B No.2
• Waste cloth (rag)
• Phillips-head screwdriver
• Hex wrench set
• Screw Lock (thread sealant)
• Ratchet handle
• Hexagonal socket set
• Extension bar
• Torque-limiting wrench
• Replacement parts (See table below.)
Replacement parts
Parts name Type No. YAMAHA Parts No. Note
SHF-32-80 KN5-M2110-001 YK700X,YK800X
Harmonic drive
SHF-32-100 KN5-M2110-101 YK1000X
S115(JIS) KN5-M2159-000 Top of harmonic drive
Rubber wire diameter 1.78mm × Ring inner diameter 78.97mm KN5-M2144-000 Base (robot pedestal)
O-ring
Rubber wire diameter 1.78mm × Ring inner diameter 69.57mm KN5-M2143-000 Motor
Rubber wire diameter 1.50mm × Ring inner diameter 87.50mm KN5-M2199-000 Supplied with harmonic drive
3) Place a sign indicating that the robot is being inspected, to keep others from
operating the controller switch.
5) Remove the base (robot pedestal) front and rear covers and the X-axis arm
upper cover.
Refer to "7 Removing the Robot Covers" in Chapter 4 for removing the cov-
ers.
6) Disconnect the connectors on the X-axis motor power cable XM and resolver
cable XP.
5-44
CHAPTER 5 Periodic Inspection
7) Remove the bolts (M6×20L, 4 pieces) securing the motor by using the ratchet
handle, M6 hexagonal socket, socket adapter and extension bar. (See Fig. 5-
35.)
M5×25
M6×20
Spacer
Fig. 5-35
8) Slowly pull out the motor while holding it slantways. (See Fig. 5-36.) If it is
difficult to remove the motor, slowly rotate the X-axis arm and again try
removing the motor.
! CAUTION
Carefully remove the motor so as not to let hands or fingers get pinched be-
tween the motor and the base.
An O-ring is fitted to the motor and the spacer, so be careful not to let it drop into
the peripheral unit.
Fig. 5-36
5-45
CHAPTER 5 Periodic Inspection
9) Remove the wave generator from the motor shaft. The wave generator is
secured with an M4 set screw and keyway. (See Fig. 5-40.)
WARNING
When you remove the X-axis arm installation bolts (M5×55L, 8 pieces) in the
next step, the X-axis arm may come off causing a hazardous situation. Be es-
pecially careful to keep the arm from falling when a heavy tool is attached to the
arm tip.
WARNING
Removing the X-axis arm is dangerous for just one person. Always use two or
more people, or remove the Y-axis arm in advance.
Refer to "2. Y-axis" of "5-2-3" for removing the Y-axis arm.
10) Remove the X-axis arm installation bolts (M5×55L, 8 pieces). (See Fig. 5-
37.)
M5×55
Fig. 5-37
11) Remove the X-axis arm and place it where it will not obstruct the work.
5-46
CHAPTER 5 Periodic Inspection
! CAUTION
An O-ring is fitted to the X-axis arm, so be careful not to let it drop into the
peripheral unit. (See Fig. 5-38.)
O-ring
(S115 : KN5-M2159-000)
Fig. 5-38
12) Remove the bolts (M5×25L 8 pieces and M5×35L 8 pieces) securing the X-
axis harmonic drive. (See Fig. 5-39.)
M5×25 M5×35
Fig. 5-39
13) Remove the X-axis harmonic drive from the top of the base.
! CAUTION
An O-ring is fitted to the X-axis harmonic drive, so be careful not to let it drop
into the base or peripheral unit.
5-47
CHAPTER 5 Periodic Inspection
14) Fit an O-ring (supplied with the harmonic drive) coated with harmonic grease
into the O-ring groove on the new harmonic drive. (See Fig. 5-40.)
Apply small amounts of "Screw Lock" to the bolts (M5×25L 8 pieces and
M5×35L 8 pieces) and tighten them to secure the harmonic drive from the
backside of the base. (See Fig. 5-39.)
! CAUTION
Do not allow the O-ring to get caught out of the groove during reassembly. A
trouble will occur if the robot is operated with the O-ring left caught out of the
groove.
15) Apply harmonic grease to the new wave generator and flexible spline.
See Fig. 5-40 for applying grease properly.
16) Fit a new O-ring into the O-ring groove on the X-axis arm and secure it to the
harmonic drive. Then apply small amounts of "Screw Lock" to the bolts
(M5×55L, 8 pieces) you removed earlier and tighten them uniformly to se-
cure the X-axis arm. (See Fig. 5-37 and Fig. 5-38.)
! CAUTION
Do not allow the O-ring to get caught out of the groove during reassembly. A
trouble will occur if the robot is operated with the O-ring left caught out of the
groove.
17) Fit the wave generator onto the motor shaft, and fully insert it against the
motor. Then, apply small amounts of "Screw Lock" to the M4 set screw (1
piece) you removed earlier and tighten it to secure the wave generator onto
the motor shaft. (See Fig. 5-40.)
Fit O-ring (supplied) into this groove
Harmonic drive will be damaged if O-ring is caught out of groove.
O-ring : KN5-M2199-000
Apply grease to entire oldham coupling.
O-ring : KN5-M2143-000
M4 set screw
Wave generator
Fig. 5-40
5-48
CHAPTER 5 Periodic Inspection
18) Fit a new O-ring to the motor and temporarily fasten the motor and spacer to
the base with the bolts (M6×20L, 4 pieces) you removed earlier. Insert a new
O-ring between the spacer and the base at this point.
Insert the motor with the wave generator into the harmonic drive while hold-
ing the motor slantways. If it is difficult to insert the motor, try inserting it
again while slowly rotating the X-axis arm. (See Fig. 5-36.)
! CAUTION
Do not allow the O-ring to get caught out of the groove during reassembly. A
trouble will occur if the robot is operated with the O-ring left caught out of the
groove.
19) Uniformly tighten the four bolts (M6×20L) temporarily fastened in the pre-
vious step while moving the X-axis by hand slowly left and right through
45°. If any jamming or catching is felt while moving the axis at this time,
then reassemble from the beginning.
20) Reattach the connectors on the X-axis motor power cable XM and resolver
cable XP.
21) Reattach the base (robot pedestal) front and rear covers and the X-axis arm
upper cover.
23) Check that no one is inside the safeguard enclosure, and then turn on the
controller.
! CAUTION
After the Harmonic drive is replaced, an absolute reset must be performed, and
the standard coordinate and point data must be reset. Refer to "Chapter 4 Ad-
justment" to adjust it.
5-49
CHAPTER 5 Periodic Inspection
2. Y-axis
1) Prepare the following tools and items.
• Harmonic grease 4B No.2
• Waste cloth (rag)
• Phillips-head screwdriver
• Hex wrench set
• Screw Lock (thread sealant)
• Torque-limiting wrench
• Replacement parts (See table below.)
Replacement parts
Parts name Type No. YAMAHA Parts No. Note
Harmonic drive SHF-25-80 KN4-M2110-001
S90(JIS) KN4-M2143-000 Lower part of harmonic drive
O-ring Rubber wire diameter 1.78mm × Ring inner diameter 69.57mm KN5-M2143-000 For motor
Rubber wire diameter 1.30mm × Ring inner diameter 66.50mm KN5-M257L-000 Supplied with harmonic drive
3) Place a sign indicating that the robot is being inspected, to keep others from
operating the controller switch.
5) Remove the Y-axis arm upper cover. Place the cover on the robot base (ped-
estal) side with the machine harness still connected.
Refer to "7 Removing the Robot Covers" in Chapter 4 for removing the covers.
6) Disconnect the connectors on the Y-axis motor power cable YM and resolver
cable YP.
7) Remove the Y-axis motor installation bolts (M6×20L, 4 pieces) and then re-
move the Y-axis motor by swaying it gently right and left. (See Fig. 5-41.)
M6×20
Spacer
Fig. 5-41
5-50
CHAPTER 5 Periodic Inspection
! CAUTION
An O-ring is fitted to the motor, so be careful not to let it drop into the peripheral
unit.
8) Remove the wave generator from the motor shaft. The wave generator is
secured with an M4 set screws. (See Fig. 5-45.)
WARNING
When you remove the Y-axis arm installation bolts (M4×20L, 16 pieces) in the
next step, the Y-axis arm may come off causing a hazardous situation. Be es-
pecially careful to keep the arm from falling when a heavy tool is attached to the
arm tip.
9) Remove the Y-axis arm installation bolts (M4×20L, 16 pieces). (See Fig. 5-
42.)
M4×20
Fig. 5-42
10) Remove the Y-axis arm and place it where it will not obstruct the work.
! CAUTION
An O-ring is fitted to the upper surface of the harmonic drive, so be careful not
to let it drop into the peripheral unit.
5-51
CHAPTER 5 Periodic Inspection
11) Remove the Y-axis harmonic drive installation bolts (M4×45L, 8 pieces).
(See Fig. 5-43.)
M4×45
Fig. 5-43
12) Remove the Y-axis harmonic drive from the top of the X-axis arm.
! CAUTION
An O-ring is fitted to the upper surface of the X-axis, so be careful not to let it
drop into the peripheral unit. (See Fig. 5-44.)
O-ring
(S90 : KN4-M2143-000)
Fig. 5-44
13) Fit a new O-ring coated with harmonic grease into the O-ring groove on the
X-axis arm. (See Fig. 5-44.)
5-52
CHAPTER 5 Periodic Inspection
14) Place the new harmonic drive on the X-axis arm, and secure it with the bolts
(M4×45L, 8 pieces) you removed earlier. Apply small amounts of "Screw
Lock" to the bolts and tighten them uniformly to secure the harmonic drive
from the backside. (See Fig. 5-43.)
! CAUTION
Do not allow the O-ring to get caught out of the groove during reassembly. A
trouble will occur if the robot is operated with the O-ring left caught out of the
groove.
15) Fit an O-ring (supplied with the harmonic drive) coated with harmonic grease
into the O-ring groove on the new harmonic drive. (See Fig. 5-45.)
16) Secure the Y-axis arm to the harmonic drive with the bolts (M4×20L, 16
pieces) you removed earlier. Apply small amounts of "Screw Lock" to the
bolts and tighten them uniformly to secure the Y-axis arm. (See Fig. 5-42.)
! CAUTION
Do not allow the O-ring to get caught out of the groove during reassembly. A
trouble will occur if the robot is operated with the O-ring left caught out of the
groove.
17) Apply harmonic grease to the new wave generator and flexible spline.
See Fig. 5-45 for applying grease properly.
18) Fit the wave generator onto the motor shaft, and fully insert it against the
motor. Then, apply small amounts of "Screw Lock" to the M4 set screw (1
piece) you removed earlier and tighten it to secure the wave generator. (See
Fig. 5-45.)
Fit O-ring (supplied) into this groove
Harmonic drive will be damaged if O-ring is caught out of groove.
O-ring : KN5-M257L-000
Apply grease to entire oldham coupling.
O-ring : KN5-M2143-000
M4 set screw
Wave generator
Apply grease to sufficiently fill in the ball space.
Apply grease to the thickness equal to the ball diameter.
Circular spline
Never remove these temporarily tightened bolts.
The axis will otherwise deviate from center.
Fig. 5-45
5-53
CHAPTER 5 Periodic Inspection
19) Fit a new O-ring to the motor and tighten the bolts (M6×20L, 4 pieces) you
removed earlier to temporarily secure the motor to the Y-axis arm. (See Fig.
5-41.)
Insert a new O-ring between the spacer and the Y-axis arm at this point.
! CAUTION
Do not allow the O-ring to get caught out of the groove during reassembly. A
trouble will occur if the robot is operated with the O-ring left caught out of groove.
20) Uniformly tighten the four bolts (M6×20L) temporarily fastened in the pre-
vious step while moving the Y-axis by hand slowly left and right through 45°.
If any jamming or catching is felt while moving the axis at this time, then
reassemble from the beginning.
21) Reattach the connectors on the Y-axis motor power cable YM and resolver
cable YP.
24) Check that no one is inside the safeguard enclosure, and then turn on the
controller.
! CAUTION
After the Harmonic drive is replaced, an absolute reset must be performed, and
the standard coordinate and point data must be reset. Refer to "Chapter 4 Ad-
justment" to adjust it.
5-54
CHAPTER 5 Periodic Inspection
3. R-axis
1) Prepare the following tools and items.
• Harmonic grease 4B No.2
• Waste cloth (rag)
• Phillips-head screwdriver
• Hex wrench set
• Screw Lock (thread sealant)
• Torque-limiting wrench
• Hook wrench
• Replacement parts (See table below.)
Replacement parts
Parts name Type No. YAMAHA Parts No. Note
Harmonic drive SHF-20-50 KN5-M1821-001
S71(JIS) KN3-M2159-000 Lower part of harmonic drive
O-ring
Rubber wire diameter 0.99mm × Ring inner diameter 53.28mm KN3-M2144-000 Supplied with harmonic drive
Edge seal VR28A KN5-M1886-000
WARNING
The Z-axis will slide down when the spline mounting bolts (M5×16L, 4 pieces)
are removed in the next step, causing a hazardous situation. Prop the Z-axis
with a support stand before loosening these bolts.
6) Remove the bolts (M5×16L, 4 pieces) securing the bearing to the upper end
of the spline and remove the spline and bearing from the holder. (See Fig. 5-
46.)
Holder
Bearing
M5×16
Spline shaft
Fig. 5-46
5-55
CHAPTER 5 Periodic Inspection
7) While placing a steel rod or similar tool through the 8mm diameter hole at
the lower part of the spline, loosen the U-nut at the top of the spline with the
hook wrench, and remove the bearing and bearing mount plate. (See Fig. 5-
47.)
Use a round steel rod with a diameter slightly smaller than 8mm. Avoid using
a square rod because the spline might be damaged by the edge of the rod.
At this time, be careful to keep the spline shaft from coming off the spline
nut.
U-nut
Spline nut
Spline shaft
Fig. 5-47
8) Remove the bolts (M4×10L, 2 pieces) on the lower side of the Y-axis arm,
and remove the R-axis dog ring from the fastening plate.
9) Remove the bolts (M3×30L, 8 pieces) on the underside of the Y-axis arm and
remove the plate fastening the spline and the harmonic drive. (See Fig. 5-48.)
M3×30
Fastening plate
Fig. 5-48
5-56
CHAPTER 5 Periodic Inspection
! CAUTION
An O-ring is fitted to the fastening plate, so be careful not to let it drop into the
peripheral unit. (See Fig. 5-49.)
O-ring : KN3-M2159-000
Fig. 5-49
10) Remove the bolts (M4×15L, 4 pieces) securing the R-axis motor plate at the
top of the Y-axis arm. (See Fig. 5-50.)
11) Loosen the pulley set screw (M4, 2 pieces) and remove the pulley from the
wave generator. (See Fig. 5-50.)
12) Remove the harmonic drive installation bolts (M3×30L, 13 pieces) and pull
out the harmonic drive from the bottom of the Y-axis arm. (See Fig. 5-50.)
M4 Set screw
M3×30 M4×15
Pulley
Fig. 5-50
! CAUTION
An O-ring is fitted to the harmonic drive, so be careful not to let it drop into the
peripheral unit.
13) Remove the retaining ring for the wave generator and pull out the wave gen-
erator from the bottom of the Y-axis arm.
5-57
CHAPTER 5 Periodic Inspection
14) Apply harmonic grease to the new wave generator. See Fig. 5-51 for apply-
ing grease properly.
Retaining ring groove
Wave generator
Apply grease to sufficiently fill in the ball space.
Apply grease to entire oldham coupling.
Fit O-ring (supplied) into this groove
Harmonic drive will be damaged if O-ring is Apply grease to the thickness equal to the
caught out of groove. ball diameter.
O-ring : KN3-M2144-000
Circular spline
Fig. 5-51
15) Insert the new wave generator into the Y-axis arm from the bottom, and se-
cure it with the retaining ring. The chamfered side of the retaining ring should
face downwards.
17) Fit an O-ring (supplied with the harmonic drive) coated with harmonic grease
into the O-ring groove on the new harmonic drive. (See Fig. 5-51.)
Apply small amounts of "Screw Lock" to the bolts (M3×30L, 13 pieces) and
tighten them to secure the harmonic drive to the Y-axis arm from the top of
the Y-axis arm. (See Fig. 5-50.)
! CAUTION
Do not allow the O-ring to get caught out of the groove during reassembly. A
trouble will occur if the robot is operated with the O-ring left caught out of the
groove.
18) Apply small amounts of "Screw Lock" to the M4 set screws (2 pieces) and
tighten them to secure the pulley to the wave generator. (See Fig. 5-50.)
19) Fit the timing belt onto the wave generator pulley and motor pulley, and then
secure the motor plate. (See Fig. 5-50.)
! CAUTION
It is necessary to apply correct tension to the timing belt during reassembly.
Refer to "8 Adjusting the Timing Belt Tension" in Chapter 4.
5-58
CHAPTER 5 Periodic Inspection
20) Fit a new O-ring into the O-ring groove on the fastening plate and also re-
place the edge seal with new one. Then secure the fastening plate to the har-
monic drive with the bolts (M3×30L, 8 pieces) coated with small amounts of
"Screw Lock". (See Fig. 5-48 and Fig. 5-52.) At this point, be careful to keep
the spline shaft from coming off the spline nut.
! CAUTION
The harmonic drive service life may shorten if the edge seal effect is insuffi-
cient, so carefully reassemble the parts.
Spline nut
Spline shaft
Fig. 5-52
21) Tighten the bolts (M4×10L, 2 pieces) to secure the dog ring to the fastening
plate.
22) Insert the bearing mount plate and bearing onto the spline from the top, and
tighten the U-nut to secure the bearing. (Utilize the φ8 through-hole when
tightening the U-nut like you did to loosen it.) (See Fig. 5-47.)
23) Insert the spline and bearing through the holder and secure them with the
bolts you removed earlier (M5×16L, 4 pieces). (See Fig. 5-46.)
26) Check that no one is inside the safeguard enclosure, and then turn on the
controller.
! CAUTION
After the Harmonic drive is replaced, the absolute reset must be performed,
and the point data must be reset. Refer to "Chapter 4 Adjustment" to adjust it.
5-59
CHAPTER 5 Periodic Inspection
5-2-4 YK1200X
The YK1200X uses a harmonic drive only for the R-axis. The following steps
describe procedures and precautions when replacing this harmonic drive. For the
bolt tightening torques in this work, refer to Table 5-2.
3) Place a sign indicating that the robot is being inspected, to keep others from
operating the controller switch.
6) Remove the bolts (M5×20L, 4 pieces) and then separate the spline support
shaft (2 pieces) from the shaft fastening plate. (See Fig. 5-53.)
M4×30
Shaft fastening plate
M5×20
Fig. 5-53
5-60
CHAPTER 5 Periodic Inspection
7) Remove the bolts (M6×20L, 4 pieces) securing the bearing to the upper end
of the spline and remove the bearing mount plate. (See Fig. 5-54.)
M6×20
Bearing
Holder
Fig. 5-54
WARNING
The Z-axis will slide down when the U-nut is removed in the next step, causing
a hazardous situation. Prop the Z-axis with a support stand before loosing the
U-nut.
8) While holding a steel rod or similar tool through the 10mm diameter hole as
shown, use the hook spanner to remove the U-nut on the spline shaft and then
remove the bearing. (See Fig. 5-55.)
Use a round steel rod with a diameter slightly smaller than 10mm. Avoid
using a square rod because the spline might be damaged by the edge of the
rod.
Be careful at this point to keep the spline shaft from coming off the spline.
U-Nut
Spline shaft
Fig. 5-55
5-61
CHAPTER 5 Periodic Inspection
9) Remove the bolts (M4×30L, 8 pieces) on the underside of the Y-axis arm and
remove the plate fastening the spline and the harmonic drive. (See Fig. 5-53.)
! CAUTION
An O-ring is fitted to the fastening plate, so be careful not to let it drop into the
peripheral unit. (See Fig. 5-56.)
O-ring : KN4-M2143-000
Fig. 5-56
10) Remove the bolts (M6×20L, 4 pieces) securing the R-axis motor plate at the
top of the Y-axis arm. (See Fig. 5-57.)
11) Loosen the pulley bolts (M3×30L, 4 pieces) and remove the pulley fastened
to the wave generator. (See Fig. 5-57.)
12) Remove the harmonic drive installation bolts (M4×45L, 12 pieces) and pull
out the harmonic drive from the bottom of the Y-axis arm. (See Fig. 5-57.)
M4×45
M3×30 M6×20
pulley
Fig. 5-57
! CAUTION
An O-ring is fitted to the harmonic drive, so be careful not to let it drop into the
peripheral unit.
13) Pull out the wave generator from the bottom of the Y-axis arm.
5-62
CHAPTER 5 Periodic Inspection
! CAUTION
An O-ring is fitted to the wave generator, so be careful not to drop it into the
peripheral unit.
14) Apply harmonic grease to the new wave generator. See Fig. 5-58 for apply-
ing grease properly.
Wave generator
O-ring groove
Apply grease to entire oldham coupling. O-ring : KN6-M1896-010
Circular spline
Fig. 5-58
15) Fit the O-ring coated with harmonic grease into the O-ring groove on the new
wave generator (wave generator support bearing section), and then insert the
wave generator into position from the bottom of the Y-axis arm.
! CAUTION
Do not allow the O-ring to get caught out of the groove during reassembly. A
trouble will occur if the robot is operated with the O-ring left caught out of the
groove.
17) Fit an O-ring (supplied with the harmonic drive) coated with harmonic grease
into the O-ring groove on the new harmonic drive. (See Fig. 5-58.)
Apply small amounts of "Screw Lock" to the bolts (M4×45L, 12 pieces) and
tighten them to secure the harmonic drive to the Y-axis arm from the top of
the Y-axis arm. (See Fig. 5-57.)
! CAUTION
Do not allow the O-ring to get caught out of the groove during reassembly. A
trouble will occur if the robot is operated with the O-ring left caught out of the
groove.
18) Apply small amounts of "Screw Lock" to the bolts (M3×30L, 4 pieces) and
tighten them to secure the pulley to the wave generator. (See Fig. 5-57.)
19) Fit the timing belt onto the wave generator pulley and motor pulley, and then
secure the motor plate. (See Fig. 5-57.)
5-63
CHAPTER 5 Periodic Inspection
! CAUTION
When securing the timing belt, the belt tension must be adjusted properly. See
"8. Adjusting the Timing Belt Tension" in Chapter 4 for how to adjust the belt
tension.
20) Fit a new O-ring into the O-ring groove on the fastening plate and also re-
place the edge seal with new one. Then, secure the fastening plate to the
harmonic drive with the bolts (M4×30L, 8 pieces) coated with small amounts
of "Screw Lock". (See Figs. 5-53 and 5-59.)
At this point, be careful to keep the spline shaft from coming off the spline
nut.
! CAUTION
The harmonic drive service life may shorten if the edge seal effect is insuffi-
cient, so carefully reassemble the parts.
Fastening plate
Spline nut
Spline shaft
Fig. 5-59
21) Insert the spline shaft into the holder, fit the bearing onto the spline and tighten
the U-nut to secure the bearing. (Utilize the φ10 through-hole when tighten-
ing the U-nut like you did to loosen it.) (See Fig. 5-55.)
22) Put the bearing into the holder and tighten the bolts (M6×20L, 4 pieces) to
secure the bearing mount plate to the holder (See Fig. 5-54.)
23) Install the spline support shafts (2 pieces) to the fastening plate, apply a small
amount of "Screw Lock" to the bolts (M5×20L, 4 pieces) and tighten. (See
Fig. 5-53.)
26) Check that no one is inside the safeguard enclosure, and then turn on the
controller.
5-64
CHAPTER 5 Periodic Inspection
5-65
CHAPTER 5 Periodic Inspection
(Operating conditions)
n : Number of axis movements per minute
q : Average turn per axis movement
N : Speed ratio
h : Operation time per day
D : Operation days per year
For example, when the robot is used under the following conditions, the
replacement period can be calculated as follows.
n : 10
q : 1/4 turn
N : 50
h : 24 hours per day
D : 240 days per year
5-66
CHAPTER 5 Periodic Inspection
WARNING
The motor and speed reduction gear casing are extremely hot after automatic
operation, so burns may occur if these are touched. Before touching these
parts, turn off the controller, wait for a while and check that the temperature has
cooled.
WARNING
Precautions when handling harmonic grease, cleaning oil:
• Inflammation may occur if they get in the eyes.
Before handling them, wear your safety goggles to ensure they will not come
in contact with the eyes.
• Inflammation may occur if they come into contact with skin. Be sure to wear
protective gloves to prevent contact with skin.
• Do not take orally or eat. (Eating will cause diarrhea and vomiting.)
• Hands and fingers might be cut when opening the container, so use protective
gloves.
• Keep out of the reach of children.
• Do not heat them or place near an open flame since this could lead to sparks
and fires.
Emergency Treatment:
• If they get in the eyes, wash liberally with pure water for about 15 minutes
and consult a physician for treatment.
• If they come in contact with the skin, wash away completely with soap and
water.
• If taken internally, do not induce vomiting but promptly consult a physician for
treatment.
WARNING
Disposing of harmonic grease, cleaning oil and the container:
• Proper disposal is compulsory under federal, state and local regulations. Take
appropriate measures in compliance with legal regulations.
• Do not pressurize the empty container. Pressurizing may cause the container
to rupture.
• Do not attempt to weld, heat up, drill holes or cut this container. This might
cause the container to explode and the remaining materials inside it to ignite.
5-67
CHAPTER 5 Periodic Inspection
WARNING
When removing the wave generator from the motor shaft or reinstalling it back
onto the motor shaft, use caution to avoid as much as possible, applying a
thrust load to the motor shaft. If a load is applied, the resolver may be damaged
resulting in a hazardous situation of the robot malfunction.
! CAUTION
The harmonic drive service life may decline drastically if the grease
recommended by YAMAHA is not used.
! CAUTION
Harmonic drive
• Do not apply strong shocks or impacts to these parts such as with a hammer.
Also, do not scratch, scar or dent these parts by dropping, etc. Such actions
will damage the harmonic drive.
• The specified performance cannot be maintained if any part of the harmonic
drive is used in a damaged state. This damage or wear may also lead to
trouble with the harmonic drive.
! CAUTION
Deviations in position may occur due to replacement of the harmonic grease.
This means that the machine reference adjustment, standard coordinate setting
and point data settings are required after replacing the grease. (Absolute reset
is also required for robots using an absolute encoder.)
1) Prepare the following tools and items necessary for replacing the grease.
• Harmonic grease HC-IA
• Waste cloth
• Phillips screwdriver
• Cleaning oil (kerosene, etc.)
• Magic marker
• Air gun
• Hex wrench set
• Screw lock
• Ratchet handle (insertion angle 6.35mm, 9.5mm)
• Hexagonal socket set (insertion angle 6.35mm, 9.5mm)
• Torque wrench (insertion angle 6.35mm, 9.5mm)
• Extension bar (insertion angle 9.5mm, length 75mm)
3) Place a sign indicating that the robot is being inspected, to keep others from
operating the controller switch.
5-68
CHAPTER 5 Periodic Inspection
5) To make reassembly easier, put marks on the motor holder, circular spline, Y-
axis arm and X-axis arm to indicate their relational positions before proceeding
to the next step, as shown in Fig. 5-60. The circular spline can be seen after
removing the motor holder.
7) Slowly pull out the motor along with the motor holder, while swaying the
motor slightly left and right. At this time, make every effort to avoid rotating
the motor shaft.
8) Remove the M6 set screw from the motor holder. (See Fig. 5-62.)
9) Align the key with the M6 hole, and insert the 2mm hex wrench into the M6
hole to loosen the internal M4 set screw. Then, remove the wave generator
from the motor shaft.
Motor holder
Y-axis motor
Flexible spline
Mark
Fig. 5-60 Harmonic drive grease replacement section and position markings
10) Remove the eight M4 bolts securing the circular spline and slowly pull out
the circular spline to remove it. Use the puller taps if difficult to remove the
circular spline.
11) Finally, remove the eight M6 bolts securing the flexible spline and washer on
the inner side of the circular spline, and remove the flexible spline and washer.
If the bolts are hard to see due to grease, remove the grease to make the job
easier. Use the puller taps on the bottom if difficult to remove these parts.
5-69
CHAPTER 5 Periodic Inspection
12) Remove the old grease from the washer, flexible spline, circular spline and
wave generator with a waste cloth, and then clean further with cleaning oil
and by blow from an air gun. The harmonic drive components are precision
parts so be careful not to drop them.
Apply grease to entire oldham coupling.
Apply grease to the
thickness of the ball. Fill all the gear
grooves completely. Fill the ball space sufficiently.
13) Apply the harmonic grease to the wave generator, circular spline, and flexible
spline. See Fig. 5-61 for the basics on applying the grease. Do not apply
grease to the washer.
14) Install the circular spline onto the Y-axis arm. Tighten the eight M4 bolts
while aligning with the marks you previously made. Take care not to let foreign
matter such as dirt or grit become mixed with the grease or parts during
installation. See below for the tightening torque of each bolt.
Tightening torque
M3 bolt —— 2.0Nm (20kgf·cm)
M4 bolt —— 4.5Nm (46kgf·cm)
M5 bolt —— 9.0Nm (92kgf·cm)
M6 bolt —— 15.3Nm (156kgf·cm)
M8 bolt —— 37Nm (380kgf·cm)
15) While aligning the Y-axis arm and X-axis arm with their marks, gently insert
the flexible spline into the circular spline. Then put the washers in place and
tighten the eight M6 bolts on the inner side of the circular spline, in order
from the diagonally opposite positions.
16) Insert the wave generator onto the motor shaft so it makes tight contact with
the motor holder as shown in Fig. 5-62, then apply small amounts of "Screw
Lock" (thread sealant) to the M4 set screw and tighten to secure the wave
generator. At this time, make every effort to avoid rotating the motor shaft.
17) While aligning the Y-axis arm mark with the motor holder mark, gently insert
the wave generator into the circular spline by moving it slightly left and right.
5-70
CHAPTER 5 Periodic Inspection
18) Tighten the four M4 bolts on the motor holder gradually while gently moving
the Y-axis arm by hand 45 degrees left and right. If you feel any hang-ups or
abnormalities, take apart and reassemble again.
20) Check that no one is inside the safeguard enclosure and then turn on the
controller.
21) Perform absolute reset and adjust the Y-axis machine reference. Also set the
reference coordinates and point data.
8.2mm (when fully inserted)
Motor
Wave generator
Key
Motor holder
5-71
CHAPTER 5 Periodic Inspection
WARNING
The motor and speed reduction gear casing are extremely hot after automatic
operation, so burns may occur if these are touched. Cool the X-axis motor for a
while with the fan and then turn off the controller. Check that the temperature
has cooled before touching these parts.
WARNING
• Bodily injury may occur from coming into contact with the X-axis cooling fan
while it is rotating.
• When removing the cover on the base (pedestal), first turn off the controller
and make sure the fan has stopped.
3) Place a sign indicating the robot is being inspected, to keep others from
operating the controller switch.
5) Remove the front and rear covers shown in the figure of the base, and also
remove the rear cover shown in Fig. 5-63 (a).
6) Unplug the connectors of the X-axis motor power wire XM and the resolver
wire XP.
7) Mark the relative positions beforehand of the motor holder, circular spline,
base (pedestal) and X-axis arm with a magic marker, in order to make the
reassembly job easier. The circular spline can be seen when the motor holder
is removed. (See Fig. 5-63 (b), (d).)
5-72
CHAPTER 5 Periodic Inspection
8) Remove the four M5 bolts for the motor holder, using the ratchet handle,
hexagonal socket, extension bar, socket adapter and hex wrench. (See Fig. 5-
63 (c).)
9)
WARNING
Carefully remove the motor so as not to let hands or fingers get pinched between
the motor and the base.
Remove the motor along with the motor holder, by pulling it gently right and
left. Make every effort to avoid rotating the motor shaft at this time.
10) Remove the M6 set screw from the motor holder. (See Fig. 5-64.)
11) Align the key with the M6 hole, and insert the 2mm hex wrench into the M6
hole to loosen the internal M4 set screw. Then, remove the wave generator
from the motor shaft.
12) From this step, use the same procedure explained from step 10) in Section 6-
2.
In reassembly, insert the wave generator all the way onto the motor shaft, so
that it is in the position as shown in Fig. 5-64. Then, apply small amounts of
"Screw Lock" to the M4 set screw and tighten to secure the wave generator.
5-73
CHAPTER 5 Periodic Inspection
X-axis arm
Mark
Base
Cover
Motor holder
Fan
X-axis motor
Rear cover
Fan
(b)
(a)
Mark
Circular spline
M5 bolt
(c) Viewed from direction A
(d)
Fig. 5-63 Harmonic drive grease replacement section and position markings
7.1mm (when fully inserted)
Motor
Wave generator
Key
Motor holder
5-74
CHAPTER 5 Periodic Inspection
Motor holder
R-axis motor
Mark
Mark
Spline
Fig. 5-65 Harmonic drive grease replacement section and position markings
5-75
CHAPTER 5 Periodic Inspection
Motor
Wave generator
Motor holder
5-76
CHAPTER 5 Periodic Inspection
! CAUTION
The RV speed reduction gear service life may shorten if the grease recom-
mended by YAMAHA is not used.
5-77
CHAPTER 5 Periodic Inspection
WARNING
The motor and speed reduction gear casing are extremely hot after automatic
operation, so burns may occur if these are touched. Before touching these
parts, turn off the controller, wait for a while and check that the temperature has
cooled.
WARNING
Precautions when handling grease:
• Inflammation may occur if this gets in the eyes.
Before handling the grease, wear your safety goggles to ensure the grease
will not come in contact with the eyes.
• Inflammation may occur if the grease comes into contact with skin. Be sure
to wear protective gloves to prevent contact with skin.
• Do not take orally or eat. (Eating will cause diarrhea and vomiting.)
• Hands and fingers might be cut when opening the container, so use protec-
tive gloves.
• Keep out of the reach of children.
• Do not heat the grease or place near an open flame since this could lead to
sparks and fires.
Emergency Treatment:
• If this grease gets in the eyes, wash liberally with pure water for about 15
minutes and consult a physician for treatment.
• If this grease comes in contact with the skin, wash away completely with
soap and water.
• If taken internally, do not induce vomiting but promptly consult a physician for
treatment.
! CAUTION
Disposing of grease and the container:
• Proper disposal is compulsory under federal, state and local regulations. Take
appropriate measures in compliance with legal regulations.
• Do not pressurize the empty container. Pressurizing may cause the con-
tainer to rupture.
• Do not attempt to weld, heat up, drill holes or cut this container. This might
cause the container to explode and the remaining materials inside it to ignite.
5-78
CHAPTER 5 Periodic Inspection
3) Place a sign indicating that the robot is being inspected, to keep others from
operating the controller switch.
5) Remove the base (robot pedestal) front cover and the X-axis arm top cover.
Refer to "7 Removing the Robot Covers" in Chapter 4 for removing the covers.
6) Remove the plug on the top of the X-axis arm. (See Fig. 5-67.)
7) To remove the old grease from the X-axis, attach the air coupler (PT1/8) into
the screw hole where the plug was fitted and connect the air tube to the air
coupler. The old grease inside the X-axis will be squeezed out by replenish-
ing new grease with a grease gun as explained in the next step.
8) Using the grease gun, pump the specified grease into the grease nipple lo-
cated on the front of the robot base. (See Fig. 5-68.)
9) After replenishing the grease, move the X-axis arm by hand back and forth a
few times (about 90 degrees) and then remove excess grease.
10) Remove the air coupler and then reattach the plug, X-axis top cover and base
front cover.
12) Check that no one is inside the safeguard enclosure, and then turn on the
controller.
plug Air tube coupler
Grease nipple
5-79
CHAPTER 5 Periodic Inspection
3) Place a sign indicating that the robot is being inspected, to keep others from
operating the controller switch.
6) Remove the plug on the top of the Y-axis arm. (See Fig. 5-69.)
7) To remove the old grease from the Y-axis, attach the air coupler (PT1/8) into
the screw hole where the plug was fitted and connect the air tube to the air
coupler. The old grease inside the Y-axis will be squeezed out by replenish-
ing new grease with a grease gun as explained in the next step.
8) Using the grease gun, pump the specified grease into the grease nipple lo-
cated on the bottom of the X-axis arm. (See Fig. 5-70.)
9) After replenishing the grease, move the Y-axis arm by hand back and forth a
few times (about 90 degrees) and then remove excess grease.
10) Remove the air coupler and then reattach the plug and X-axis arm under
cover.
12) Check that no one is inside the safeguard enclosure, and then turn on the
controller.
Grease nipple
Air tube coupler
plug Y-axis arm
X-axis arm
(viewed from bottom)
X-axis arm
5-80
CHAPTER 6
q Gate motion
From point P1 to P4 via P2 and P3: Z=0 P2 P3
MOVE P, P2
MOVE P, P3
MOVE P, P 4 P1 P4
When the Z-axis moves upward from P1 and enters the M3 arch position range
(2000 pulses prior to Z=0), the X, Y and R axes begin to move. When these 3 axes
enter the M1, M2 and M4 arch position range (2000 pulses prior to P2), the Z-
axis moves downward to P2. Compared with the gate motion q, this arch motion
shortens the cycle time approximately 20% by moving the robot arm along an
arc.
6-1
CHAPTER 6 Increasing the robot operating speed
P1 P2 P3
6-2
CHAPTER 6 Increasing the robot operating speed
[Example]
From P1 when chuck is open:
WEIGHT 5 ........ Changes the axis tip weight parameter to 5kg (no workpiece).
MOVE P, P2, Z=0
DO3 (0) = 1 ....... Chuck closes.
WEIGHT 10 ...... Changes the axis tip weight parameter to 10kg (with workpiece).
MOVE P, P3, Z=0
In the above program, the acceleration can be set to a higher level by reducing the
axis tip weight parameter to 5kg while the chuck does not grip any workpiece,
and then set to a lower level by changing the axis tip weight parameter to 10kg.
Compared to programs using an axis tip weight parameter left set at 10kg, this
method shortens the cycle time since the acceleration is increased.
No workpiece Chuck is gripping workpiece.
Z=0
Chuck 5kg
P1
Chuck opens.
Workpiece 5kg
P2 P3
Chuck closes.
6-3
CHAPTER 6 Increasing the robot operating speed
[Example] P3
From P1 to P3 via P2 P1
TOLE (1) = 2048 ... X-axis tolerance (pulses) : Increases the tolerance.
TOLE (2) = 2048 ... Y-axis tolerance (pulses) Tolerance can be set for each axis.
TOLE (3) = 2048 ... Z-axis tolerance (pulses) If the same tolerance is used for all
axes, you can write as "TOLE
TOLE (4) = 2048 ... R-axis tolerance (pulses) 2048".
MOVE P, P2
TOLE (1) = 80 ....... Returns the tolerance to the default value. If the same tolerance is used for all
TOLE (2) = 80 axes, you can write as "TOLE 80".
TOLE (3) = 80
TOLE (4) = 80
MOVE, P, P3
When P2 is an escape point and does not need to be accurately positioned, setting
the tolerance parameter to a larger value allows the robot arm to pass through P2
quickly. The larger the tolerance value for the positioning time, the shorter the
cycle time will be.
The maximum value of the tolerance parameter is 2048 (pulses) and the default is
80 (pulses).
6-4
CHAPTER 6 Increasing the robot operating speed
[Example]
From P1 when chuck is open:
OUTPOS (1) = 10000 ... X-axis OUT effective position (pulses) : Increases the OUT effective position.
OUTPOS (2) = 10000 ... Y-axis OUT effective position (pulses) The OUT effective position can
OUTPOS (3) = 10000 ... Z-axis OUT effective position (pulses) be set for each axis.
If the same OUT effective
OUTPOS (4) = 10000 ... R-axis OUT effective position (pulses) position is used for all axes, you
MOVE P, P2, Z=0 can write as "OUTPOS 10000".
DO3 (0) = 1 .................. Chuck closes.
OUTPOS (1) = 2000 ..... Returns the OUT effective position to the default value. If the same OUT effective
OUTPOS (2) = 2000 position is used for all
axes, you can write as
OUTPOS (3) = 2000 "OUTPOS 2000".
OUTPOS (4) = 2000
P1 P2
Chuck closed.
When all of the X, Y, Z and R axes enter the OUT effective position (10000
pulses prior to P2), the chuck starts closing.
By setting the OUT effective position larger, the chuck starts closing while the
robot arm is still moving at an earlier point, so that the chuck can grip the workpiece
more quickly.
The default value of the OUT effective position is 2000 (pulses).
[Reference]
Relation between X, Y, R-axis rotating angle, Z-axis movement distance and pulse values
The arch position, tolerance and OUT effective position parameters are set in
pulses.
For the relation between X, Y, R-axis rotating angle, Z-axis movement distance
and pulse values, refer to the tables listed under item (4) in "4. Setting the soft
limits". (Chapter 4 in this manual)
6-5
MEMO
6-6
CHAPTER 7
Specifications
1 Manipulator .............................................................................7-1
1-1 Basic specification ........................................................................... 7-1
1-2 External view and dimensions ......................................................... 7-4
1-3 Robot inner wiring diagram ............................................................ 7-24
1-4 Wiring table .................................................................................... 7-27
MEMO
CHAPTER 7 Specifications
1 Manipulator
7-1
CHAPTER 7 Specifications
7-2
CHAPTER 7 Specifications
*12 There
At constant ambient temperature (XY)
are limits to acceleration coefficient settings.
*
Sound level
Maximum sound pressure level
of robot
Position of maximum sound pressure
Robot model (lat 10dB or more difference
level
from background sound
pressure level )
YK250X, YK350X, YK400X 69.8dB 1.0m away from the rear of robot, 1.6m height
YK500X, YK600X 69.7dB 1.0m away from the rear of robot, 1.6m height
YK700X, YK800X,YK1000X 69.4dB 1.0m away from the rear of robot, 1.6m height
Note: Sound level may increase when sound reflecting objects are located near the robot.
7-3
CHAPTER 7 Specifications
0
(No. 1 to 10 usable)
R5
125
55
100
120
140
74
135 15 4-φ9
Use M8 bolt for installation
User tubing 1 (φ4 black) 165
576
454
251 250
36
152±2
0
12 -0.018
M8×1.25 Depth15
86
150
45
Interference position
(a) Base flange
1 40
0°
(b) Base rear side
14
11
°
5°
5°
11
0
R25
R86 R125
90°
90°
Manipulator interference area 120
Working envelope
13
145
2°
2°
145
13
R250
5
R7
63°
63°
Manipulator interference area 120
M4 ground terminal
7-5
CHAPTER 7 Specifications
0
(No. 1 to 10 usable)
R5
125
55
100
120
140
74
4-φ9
135 15
Use M8 bolt for installation
User tubing 1 (φ4 black) 165
576
454
251 250
36
152±2
0
12 -0.018
M8×1.25 Depth15
86
150
45
7-6
CHAPTER 7 Specifications
Interference position
(a) Base flange
(b) Base rear side
11
5°
5°
11
R1
52 50
R3
R125
R1
) 5(a
4(b )
R3
140° 140°
Working envelope
145°
145°
132
°
132
R14 50
2 R3
5
R12
R3
(a)
)
(b
11
R
107° 107°
Manipulator interference area 120
M4 ground terminal
7-7
CHAPTER 7 Specifications
0
(No. 1 to 10 usable)
R5
175
55
100
120
140
74
4-φ9
135 15 Use M8 bolt for installation
576
454
251
250
Z-axis upper end
mechanical stopper φ5
position 203.5
5
41
36
152±2
0
12 -0.018
M8×1.25 Depth15
86
150
45
0 0
7
7-8
CHAPTER 7 Specifications
Interference position
(a) Base flange
(b) Base rear side
11
5°
5°
11
R1 00
45 R4
R175
R6
)
4(b
(a
R1
)
140° 140°
Manipulator interference area 120
Working envelope
156°
156°
132
°
132
R400
2
R9
R175
86° 86°
120
Manipulator interference area
User tubing 1 (φ4 black) D-sub connector for user wiring (No. 1 to 10 usable)
M4 ground terminal
7-9
CHAPTER 7 Specifications
R80
R2
User tubing 1 (φ6 black) 0
User tubing 2 (φ6 red)
90
65
110
R200
φ108
160
94
70
65
R55
D-sub connector for user wiring (No. 1 to 20 usable)
User tubing 3 (φ6 blue) 57 73
80 86 4-φ11
166 (Base size) Use M10 bolt for installation
790
667
2×2-M4×0.7 561
Depth10
(Same on opposite side)
36
363 364
41
237±2
0
φ18 -0.018
M12×1.75 Depth20
200
300
91
Z-axis stroke 200mm
Working envelope
15
0 0
12
7-10
CHAPTER 7 Specifications
Interference position
(a) Base flange
(b) Base rear side
(c) Base
12
0°
0°
R7
R1
12
9(
00
50
c) )
R5
3(a
R5
100
50
R2
R9
5
145° 145°
Manipulator interference area
Working envelope
12
R7
2°
2°
R1
1( 00
12
c) a)
42
4(
R5
R4
100
50
R2
R9
5
147°
147°
Manipulator interference area
M4 ground terminal
73
55 53
35
0 0
2
7-11
CHAPTER 7 Specifications
R80
User tubing 1 (φ6 black) R2
0
User tubing 2 (φ6 red)
90
65
110
R200
φ108
160
94
70
65
R55
D-sub connector for user wiring (No. 1 to 20 usable)
User tubing 3 (φ6 blue)
57 73
80 86
4-φ11
166(Base size)
Use M10 bolt for installation
Z-axis 300mm stroke 876
800
667
2×2-M4×0.7 561
Depth10
(Same on opposite side)
36
363 364
54 20
Z-axis upper end
mechanical stopper φ7 318
position
282
8
48
41
237±2
φ18 0
-0.018
M12×1.75 Depth20
200
300
91
Z-axis stroke 200mm
Working envelope
15
0 0
12
7-12
CHAPTER 7 Specifications
Interference position
(a) Base flange
(b) Base rear side
(c) Base
12
0°
0°
12
00
a)
R1
6(
R2
R6
33
10
04
(c
R
)
50
R2
b)
8(
R7
145°
145°
Working envelope
12
2°
R1
2°
00
12
R1
24
R6
(a)
(c)
96
R98
50
R2
b)
0(
R7
147°
147°
X and Y-axis mechanical stopper positions (maximum working envelope)
M4 ground terminal
73
55 53
35
0 0
2
7-13
CHAPTER 7 Specifications
R1
06
58 350 350 147
R2
0
126
75
R15
0
φ116
106
112
180
70
75
R76
4-φ14
70 80
Use M12 bolt for installation
106 93
877
683
586
2×2-M4×0.7
Depth10
(Same on opposite side)
41
376 371
54 20
Z-axis upper end φ8 327
mechanical stopper
position
279
50.5
8
45
236±2
φ22 -0.021
0
M12×1.75 Depth20
200
97
Z-axis stroke 200mm
400
Working envelope
20
0 0
12
119.5
7-14
CHAPTER 7 Specifications
Interference position
(a) Base flange
(b) Base rear side
(c) Base
12
R1
0°
00
R2
25
0°
12
R7
(c a)
10
) 5(
R9
5 0
R3
b)
0(
R6
145°
145°
Working envelope
12
R1
3°
00
14
3°
R1
12
(c a)
R7
99
) 3(
R8
100
50
R3
R1
45
147° 147°
Manipulator interference area
M4 ground terminal
User tubing 1 (φ6 black) D-sub connector for user wiring (No. 1 to 20 usable)
User tubing 2 (φ6 red)
User tubing 3 (φ6 blue)
79
61 59
41
0 0
4
7-15
CHAPTER 7 Specifications
R1
06
58 350 450 147
R2
0
126
75
R15
0
112
180
φ116
106
70
75
R 76
4-φ14
70 80
Use M12 bolt for installation
106 93
877
683
586
2×2-M4×0.7
Depth10
(Same on opposite side)
41
376 371
54 20
Z-axis upper end
mechanical stopper φ8 327
position
279
50.5
8
45
236±2
0
φ22 -0.021
M12×1.75 Depth20
200
97
Z-axis stroke 200mm
400
Working envelope
20
0 0
119.5
12
7-16
CHAPTER 7 Specifications
Interference position
(a) Base flange
(b) Base rear side
(c) Base
12
0
0°
0°
0
)
R8
(a
17
12
R2
43
4(
R1
59
c)
50
R3
b)
0 8(
R1
145°
Working envelope 145°
12
00
3°
3°
R8
12
R1 R2 )
47 (a
62 31
(c) R1
50
R3
b)
6(
R9
147°
147°
M4 ground terminal
User tubing 1(φ6 black)
D-sub connector for user wiring (No. 1 to 20 usable)
User tubing 2(φ6 red)
User tubing 3(φ6 blue)
79
61 59
41
0 0
4
7-17
CHAPTER 7 Specifications
R1
06
58 450 550 147
R2
126
0
R150
75
φ116
106
112
180
70
75
R76
70 80 4-φ14
106 93 Use M12 bolt for installation
877
671
588
2×2-M4×0.7
Depth10
(Same on opposite side)
41
376 371
Z-axis upper end 54 20
mechanical stopper φ8 327
position
279
8
50.5
45
236±2 0
φ22 -0.021
M12×1.75 Depth 20
200
97
400
20
0 0
119.5
12
7-18
CHAPTER 7 Specifications
Interference position
(a) Base flange
(b) Base rear side
(c) Base
12
00
0°
a)
0°
R1
12
R2 R3 0(
30 15 20
( R
c)
50
R4
)
(b
65
R1
145° 145°
Working envelope
12
0
3°
00
3°
12
R3 )
R1
00 (a
R2 84
15
(c) R1
50
R4
(b)
49
R1
147°
147°
M4 ground terminal
User tubing 1(φ6 black)
User tubing 2(φ6 red) D-sub connector for user wiring (No. 1 to 20 usable)
User tubing 3(φ6 blue)
79
61 59
41
0 0
4
7-19
CHAPTER 7 Specifications
R13
(No. 1 to 20 usable, socket contact)
R2
5
150
0
140
170
200
250
90
R290
R9
User tubing 1 (φ6 black)
1
User tubing 2 (φ6 red) 103 97 4-φ14
140 112 Use M12 bolt for installation
User tubing 3 (φ6 blue)
252(Base size)
1168
2×2-M4×0.7
Depth10
(Same on 830
opposite side) 783
60
541 542
Z-axis upper end 95 20
mechanical stopper
position 442
69
4
φ10
45
381±2 390
φ25 -0.01
-0.02
M16×2 Depth25
400
131
25
0 0
Z-axis lower end 161.5
mechanical stopper
10
position
7-20
CHAPTER 7 Specifications
Interference position
(a) Base flange
(b) Base rear side
(c) Base
R1
12
5°
5°
0
1(
)
12
20
(a
c)
6
R1
7
R1
1
R31 00
R6
)
(b
0 3
R1
150° 150°
Working envelope
R1
128
°
70
128
°
)
20
(a
(c)
5
R1
5
R1
90 00
R2 R6
)
(b
3
R8
° 152
152 °
M4 ground terminal
D-sub connector for user wiring
User tubing 1(φ6 black) (No. 1 to 20 usable, pin contact)
User tubing 2(φ6 red)
User tubing 3(φ6 blue)
67
49 47
29
0 0
7-21
CHAPTER 7 Specifications
01
R1
R57
250
140
70
70
82
812
670
M4 ground terminal
15
15
492
446
Z-axis upper end
9
2-M4×0.7 Depth 6
mechanical stopper
position 381 (Same on
opposite side) 359
15
7-22
CHAPTER 7 Specifications
° 90
90 °
50
R5
R86
a)
2(
Interference position
(c)
R6
(a) Base flange
(b) Base rear side
R172 (c) Base
145° 145°
Working envelope R6
0(
b)
Radius in which load in working
envelope interferes with robot
°
93 93
° 50
R5
a)
R1
6(
59 R5
0
R2
(c
)
R41 (b
)
148° 148° Radius in which load interferes with robot
when X or Y-axis strikes mechanical stopper
X and Y-axis mechanical stopper positions (maximum working envelope)
*The area between working envelope and X or Y-axis mechanical stopper position cannot be used.
φ18.2
-0.25
0
14
10
30
φ16h7 0
-0.018
M12×1.75 Depth 20
7-23
CHAPTER 7 Specifications
User IO connector
User tubing
RORG RORG
YORG YORG
IO
YP YP
YM YM Y-axis resolver
RP RP Y-axis motor
RM RM
ZP ZP
ZM ZM
ZBK ZBK Round terminal
Z-axis resolver
Z-axis motor R-axis resolver Y-axis arm
Z-axis brake R-axis motor
X-axis arm
X-axis motor
IO
User tubing
X-axis resolver
ZM ZM
ZP ZP Round terminal
RM RM XM
RP RP M4 ground terminal YM
XORG
ZBK ZBK
ZM
YORG YORG
RORG RORG RM
FG FG XY
FG
ZR
Robot cable
7-24
CHAPTER 7 Specifications
Machine harness
User IO connector
User tubing
RORG RORG
YORG YORG IO
YM YM
YP YP
ZBK ZBK
ZM ZM
ZP ZP
RP RP R-axis resolver
RM RM R-axis motor Round terminal
Z-axis resolver
Z-axis motor
Y-axis resolver
Z-axis brake
Y-axis motor
X-axis resolver
XP XP
XM XM
Round terminal
YM YM
XORG
YP YP
ZM ZM M4 ground terminal
ZP ZP
RM RM User tubing
RP RP
ZBK ZBK
YORG YORG User IO connector
RORG RORG
FG FG
XM
FG YM
ZM
RM
XY
ZR
Robot cable
7-25
CHAPTER 7 Specifications
Machine harness
Round terminal
User tubing
User IO connector
RORG RORG
IO
Round terminal
YORG YORG R-axis
Y-axis resolver
YM YM
resolver Z-axis
YP YP resolver
R-axis
ZM ZM motor
ZBK ZBK Y-axis Z-axis
motor brake
ZP ZP
Z-axis
RM RM motor
RP RP
M4 ground terminal
X-axis motor
Fan
X-axis resolver
XORG
XP XP
Round terminal
XM XM
Fan
FAN1 FAN1
FAN2 FAN2
YM YM
FAN
ZM ZM
RM RM
YP YP
User tubing
ZP ZP
ZORG
RP RP
IO User IO connector
YORG YORG
XM
RORG RORG YM
ZBK ZBK ZM
FG FG
RM
FG FG
XY
ZLMT LMT
RLMT LMT
ZR
Robot cable
Round terminal (2 pcs)
M4 ground terminal Round terminal (2 pcs)
7-26
CHAPTER 7 Specifications
7-27
CHAPTER 7 Specifications
7-28
CHAPTER 7 Specifications
1 1 Brown
2 2 Red
3 3 Orange
4 4 Blue
0.2mm2
5 5 Purple
User signal line IO IO
6 6 Gray
7 7 White
8 8 Brown
9 9 Red
10 10 Orange
11 11
0.2mm2
12 12
13 13
14 14
Frame ground 15 15 Green Shield
Frame ground 1 FG Green Shield
Origin Sensor 24V 1 1 White
ORG YORG 2 2 YORG Purple 0.2mm2
GND 3 3 Gray
Origin Sensor 24V 1 1 White
ORG RORG 2 2 RORG Blue 0.2mm2
GND 3 3 Gray
Round terminal Round terminal Yellow/Green 0.75sq
Round terminal Round terminal Blue 0.75sq
7-29
CHAPTER 7 Specifications
1 1 Brown
2 2 Red
3 3 Orange
4 4 Blue
5 5 Purple
6 6 Gray
7 7 White 0.2mm2
8 8 Black
9 9 Brown
10 10 Red
11 11 Orange
12 12 Blue
User signal line IO IO
13 13 Brown
14 14 Red
15 15 Orange
16 16 Blue
17 17 Purple
18 18 Gray
0.2mm2
19 19 White
20 20 Black
21 21 Brown
22 22 Red
23 23 Orange
24 24 Blue
Frame ground 25 25 Green Shield
Frame ground 1 FG Green Shield
Origin Sensor 24V 1 1 Brown
ORG YORG 2 2 YORG Red 0.2mm2
GND 3 3 Orange
Origin Sensor 24V 1 1 Brown
ORG RORG 2 2 RORG Blue 0.2mm2
GND 3 3 Orange
Round terminal Round terminal Yellow/Green 0.75sq
Round terminal Round terminal Black 0.75sq
7-30
CHAPTER 7 Specifications
7-31
CHAPTER 7 Specifications
S2 Yellow 1
S4 Blue 2
S1 Red 3
Resolver S3 Black 4 XP,YP,ZP,RP
R1 White 5
R2 Green 6
SHIELD Black 7
U Red 1
V White 2 XM, YM, ZM, RM
Motor
W Black 3
BK Yellow 1
Brake ZBK (Z-axis motor only)
BK Yellow 2
7-32
MEMO
YAMAHA SCARA ROBOTS
YK-X SERIES
OWNER'S MANUAL
May. 2004, Ver. 5.12
© YAMAHA MOTOR CO., LTD.
IM Company
All rights reserved. No part of this publication
may be reproduced in any form without the
permission of YAMAHA MOTOR CO., LTD.
Information furnished by YAMAHA in this manual is believed to be reli-
able. However, no responsibility is assumed for possible inaccuracies or
omissions. If you find any part unclear in this manual, please contact
YAMAHA or YAMAHA sales representatives. The contents of this manual
are subject to change without prior notice.