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The document discusses the importance of setting the origin position of a robot before using it and outlines the different procedures for doing so depending on the desired origin position.

The origin position needs to be set before using the robot to properly calibrate its movements and positions. Failing to do so could require reteaching the robot and cause malfunctions.

The two types of origin position settings are: 1) Setting the extended arm position as the origin position and 2) Setting a position other than the extended arm position as the origin position.

OWNER'S MANUAL

Before using the robot


(Be sure to read the following notes.)
At this time, our thanks for your purchase of this YAMAHA YK-X series SCARA
robot.
Please be sure to perform the following tasks before using the robot.
Failing to perform the tasks below will require re-teaching of the robot since the
origin position cannot be set to the same previous position. Robot malfunctions
(vibration, noise) may also occur.

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.

2. Affixing the origin position sticker


Set in emergency stop when absolute reset is complete, and immediately affix
the origin point sticker according to instructions in "6. Affixing Stickers for
Origin Positions, Movement Directions and Axis Names" in Chapter 4 of this
manual.
3. Setting the reference coordinates
Set the reference coordinates while referring to instructions in "5. Setting the
Reference Coordinates" in Chapter 4 of this manual and also to "Setting the
Reference Coordinates" in the "YAMAHA robot controller owner's manual".
Robot malfunctions (vibration, noise) may occur if the reference coordinates
are not set correctly.

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.

YAMAHA MOTOR CO., LTD.


IM Company
MEMO
CONTENTS

CHAPTER 1 Using the Robot Safely


1 Safety Information ......................................................... 1-1 #
2 Essential Caution Items ................................................. 1-2 #
3 Special Training for Industrial Robot Operation ............. 1-8 #
4 Robot Safety Functions ................................................. 1-9 #
5 Safety Measures for the System ................................. 1-10 #
6 Trial Operation ............................................................. 1-11 #
7 Work Within the Safeguard Enclosure ......................... 1-12 #
8 Automatic Operation .................................................... 1-13 #
9 Adjustment and Inspection .......................................... 1-13 #
10 Repair and Modification ............................................... 1-13 #
11 Warranty ...................................................................... 1-14 #
12 CE Marking .................................................................. 1-15 #

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 #

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 #

3 Protective Bonding ...................................................... 3-12 #


4 Robot Cable Connection ............................................. 3-14 #
5 User Wiring and User Tubing ...................................... 3-16 #
6 Attaching The End Effector .......................................... 3-20
6-1 R-axis tolerable moment of inertia and acceleration coefficient ... 3-20 #
6-1-1 Acceleration coefficient vs. moment of inertia (YK250X) ....... 3-22 #
6-1-2 Acceleration coefficient vs. moment of inertia (YK350X) ....... 3-23 #
6-1-3 Acceleration coefficient vs. moment of inertia (YK400X) ....... 3-24 #
6-1-4 Acceleration coefficient vs. moment of inertia (YK500X) ....... 3-25 #
6-1-5 Acceleration coefficient vs. moment of inertia (YK600X) ....... 3-28 #
6-1-6 Acceleration coefficient vs. moment of inertia (YK700X) ....... 3-31 #
6-1-7 Acceleration coefficient vs. moment of inertia (YK800X) ....... 3-34 #
6-1-8 Acceleration coefficient vs. moment of inertia (YK1000X) ..... 3-37 #
6-1-9 Acceleration coefficient vs. moment of inertia (YK1200X) ..... 3-40
6-1-10 Acceleration coefficient vs. moment of inertia
(YK550X with standard R-axis specifications) ....................... 3-43
6-1-11 Acceleration coefficient vs. moment of inertia
(YK550X with high-speed R-axis specifications) ................... 3-44
6-2 Equation for moment of inertia calculation ............................. 3-46 #
6-3 Example of moment of inertia calculation .............................. 3-49 #
6-4 Attaching the end effector ...................................................... 3-51 #
6-5 Gripping force of end effector ................................................ 3-56 #

7 Limiting the Movement Range with X-Axis


Mechanical Stoppers
(Excluding YK250X, YK350X, YK400X) ...................... 3-57 #
7-1 YK500X, YK600X, YK700X, YK800X, YK1000X, YK1200X .. 3-58
7-2 YK550X .................................................................................. 3-61

8 Limiting the Movement Range with Y-Axis


Mechanical Stoppers (YK550X only) ........................... 3-63
9 Working Envelope and Mechanical Stopper Positions for
Maximum Working Envelope ....................................... 3-64 #

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

4 Setting the Soft Limits .................................................. 4-59 #


5 Setting the Standard Coordinates ............................... 4-62 #
6 Affixing Stickers for Origin Positions,
Movement Directions and Axis Names ........................ 4-63 #
7 Removing the Robot Covers ....................................... 4-65
8 Adjusting the Timing Belt Tension ................................ 4-70
8-1 Adjusting the belt tension (YK250X, YK350X, YK400X) ........ 4-71 #
8-2 Adjusting the belt tension (YK500X, YK600X) ....................... 4-73 #
8-3 Adjusting the belt tension (YK700X, YK800X, YK1000X) ...... 4-75 #
8-4 Adjusting the belt tension (YK1200X) .................................... 4-77
8-5 Adjusting the Z-axis and R-axis belts (YK550X) .................... 4-80
(1) Adjusting the Z-axis belt tension ............................................ 4-80
(2) Adjusting the R-axis belt tension ............................................ 4-83

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

6 Replacing the Harmonic Grease (YK550X) ................. 5-66


6-1 Replacement period ............................................................... 5-66
6-2 Basic replacement procedure for harmonic grease
and precautions (Y-axis) ........................................................ 5-67
6-3 Replacing the X-axis harmonic grease .................................. 5-72
6-4 Replacing the R-axis harmonic grease .................................. 5-75
7 Replacing the Grease for RV Speed Reduction Gears
(YK1200X).................................................................... 5-77
7-1 Replacement period ............................................................... 5-77
7-2 Recommended grease ........................................................... 5-77
7-3 Replacement procedure ......................................................... 5-78
7-3-1 Replacing the X-axis grease .................................................. 5-79
7-3-2 Replacing the Y-axis grease .................................................. 5-80

CHAPTER 6 Increasing the robot operating speed


1 Increasing the robot operating speed ............................ 6-1 #

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

Using the Robot Safely

1 Safety Information ..................................................................1-1


2 Essential Caution Items ..........................................................1-2
3 Special Training for Industrial Robot Operation ......................1-8
4 Robot Safety Functions ..........................................................1-9
5 Safety Measures for the System ..........................................1-10
6 Trial Operation ...................................................................... 1-11
7 Work Within the Safeguard Enclosure ..................................1-12
8 Automatic Operation .............................................................1-13
9 Adjustment and Inspection ...................................................1-13
10 Repair and Modification ........................................................1-13
11 Warranty ...............................................................................1-14
12 CE Marking ...........................................................................1-15
MEMO
CHAPTER 1 Using the Robot Safely

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.

Refer to the instruction manual by any of the following methods to operate or


adjust the robot safely and correctly.
1. Operate or adjust the robot while referring to the printed version of the in-
struction manual (available for an additional fee).
2. Operate or adjust the robot while viewing the CD-ROM version of the in-
struction manual on your computer screen.
3. Operate or adjust the robot while referring to a printout of the necessary
pages from the CD-ROM version of the instruction manual.

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

2 Essential Caution Items


Particularly important cautions for handling or operating the robot are described
below. In addition, safety information about installation, operation, inspection
and maintenance is provided in each chapter. Be sure to comply with these in-
structions to ensure safe use of the robot.

(1) Observe the following cautions during automatic operation.


Warning labels 1 (Fig. 1-1) are affixed to the robot. See Fig. 2-2 to Fig. 2-6
for the locations of warning labels.
• Install a safeguard enclosure (protective enclosure) to keep any person from
entering within the movement range of the robot and suffering injury due
to being struck by moving parts.
• Install a safety interlock that triggers emergency stop when the door or
panel is opened.
• Install safeguards so that no one can enter inside except from doors or
panels equipped with safety interlocks.
• The warning labels shown in Fig. 1-1 are supplied with the robot and should
be affixed to a conspicuous spot on doors or panels equipped with safety
interlocks.

DANGER
Serious injury or death will result from impact with moving robot.
• Keep outside of guard during operation.
• Lock out power before approaching robot.

(2) Use caution to prevent hands or fingers from being pinched or


crushed.
Warning labels 2 (Fig. 1-2) are affixed to the robot. See Fig. 2-2 to Fig. 2-6
for the locations of warning labels.
Be careful not to let hands or fingers be pinched or crushed by the moving
parts of the robot during transportation or teaching.

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.

■Fig. 1-1 Warning label 1 ■Fig. 1-2 Warning label 2

1-2
CHAPTER 1 Using the Robot Safely

(3) Follow the instructions on warning labels and in this manual.


Warning label 3 (Fig. 1-3) is affixed to the robot. See Fig. 2-2 to Fig. 2-6 for
the locations of warning labels.
• Be sure to read the warning label and this manual carefully and make your
thoroughly understand the contents before attempting installation and op-
eration of the robot.
• Before starting the robot operation, even after you have read through this
manual, read again the corresponding procedures and cautions in this manual
as well as descriptions in the this chapter (Chapter 1, "Using the Robot
Safely").
• Never install, adjust, inspect or service the robot in any manner that does
not comply with the instructions in this manual.

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.

■Fig. 1-3 Warning label 3


(4) Do not use the robot in environments containing inflammable
gas, etc.

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.

(5) Do not use the robot in locations possibly subject to electro-


magnetic interference, etc.

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.

(7) Provide safety measures for end effector (gripper, etc.).

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.

(8) Be cautious of possible Z-axis movement when the controller is


turned off or emergency stop is triggered. (2-axis robots with
air-driven Z-axis)

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.

(11) Use the following caution items when disassembling or replac-


ing the pneumatic equipment.

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.

(13) Use the following caution during inspection of controller.

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

(14) Consult us for corrective action when the robot is damaged or


malfunction occurs.

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.

Damage or Trouble Possible Danger


Damage to machine harness or robot cable Electrical shock, malfunction of robot
Flying outwards of damaged parts during robot
Damage to exterior of robot
operation
Abnormal operation of robot
Malfunction of robot
(positioning error, excessive vibration, etc.)
Z-axis brake trouble Dropping of load

(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.

(17) Do not remove, alter or stain the warning labels.

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

(18) Protective bonding

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.

(20) Be sure to make correct parameter settings.

! 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

3 Special Training for Industrial Robot Opera-


tion
Companies or factories using industrial robots must make sure that every person,
who handles the robot such as for teaching, programming, movement check, in-
spection, adjustment and repair, has received appropriate training and also has
the skills needed to perform the job correctly and safely.
Since the YK-X series robots fall under the industrial robot category, the user
must observe local regulations and safety standards for industrial robots, and
provide special training for every person involved in robot-related tasks (teach-
ing, programming, movement check, inspection, adjustment, repair, etc.).

1-8
CHAPTER 1 Using the Robot Safely

4 Robot Safety Functions


(1) Overload detection
This function detects an overload applied to the motor and shuts off the servo
power. If an overload error occurs, take the following measures.
1. Insert a timer in the program.
2. Reduce the acceleration coefficient.
(2) Overheat detection
This function detects an abnormal temperature rise in the driver inside the
controller and shuts off the servo power. If an overheat error occurs, take the
following measures.
1. Insert a timer in the program.
2. Reduce the acceleration coefficient.
(3) Soft limits
Soft limits can be set on each axis to limit the working envelope in manual
operation after return-to-origin and during automatic operation.
Note: The working envelope is the area limited by soft limits.
(4) Mechanical stoppers
If the servo power is suddenly shut off during high-speed operation by emer-
gency stop or safety functions, these mechanical stoppers prevent the axis
from exceeding the movement range. The movement ranges of the X-axis
arm can be limited as needed by use of mechanical stoppers. (Excluding the
YK250X, YK350X and YK400X)
On the Y-axis arm, mechanical stoppers are fixed at both ends of the maxi-
mum movement range.
The Z-axis has a mechanical stopper at the upper end and lower end.
No mechanical stopper is provided on the R-axis.
Note: The movement range is the area limited by mechanical stoppers.

WARNING
Axis movement will not stop immediately after the servo power supply is shut
off by emergency stop or other safety functions.

(5) Z-axis (vertical axis) brake


An electromagnetic brake is installed on the Z-axis to prevent the Z-axis
from sliding down when servo power is turned off. This brake is working
when the controller is off or the Z-axis servo power is off even when the
controller is on. The Z-axis brake can be released by means of the program-
ming unit or by a command in the program when the controller is on.

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

5 Safety Measures for the System


Since the robot is commonly used in conjunction with an automated system, dan-
gerous situations are more likely to occur from the automated system than from
the robot itself. Accordingly, appropriate safety measures must be taken on the
part of the system manufacturer according to the individual system. The system
manufacturer should provide a proper instruction manual for safe, correct opera-
tion and servicing of the system.

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

7 Work Within the Safeguard Enclosure


(1) When work is required inside the safeguard enclosure, always turn off the
controller and place a sign indicating that the robot is being adjusted or serv-
iced in order to keep any other person from touching the controller switch or
operation panel, except for the following cases.
1) Origin position setting (See Section 3 in Chapter 4.)
2) Soft limit settings (See Section 4 in Chapter 4.)
3) Standard coordinate settings (See Section 5 in Chapter 4.)
4) Inspection of the X-axis motor cooling fan inside the base (YK550X only)
(See (2) of Section 4 in Chapter 5.)
5) Teaching

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) Check the following before starting automatic operation.


1. No one is within the safeguard enclosure.
2. The programming unit and tools are in their specified locations.
3. The alarm or error lamps on the robot and peripheral equipment do not
flash.
4. The safeguard enclosure is securely installed with safety interlocks ac-
tuated.
(2) Observe the following during automatic operation or in cases where an error
occurs.
1) After automatic operation has started, check the operation status and warn-
ing lamp to ensure that the robot is in automatic operation.
2) Never enter the safeguard enclosure during automatic operation.
3) If an error occurs in the robot or peripheral equipment, observe the fol-
lowing procedure before entering the safeguard enclosure.
1. Press the emergency stop button to set the robot to emergency stop.
2. Place a sign on the start switch, indicating that the robot is being in-
spected in order to keep any other person from touching the start switch
and restarting the robot.

9 Adjustment and Inspection


Do not attempt any installation, adjustment, inspection or maintenance unless it
is described in this manual.

10 Repair and Modification


Do not attempt any repair, parts replacement and modification unless described
in this manual. These works require technical knowledge and skill, and may also
involve work hazards.

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.

Warranty Scope : If any failure should arise in the genuine parts


constituting the YAMAHA robot due to defects
in materials or workmanship, YAMAHA will
repair or replace those parts free of charge (here-
after called "warranty repair").

Warranty Period : This warranty is effective for a period of:


(1) 18 months (one and a half years) after ship-
ment from Japan, or
(2) One year after installation or
(3) 2,400 hours of actual operation whichever
comes first.

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.

1) Damage due to earthquakes, storms, floods, thunderbolt, fire or any other


natural or man-made calamities.

2) Troubles caused by procedures prohibited in this manual.

3) Modification to the robot not approved by YAMAHA or YAMAHA sales


representatives.

4) Use of any other than genuine parts and specified lubricant and grease.

5) Insufficiency or errors in maintenance and inspection.

6) Repairs by other than authorized dealers.

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 ..................................................................2-1


2 Robot Controller .....................................................................2-7
3 Robot initialization number list ................................................2-8
MEMO
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
(+)

(–)
(–)

Z-axis (–) (+)

(+) Y-axis arm X-axis

(–) (+)
R-axis

Fig. 2-1 Manipulator movement

2-1
CHAPTER 2 Functions

D-sub connector for user wiring (No.1 to 10)

User tubing 1 (φ4 black)

User tubing 2 (φ4 red)

User tubing 3 (φ4 blue)

Ball screw Machine harness

Warning label 1

Warning label 2

Z-axis motor

R-axis motor

Z-axis,R-axis pulley, belt

Y-axis speed Y-axis motor


reduction gear
Y-axis arm Y-axis mechanical stopper
X-axis arm

X-axis speed reduction gear

X-axis mechanical stopper

R-axis speed reduction gear

Z-axis spline
End effector attachment

X-axis speed reduction gear


X-axis motor Serial label

D-sub connector for user wiring


User tubing 1 (φ4 black) (No.1 to 10)

User tubing 2 (φ4 red)

User tubing 3 (φ4 blue)

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

User tubing 2 (φ6 red)

D-sub connector for user wiring (No.1 to 20)


Y-axis mechanical stopper
User tubing 3 (φ6 blue)
Warning label 1 (Same on opposite side) Machine harness
Ball screw

Warning label 2 (Same on opposite side)

Y-axis motor
Z-axis motor
R-axis motor

Y-axis speed reduction gear

Y-axis arm
X-axis arm
Z-axis,R-axis pulley, belt

R-axis speed reduction gear

Z-axis spline X-axis speed reduction gear

X-axis motor
End effector attachment

Warning label 3

Serial label

M4 ground terminal

User tubing 1 (φ6 black) D-sub connector for user wiring


User tubing 2 (φ6 red) (No.1 to 20)

User tubing 3 (φ6 blue) Robot cable

Fig. 2-3 YK500X, YK600X


2-3
CHAPTER 2 Functions

User tubing 1 (φ6 black)


Eyebolt installation position X-axis movable mechanical stopper
User tubing 2 (φ6 red)

User tubing 3 (φ6 blue)

D-sub connector for user wiring (No.1 to 20) Y-axis mechanical stopper Machine harness

Warning label 1 (Same on opposite side)


Warning label 2 (Same on opposite side)
Ball screw

R-axis motor

Z-axis motor

Y-axis motor

Y-axis speed reduction gear X-axis arm

Y-axis arm

Z-axis,R-axis pulley, belt

R-axis speed reduction gear


Z-axis spline X-axis speed reduction gear

X-axis motor
End effector attachment

Warning label 3

Serial label

M4 ground terminal

User tubing 1 (φ6 black)


D-sub connector for user wiring
User tubing 2 (φ6 red) (No.1 to 20)
User tubing 3 (φ6 blue) Robot cable

Fig. 2-4 YK700X, YK800X, YK1000X

2-4
CHAPTER 2 Functions

X-axis movable mechanical stopper

D-sub connector for user wiring Eyebolt installation position


(No.1 to 20)

User tubing 1 (φ6 black)


User tubing 2 (φ6 red)
User tubing 3 (φ6 blue) Y-axis mechanical stopper

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

Y-axis speed reduction gear

X-axis arm

R-axis speed Y-axis arm


reduction gear Z-axis,
R-axis pulley, belt
Z-axis spline Z-axis support shaft
End effector
attachment

X-axis speed reduction gear

X-axis motor
Warning label 3

Serial label
M4 ground terminal

User tubing 1 (φ6 black) Robot cable


User tubing 2 (φ6 red) D-sub connector for user wiring (No.1 to 20)
User tubing 3 (φ 6blue)

Fig. 2-5 YK1200X

2-5
CHAPTER 2 Functions

Eyebolt installation position Window for X-axis origin adjustment (inside of cover)

mechanical stopper

Window for Y-axis origin adjustment

User tubing 1 (φ6 black) X-axis movable mechanical stopper


User tubing 2 (φ6 blue)
D-sub connector for user wiring (No.1 to 20)

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

M4 ground terminal R-axis speed reduction gear

User M4 tap
(Same on
opposite side)
R-axis origin sensor
Z-axis spline

End effector X-axis speed reduction gear


attachment Z-axis, R-axis pulley, belt X-axis arm

Y-axis movable mechanical stopper


User tubing 2 (φ6 blue)
User tubing 1 (φ6 black)
Fan (Rear side)

X-axis motor
Robot cable
D-sub connector
for user wiring
Fan (No.1 to 20)

M4 ground terminal

Fig. 2-6 YK550X

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

3 Robot initialization number list


The YK-X series robots are initialized for optimum setting (default setting) ac-
cording to the robot model prior to shipping. The robot controllers do not have to
be reinitialized during normal operation. However, if for some reason the con-
troller must be reinitialized, proceed while referring to the list below.

! 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.

Robot initialization number list (Origin mark model)


Robot initialization number Model name Robot initialization number Model name
2000 YK250X Z150 2010 YK500X Z300
2001 YK350X Z150 2011 YK600X Z300
2002 YK400X Z150 2012 YK700X Z400
2003 YK500X Z200 2013 YK800X Z400
2004 YK600X Z200 2014 YK1000X Z400
2005 YK700X Z200 2015 YK550XH
2006 YK800X Z200 YK550X: Standard R-axis specifications
2007 YK1000X Z200 YK550XH: High-speed R-axis specifications
2008 YK1200X Z400
2009 YK550X

Robot initialization number list (Origin sensor model)


Robot initialization number Model name Robot initialization number Model name
2100 YK250X Z150 2110 YK500X Z300
2101 YK350X Z150 2111 YK600X Z300
2102 YK400X Z150 2112 YK700X Z400
2103 YK500X Z200 2113 YK800X Z400
2104 YK600X Z200 2114 YK1000X Z400
2105 YK700X Z200
2106 YK800X Z200
2107 YK1000X Z200
* When initializing the robot controllers for clean room models and dust/drip proof models, use
the robot initialization number for the robot models containing the same number.
[Example] YK250XC Z150 : Origin sensor model
YK250XP Z150 : Origin sensor model ) → Robot initialization number: 2100 (YK250X Z150 : Same as origin sensor model)

2-8
CHAPTER 3

Installation

1 Robot Installation Conditions ..................................................3-1


1-1 Installation environments ................................................................. 3-1
1-2 Installation base ............................................................................... 3-3

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

3 Protective Bonding ...............................................................3-12


4 Robot Cable Connection ......................................................3-14
5 User Wiring and User Tubing ...............................................3-16
6 Attaching The End Effector ...................................................3-20
6-1 R-axis tolerable moment of inertia and acceleration coefficient ..... 3-20
6-1-1 Acceleration coefficient vs. moment of inertia (YK250X) ............... 3-22
6-1-2 Acceleration coefficient vs. moment of inertia (YK350X) ............... 3-23
6-1-3 Acceleration coefficient vs. moment of inertia (YK400X) ............... 3-24
6-1-4 Acceleration coefficient vs. moment of inertia (YK500X) ............... 3-25
6-1-5 Acceleration coefficient vs. moment of inertia (YK600X) ............... 3-28
6-1-6 Acceleration coefficient vs. moment of inertia (YK700X) ............... 3-31
6-1-7 Acceleration coefficient vs. moment of inertia (YK800X) ............... 3-34
6-1-8 Acceleration coefficient vs. moment of inertia (YK1000X) ............. 3-37
6-1-9 Acceleration coefficient vs. moment of inertia (YK1200X) ............. 3-40
6-1-10 Acceleration coefficient vs. moment of inertia
(YK550X with standard R-axis specifications) ............................... 3-43
6-1-11 Acceleration coefficient vs. moment of inertia
(YK550X with high-speed R-axis specifications) ........................... 3-44
6-2 Equation for moment of inertia calculation ..................................... 3-46
6-3 Example of moment of inertia calculation ...................................... 3-49
6-4 Attaching the end effector .............................................................. 3-51
6-5 Gripping force of end effector ........................................................ 3-56
7 Limiting the Movement Range with X-Axis Mechanical Stoppers
(Excluding YK250X, YK350X, YK400X) ...............................3-57
7-1 YK500X, YK600X, YK700X, YK800X, YK1000X, YK1200X .......... 3-58
7-2 YK550X .......................................................................................... 3-61

8 Limiting the Movement Range with Y-Axis Mechanical Stoppers


(YK550X only) .......................................................................3-63
9 Working Envelope and Mechanical Stopper Positions for
Maximum Working Envelope ................................................3-64
CHAPTER 3 Installation

1 Robot Installation Conditions

1-1 Installation environments


Be sure to install the robot in the following environments.
Items Specifications
Allowable ambient temperature 0 to 40°C
Allowable ambient humidity 35 to 85% RH (non condensation)
Altitude 0 to 1000 meters above sea level
Ambient environments Avoid installing near water, cutting water, oil, dust, metallic chips and
organic solvent.
Avoid installation near corrosive gas and corrosive materials.
Avoid installation in atmosphere containing inflammable gas, dust and liquid.
Avoid installation near objects causing electromagnetic interference,
electrostatic discharge and radio frequency interference.
Vibration Do not subject to impacts or vibrations.
Air supply pressure, etc. Below 0.58MPa (6.0kgf/cm2); clean dry air not containing deteriorated
compressor oil; filtration 40µm or less

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

1-2 Installation base


1) Prepare a sufficiently rigid and stable installation base, taking account of the
robot weight including the end effector (gripper), workpiece and reaction
force while the robot is operating. The maximum reaction force (see Fig. 3-
1) applied to the X-axis and Z-axis of each robot during operation is shown
in the table below. These values are an instantaneous force applied to the
robot during operation and do not indicate the maximum load capacity.
The maximum reaction force
FXmax MXmax FZmax
Robot Model N kgf Nm kgfm N kgf
YK250X 305 31 56 6 40 4
YK350X 330 34 56 6 40 4
YK400X 391 40 56 6 40 4
YK500X 708 72 137 14 89 9
YK600X 735 75 137 14 89 9
YK700X 1653 169 304 31 159 16
YK800X 1707 174 304 31 159 16
YK1000X 1618 165 333 34 127 13
YK1200X 3293 336 1029 105 108 11
YK550X 628 64 216 22 135 14

Fxmax

Fzmax
Load

Mxmax

Fig. 3-1 Maximum reaction force applied during operation

2) The parallelism of the installation base surface must be machined within a


precision of ±0.05mm/500mm. The robot base mount must be installed fac-
ing down and in a level position (except ceiling-mount models which should
be installed with the base mount facing up).
3) Tap holes into the surface of the installation base. Refer to "1-2 External
view and dimensions" in Chapter 7 for machining dimensions and positions.
4) Securely fix the installation base on the floor with anchor bolts.

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

Robot controller and


accessories

Arm clamping stay


(Used only for transportation.
Remove after installation.)

YK500X, YK600X, YK700X, YK800X, YK1000X, YK1200X, YK550X

Fig. 3-2 Packed state

3-5
CHAPTER 3 Installation

2-2 Checking the product


After unpacking, check the product configuration and conditions.
The following configurations are typical examples, so please check that the prod-
uct is as specified in your order.

! CAUTION
If there is any damage due to transportation or insufficient parts, please notify
your YAMAHA sales office or dealer immediately.

Controller : RCX40 or QRCX


Robot : YK250X, YK350X, YK400X, YK500X, YK600X, YK700X,
YK800X, YK1000X, YK1200X, YK550X

Standard

STD. DIO
connector ( × 1)

Power plug ( × 1)

Terminator ( × 1)

Warning label ( × 1)
Owner's manual

D-sub connector/hood
( × 2)

A B Origin position stickers ( × 2)


Robot manipulator
(YK500X,YK600X × 3)
X Y
Z R
YK-X series

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

Fig. 3-3 Product configurations

3-6
CHAPTER 3 Installation

2-3 Moving the robot

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.

2-3-1 Moving the YK250X, YK350X, YK400X

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

2-3-2 Moving the YK500X, YK600X, YK700X, YK800X, YK1000X,


YK1200X, YK550X

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.)

2) Remove the X-axis arm cover and set screws.

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)

Bearing surface for eyebolt

Arm clamping stay (supplied with the robot)

Bolt (2 pieces supplied with the robot) YK500X,YK600X


Tightening toeque 4.5N•m (46kgf•cm)
X-axis arm cover

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)

Bolt and nut (4 pieces each supplied with the robot)

Pallet (supplied with the robot)

Fig. 3-5 YK550X

3-10
CHAPTER 3 Installation

2-4 Installing the robot


Install the robot securely with the four hex socket head bolts as shown in Fig. 3-
6.

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)

Depth of tapped holes in installation base:


Iron installation base Bolt diameter × 1.5 or more
Aluminum installation base Bolt diameter × 3 or more

Hex socket head bolt

Installation base

Fig. 3-6 Installing the robot

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.

The robot must be grounded as follows:


1) Provide a terminal marked "PE" for the protective conductor of the entire
system and connect it to an external protective conductor. In addition, se-
curely connect the ground terminal on the robot pedestal to the same protec-
tive conductor. (See Fig. 3-7 for example of the YK500X.)

(Symbol 417-IEC-5019)

2) When the end effector uses an electrical device which, if it malfunctions,


might make contact with the power supply, the user must provide proper
grounding on his own responsibility. The YK-X series robots do not have a
ground terminal for this purpose.

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

Fig. 3-7 Ground terminal

3-13
CHAPTER 3 Installation

4 Robot Cable Connection


The robot cable is pre-connected to the YK-X series robot. Correctly install the
other end of the robot cable to the robot controller. For details on connections to
the robot controller, refer to Fig. 3-8 and the "YAMAHA RCX40 robot controller
owner's manual" or "YAMAHA QRCX robot controller owner's manual". After
making connections, check the operation while referring to "6 Trial operation" in
Chapter 1.

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

Controller side connector


Robot side connector QRCX RCX40

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

Fig. 3-8 Robot cable connections

3-15
CHAPTER 3 Installation

5 User Wiring and User Tubing

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

3) Signal wiring connections in the machine harness

1. YK250X, YK350X, YK400X


Connector pins 1 to 10 can be used. Pin 15 is connected to a shield wire
and cannot be used as a signal wire.
Signal Connector NO Connection NO Connector Color

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

Flame ground 1 FG Green

(Robots models with non-standard specifications


may have different wiring colors.)

2. YK500X, YK600X, YK700X, YK800X, YK1000X, YK1200X, YK550X


Connector pins 1 to 20 can be used. Pin 25 is connected to a shield wire
and cannot be used as a signal wire.
Signal Connector NO Connection NO Connector Color
1 1 Brown
2 2 Red
3 3 Orange
4 4 Blue
5 5 Violet
6 6 Grey
7 7 White
8 8 Black
9 9 Brown
User signal line IO 10 10 IO Red
(Arm side) (Base side)
11 11 Orange
12 12 Blue
13 13 Violet
14 14 Grey
15 15 White
16 16 Black
17 17 Brown
18 18 Red
19 19 Orange
20 20 Blue
21 21
22 22
23 23
24 24
Shield 25 25 Green
Flame Ground 1 FG Green
(FG wire is not provided for YK550X.)

(Robots models with non-standard specifications


may have different wiring colors.)

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

D-sub connector on arm side D-sub connector on base side


(As viewed from solder side) (As viewed from solder side)

YK250X, YK350X, YK400X

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

D-sub connector on arm side D-sub connector on base side


(As viewed from solder side) (As viewed from solder side)

YK500X, YK600X, YK700X, YK800X, YK1000X, YK1200X, YK550X

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.

D-sub connectors (supplied with robot)


D-sub connector D-sub connector
Robot model Hood
on arm side on base side

YK250X, YK350X, YK400X DA-15P-N DA-15S-N DA-C1-J10

YK500X, YK600X, YK700X, YK800X,


DB-25P-N DB-25S-N DB-C2-J9
YK1000X, YK1200X, YK550X
Manufacturer : Japan Aviation Electronics Industry, Limited.

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

6 Attaching The End Effector

6-1 R-axis tolerable moment of inertia and acceleration coeffi-


cient
1) The moment of inertia of a load (end effector and workpiece) that can be
attached to the R-axis is limited by the strength of the robot drive unit and
residual vibration during positioning. It is therefore necessary to reduce the
acceleration coefficient in accordance with the moment of inertia.

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

6-1-1 Acceleration coefficient vs. moment of inertia (YK250X)

AX, AY, AR (%)


0.01(0.1)
100

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)

Fig. 3-10 m=1kg

AX, AY, AR (%)


0.01(0.1)
100

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)

Fig. 3-11 m=2kg

AX, AY, AR (%)


0.01(0.1)
100

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)

Fig. 3-12 m=3kg

3-22
CHAPTER 3 Installation

6-1-2 Acceleration coefficient vs. moment of inertia (YK350X)

AX, AY, AR (%)


0.005(0.05)
100

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)

Fig. 3-13 m=1kg

AX, AY, AR (%)


0.004(0.04)
100

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)

Fig. 3-14 m=2kg

AX, AY, AR (%)


0.005(0.05)
100

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)

Fig. 3-15 m=3kg

3-23
CHAPTER 3 Installation

6-1-3 Acceleration coefficient vs. moment of inertia (YK400X)

AX, AY, AR (%)


100

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)

Fig. 3-16 m=1kg

AX, AY, AR (%)


100

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)

Fig. 3-17 m=2kg

AX, AY, AR (%)


100

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)

Fig. 3-18 m=3kg

3-24
CHAPTER 3 Installation

6-1-4 Acceleration coefficient vs. moment of inertia (YK500X)

AX, AY, AR (%)


0.005(0.05)
100

80

60

40

20

0 0.04 0.08 0.12 Ir (kgm2)


0 0.4 0.8 1.2 Jr (kgf • cm • sec2)

Fig. 3-19 m=1kg

AX, AY, AR (%)


0.005(0.05)
100

80

60

40

20

0 0.04 0.08 0.12 Ir (kgm2)


0 0.4 0.8 1.2 Jr (kgf • cm • sec2)

Fig. 3-20 m=2kg

AX, AY, AR (%)


0.005(0.05)
100

80

60

40

20

0 0.04 0.08 0.12 Ir (kgm2)


0 0.4 0.8 1.2 Jr (kgf • cm • sec2)

Fig. 3-21 m=3kg

3-25
CHAPTER 3 Installation

AX, AY, AR (%)


0.005(0.05)
100

80

60

40

20

0 0.04 0.08 0.12 Ir (kgm2)


0 0.4 0.8 1.2 Jr (kgf • cm • sec2)

Fig. 3-22 m=4kg

AX, AY, AR (%)


0.005(0.05)
100

80

60

40

20

0 0.04 0.08 Ir (kgm2)


0.12
0 0.4 0.8 1.2 Jr (kgf • cm • sec2)

Fig. 3-23 m=5kg

AX, AY, AR (%)


0.007(0.07)
100

80

60

40

20

0 0.04 0.08 Ir (kgm2)


0.12
0 0.4 0.8 1.2 Jr (kgf • cm • sec2)

Fig. 3-24 m=6, 7kg

3-26
CHAPTER 3 Installation

AX, AY, AR (%)


0.007(0.07)
100

80

60

40

20

0 0.04 0.08 0.12 Ir (kgm2)


0 0.4 0.8 1.2 Jr (kgf • cm • sec2)

Fig. 3-25 m=8, 9kg

AX, AY, AR (%)


0.03(0.3)
100

80

60

40

20

0 0.04 0.08 Ir (kgm2)


0.12
0 0.4 0.8 1.2 Jr (kgf • cm • sec2)

Fig. 3-26 m=10kg

3-27
CHAPTER 3 Installation

6-1-5 Acceleration coefficient vs. moment of inertia (YK600X)

AX, AY, AR (%)


0.005(0.05)
100

80

60

40

20

0 0.04 0.08 0.12 Ir (kgm2)


0 0.4 0.8 1.2 Jr (kgf • cm • sec2)

Fig. 3-27 m=1kg

AX, AY, AR (%)


0.005(0.05)
100

80

60

40

20

0 0.04 0.08 0.12 Ir (kgm2)


0 0.4 0.8 1.2 Jr (kgf • cm • sec2)

Fig. 3-28 m=2kg

AX, AY, AR (%)


0.01(0.1)
100

80

60

40

20

0 0.04 0.08 0.12 Ir (kgm2)


0 0.4 0.8 1.2 Jr (kgf • cm • sec2)

Fig. 3-29 m=3kg

3-28
CHAPTER 3 Installation

AX, AY, AR (%)


0.005(0.05)
100

80

60

40

20

0 0.04 0.08 0.12 Ir (kgm2)


0 0.4 0.8 1.2 Jr (kgf • cm • sec2)

Fig. 3-30 m=4kg

AX, AY, AR (%)


0.01(0.1)
100

80

60

40

20

0 0.04 0.08 Ir (kgm2)


0.12
0 0.4 0.8 1.2 Jr (kgf • cm • sec2)

Fig. 3-31 m=5kg

AX, AY, AR (%)


0.005(0.05)
100

80

60

40

20

0 0.04 0.08 Ir (kgm2)


0.12
0 0.4 0.8 1.2 Jr (kgf • cm • sec2)

Fig. 3-32 m=6, 7kg

3-29
CHAPTER 3 Installation

AX, AY, AR (%)


0.005(0.05)
100

80

60

40

20

0 0.04 0.08 0.12 Ir (kgm2)


0 0.4 0.8 1.2 Jr (kgf • cm • sec2)

Fig. 3-33 m=8, 9kg

AX, AY, AR (%)


0.015(0.15)
100

80

60

40

20

0 0.04 0.08 Ir (kgm2)


0.12
0 0.4 0.8 1.2 Jr (kgf • cm • sec2)

Fig. 3-34 m=10kg

3-30
CHAPTER 3 Installation

6-1-6 Acceleration coefficient vs. moment of inertia (YK700X)

AX, AY, AR (%)


0.02(0.2)
100

80

60

40

20

0 0.1 0.2 0.3 Ir (kgm2)


0 1.0 2.0 3.0 Jr (kgf • cm • sec2)

Fig. 3-35 m=1kg

AX, AY, AR (%)


0.01(0.1)
100

80

60

40

20

0
0.1 0.2 0.3 Ir (kgm2)
0 1.0 2.0 3.0 Jr (kgf • cm • sec2)

Fig. 3-36 m=2kg

AX, AY, AR (%)


0.03(0.3)
100

80

60

40

20

0 0.1 0.2 0.3 Ir (kgm2)


0 1.0 2.0 3.0 Jr (kgf • cm • sec2)

Fig. 3-37 m=3, 4kg

3-31
CHAPTER 3 Installation

AX, AY, AR (%)


0.01(0.1)
100

80

60

40

20

0
0.1 0.2 0.3 Ir (kgm2)
0 1.0 2.0 3.0 Jr (kgf • cm • sec2)

Fig. 3-38 m=5, 6kg

AX, AY, AR (%)


0.01(0.1)
100

80

60

40

20

0 0.1 0.2 0.3 Ir (kgm2)


0 1.0 2.0 3.0 Jr (kgf • cm • sec2)

Fig. 3-39 m=7, 8kg

AX, AY, AR (%)


0.01(0.1)
100

80

60

40

20

0
0.1 0.2 0.3 Ir (kgm2)
0 1.0 2.0 3.0 Jr (kgf • cm • sec2)

Fig. 3-40 m=9, 10kg

3-32
CHAPTER 3 Installation

AX, AY, AR (%)


0.01(0.1)
100

80

60

40

20

0
0.1 0.2 0.3 Ir (kgm2)
0 1.0 2.0 3.0 Jr (kgf • cm • sec2)

Fig. 3-41 m=11 to 13kg

AX, AY, AR (%)


0.01(0.1)
100

80

60

40

20

0
0.1 0.2 0.3 Ir (kgm2)
0 1.0 2.0 3.0 Jr (kgf • cm • sec2)

Fig. 3-42 m=14 to 16kg

AX, AY, AR (%)


0.01(0.1)
100

80

60

40

20

0
0.1 0.2 0.3 Ir (kgm2)
0 1.0 2.0 3.0 Jr (kgf • cm • sec2)

Fig. 3-43 m=17 to 20kg

3-33
CHAPTER 3 Installation

6-1-7 Acceleration coefficient vs. moment of inertia (YK800X)

AX, AY, AR (%)


0.02(0.2)
100

80

60

40

20

0
0.1 0.2 0.3 Ir (kgm2)
0 1.0 2.0 3.0 Jr (kgf • cm • sec2)

Fig. 3-44 m=1kg

AX, AY, AR (%)


0.03(0.3)
100

80

60

40

20

0
0.1 0.2 0.3 Ir (kgm2)
0 1.0 2.0 3.0 Jr (kgf • cm • sec2)

Fig. 3-45 m=2kg

AX, AY, AR (%)


0.03(0.3)
100

80

60

40

20

0 0.1 0.2 0.3 Ir (kgm2)


0 1.0 2.0 3.0 Jr (kgf • cm • sec2)

Fig. 3-46 m=3, 4kg

3-34
CHAPTER 3 Installation

AX, AY, AR (%)


0.02(0.2)
100

80

60

40

20

0
0.1 0.2 0.3 Ir (kgm2)
0 1.0 2.0 3.0 Jr (kgf • cm • sec2)

Fig. 3-47 m=5, 6kg

AX, AY, AR (%)


0.01(0.1)
100

80

60

40

20

0
0.1 0.2 0.3 Ir (kgm2)
0 1.0 2.0 3.0 Jr (kgf • cm • sec2)

Fig. 3-48 m=7, 8kg

AX, AY, AR (%)


0.01(0.1)
100

80

60

40

20

0
0.1 0.2 0.3 Ir (kgm2)
0 1.0 2.0 3.0 Jr (kgf • cm • sec2)

Fig. 3-49 m=9, 10kg

3-35
CHAPTER 3 Installation

AX, AY, AR (%)


0.02(0.2)
100

80

60

40

20

0
0.1 0.2 0.3 Ir (kgm2)
0 1.0 2.0 3.0 Jr (kgf • cm • sec2)

Fig. 3-50 m=11 to 13kg

AX, AY, AR (%)


0.02(0.2)
100

80

60

40

20

0
0.1 0.2 0.3 Ir (kgm2)
0 1.0 2.0 3.0 Jr (kgf • cm • sec2)

Fig. 3-51 m=14 to 16kg

AX, AY, AR (%)


0.02(0.2)
100

80

60

40

20

0
0.1 0.2 0.3 Ir (kgm2)
0 1.0 2.0 3.0 Jr (kgf • cm • sec2)

Fig. 3-52 m=17 to 20kg

3-36
CHAPTER 3 Installation

6-1-8 Acceleration coefficient vs. moment of inertia (YK1000X)

AX, AY, AR (%)


0.02(0.2)
100

80

60

40

20

0
0.1 0.2 0.3 Ir (kgm2)
0 1.0 2.0 3.0 Jr (kgf • cm • sec2)

Fig. 3-53 m=1kg

AX, AY, AR (%)


0.01(0.1)
100

80

60

40

20

0
0.1 0.2 0.3 Ir (kgm2)
0 1.0 2.0 3.0 Jr (kgf • cm • sec2)

Fig. 3-54 m=2kg

AX, AY, AR (%)


0.01(0.1)
100

80

60

40

20

0 0.1 0.2 0.3 Ir (kgm2)


0 1.0 2.0 3.0 Jr (kgf • cm • sec2)

Fig. 3-55 m=3, 4kg

3-37
CHAPTER 3 Installation

AX, AY, AR (%)


0.01(0.1)
100

80

60

40

20

0
0.1 0.2 0.3 Ir (kgm2)
0 1.0 2.0 3.0 Jr (kgf • cm • sec2)

Fig. 3-56 m=5, 6kg

AX, AY, AR (%)


0.01(0.1)
100

80

60

40

20

0
0.1 0.2 0.3 Ir (kgm2)
0 1.0 2.0 3.0 Jr (kgf • cm • sec2)

Fig. 3-57 m=7, 8kg

AX, AY, AR (%)


0.015(0.15)
100

80

60

40

20

0
0.1 0.2 0.3 Ir (kgm2)
0 1.0 2.0 3.0 Jr (kgf • cm • sec2)

Fig. 3-58 m=9, 10kg

3-38
CHAPTER 3 Installation

AX, AY, AR (%)


0.02(0.2)
100

80

60

40

20

0
0.1 0.2 0.3 Ir (kgm2)
0 1.0 2.0 3.0 Jr (kgf • cm • sec2)

Fig. 3-59 m=11 to 13kg

AX, AY, AR (%)


0.025(0.25)
100

80

60

40

20

0
0.1 0.2 0.3 Ir (kgm2)
0 1.0 2.0 3.0 Jr (kgf • cm • sec2)

Fig. 3-60 m=14 to 16kg

AX, AY, AR (%)


0.030(0.30)
100

80

60

40

20

0
0.1 0.2 0.3 Ir (kgm2)
0 1.0 2.0 3.0 Jr (kgf • cm • sec2)

Fig. 3-61 m=17 to 20kg

3-39
CHAPTER 3 Installation

6-1-9 Acceleration coefficient vs. moment of inertia (YK1200X)

AX, AY (%) AR (%)


0.1(1.0) 0.1(1.0)
100 100

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)

Fig. 3-62 m=0 to 5kg

AX, AY (%) AR (%)


0.1(1.0) 0.1(1.0)
100 100

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)

Fig. 3-63 m=6 to 10kg

AX, AY (%) AR (%)


0.1(1.0) 0.1(1.0)
100 100

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)

Fig. 3-64 m=11 to 15kg

3-40
CHAPTER 3 Installation

AX, AY (%) AR (%)


0.1(1.0) 0.1(1.0)
100 100

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)

Fig. 3-65 m=16 to 20kg

AX, AY (%) AR (%)


0.15(1.5) 0.15(1.5)
100 100

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)

Fig. 3-66 m=21 to 25kg

AX, AY (%) AR (%)


0.2(2.0) 0.2(2.0)
100 100

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)

Fig. 3-67 m=26 to 30kg

3-41
CHAPTER 3 Installation

AX, AY (%) AR (%)


0.5(5.0) 0.3(3.0)
100 100

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)

Fig. 3-68 m=31 to 35kg

AX, AY (%) AR (%)


1.2(12.0) 0.3(3.0)
100 100

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)

Fig. 3-69 m=36 to 40kg

AX, AY (%) AR (%)


1.0(10.0) 0.4(4.0)
100 100

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)

Fig. 3-70 m=41 to 50kg

3-42
CHAPTER 3 Installation

6-1-10 Acceleration coefficient vs. moment of inertia


(YK550X with standard R-axis specifications)
For YK550X with high-speed R-axis specifications, refer to Section 6-1-11.
AX, AY, AR (%) 0.001
(0.01)
100

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)

Fig. 3-71 m=1, 2kg

AX, AY, AR (%) 0.0025


(0.025)
100

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)

Fig. 3-72 m=3, 4kg

AX, AY, AR (%) 0.004


(0.04)
100

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)

Fig. 3-73 m=5kg

3-43
CHAPTER 3 Installation

6-1-11 Acceleration coefficient vs. moment of inertia


(YK550X with high-speed R-axis specifications)

! 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.

AX, AY, AR (%) 0.001


(0.01)
100

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)

Fig. 3-74 m=1kg

AX, AY, AR (%) 0.001


(0.01)
100

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)

Fig. 3-75 m=2kg

3-44
CHAPTER 3 Installation

AX, AY, AR (%) 0.001


(0.01)
100

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)

Fig. 3-76 m=3kg

AX, AY, AR (%) 0.001


(0.01)
100

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)

Fig. 3-77 m=4kg

AX, AY, AR (%) 0.001


(0.01)
100

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)

Fig. 3-78 m=5kg

3-45
CHAPTER 3 Installation

6-2 Equation for moment of inertia calculation


Usually the R axis load is not a simple form, and the calculation of the moment of
inertia is not easy.
As a method, the load is replaced with several factors that resemble a simple form
for which the moment of inertia can be calculated. The total of the moment of
inertia for these factors is then obtained.
The objects and equations often used for the calculation of the moment of inertia
are shown below. Incidentally, there is the following relation:
J (kgf·cm·sec2) = I (kgm2) × 10.2.

1) Moment of inertia for material particle


The equation for the moment of inertia for a material particle that has a rota-
tion center such as shown in Fig. 3-79 is as follows:
This is used as an approximate equation when x is larger than the object size.
I= mx2 (kgm2)
2
J= Wx (kgf · cm · sec2)
g
... (Eq. 3.1)
x

g : Gravitational acceleration (cm/sec2)


m : Mass of material particle (kg)
W : Weight of material particle (kgf)
Fig. 3-79

2) Moment of inertia for cylinder (part 1)


The equation for the moment of inertia for a cylinder that has a rotation center
such as shown in Fig. 3-80 is given below.
ρπ D 4 h 2
I= = mD (kgm2)
32 8
ρπ D 4 h 2
J= = WD (kgf · cm · sec2)
32g 8g
... (Eq. 3.2)
h

ρ : Density (kg/m , kg/cm )


3 3

g : Gravitational acceleration (cm/sec2)


m : Mass of cylinder (kg)
W : Weight of cylinder (kgf) D

Fig. 3-80

3-46
CHAPTER 3 Installation

3) Moment of inertia for cylinder (part 2)


The equation for the moment of inertia for a cylinder that has a rotation center
such as shown in Fig. 3-81 is given below.
ρπ D 2 h D2 h2 D2 h2
I= ( + ) = m ( + ) (kgm2)
16 4 3 4 4 3
ρπ D 2 h D2 h2 D2 h2
J= ( + ) = W ( + ) (kgf · cm · sec2)
16g 4 3 4g 4 3
... (Eq. 3.3)

ρ : Density (kg/m3, kg/cm3)


g : Gravitational acceleration (cm/sec2)
m : Mass of cylinder (kg) D
W : Weight of cylinder (kgf)
h
2

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)

ρ : Density (kg/m3, kg/cm3)


g : Gravitational acceleration (cm/sec2) D
x
m : Mass of cylinder (kg)
W : Weight of cylinder (kgf)
Fig. 3-83

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

m : Mass of prism (kg)


W : Weight of prism (kgf)
Fig. 3-85

3-48
CHAPTER 3 Installation

6-3 Example of moment of inertia calculation


Let's discuss an example in which the chuck and workpiece are at a position
offset by 10cm from the R-axis by a stay, as shown in Fig. 3-86.
The moment of inertia is calculated with the following three factors, assuming
that the load material is steel and its density ρ is 0.0078kg/cm3.
R-axis

2cm
Stay
2cm
2cm

1cm

4cm 10cm

1cm

6cm

Chuck

Workpiece

4cm
2cm

Fig. 3-86

1) Moment of inertia of the stay

From Fig. 3-87, the weight of the


Center line
stay (Ws) is given as follows: R-axis
Ws = ρabc = 0.0078 × 12 × 2 × 2
= 0.37 (kgf)

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

2) Moment of inertia of the chuck

10cm R-axis
When the chuck form resem- 2cm

bles that shown in Fig. 3-88,


the weight of the chuck (Wc)
4cm
is
Wc = 0.0078 × 2 × 4 × 6
6cm
= 0.37 (kgf)
The moment of inertia of the
chuck (Jc) is then calculated
from Eq. 3-7.
0.37 × (22+42)
Jc = Fig. 3-88
12 × 980
0.37 × 102
+
980
= 0.038 (kgf · cm · sec2)

3) Moment of inertia of workpiece

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)

The moment of inertia of the


2cm
workpiece (Jw) is then calcu-
lated from Eq. 3-5.
0.097 × 22 0.097 × 102
Jw= + Fig. 3-89
8 × 980 980
= 0.010 (kgf · cm · sec2)

4) Total weight

The total weight (W) is calculated as follows:


W = Ws + Wc + Ww = 0.84 (kgf)

5) Total moment of inertia

The total moment of inertia (J) is then obtained as follows:


J = Js + Jc + Jw = 0.062 (kgf · cm · sec2)

3-50
CHAPTER 3 Installation

6-4 Attaching the end effector

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

Retaining ring to set the user tool


(See cautions on page 3-55.)

O-ring groove for clean room models


41

36

Spline shaft (hollow): hollow diameter φ6

φ12 0
-0.018

M8×1.25, depth 15

YK250X, YK350X, YK400X: Z-axis tip shape

φ7 +0.2
0 (Hole for attaching user tool or
R-axis rotation during direct teaching)
Z-axis mechanical stopper

Retaining ring to set the user tool


(See cautions on page 3-55.)

O-ring groove for clean room models


48

Spline shaft (hollow): hollow diameter φ10


41 (φ18 range)

φ18 0
-0.018

M12×1.75, depth 20

YK500X, YK600X: Z-axis tip shape

Fig. 3-90 (1)

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

Retaining ring to set the user tool


(See cautions on page 3-55.)

50.5
O-ring groove for clean room models

Spline shaft (hollow): hollow diameter φ10

45(φ22 range)
0
φ22 -0.021

M12×1.75, depth 20

YK700X, YK800X, YK1000X: Z-axis tip shape

φ10 +0.2
0
(Hole for attaching user tool or
R-axis rotation during direct teaching)

Support shaft clamp plate


69

45

Spline shaft (hollow): hollow diameter φ12


47.8

φ25 -0.01
-0.02

φ39

M16×2 depth25

YK1200X: Z-axis tip shape

Fig. 3-90 (2)

! 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

Fig. 3-91 Maximum load applied to end effector attachment

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

End effector or stay

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

6-5 Gripping force of end effector


The gripping force of the end effector must have a sufficient extra margin of
strength versus the workpiece weight and reaction force applied to the workpiece
during robot operation.
The reaction force applied to the workpiece during operation can be calculated
from the acceleration applied to the end effector attachment. The maximum ac-
celeration on the end effector attachment of each robot model is listed in the table
below. When the workpiece position is offset to the end effector attachment, the
accelerations Amax and AXYmax become larger by an amount equal to the offset
versus the arm length. When the R-axis rotates during operation, this acceleration
ARmax must be taken into account.

Table 3-3 Maximum acceleration during robot operation


Robot Model Amax(m/sec2) AXYmax(m/sec2) Azmax(m/sec2) ARmax(rad/sec2)
YK250X 62 45 23 140
YK350X 71 48 23 120
YK400X 91 46 23 120
YK500X 48 32 38 140
YK600X 52 27 38 140
YK700X 64 46 32 160
YK800X 67 39 32 160
YK1000X 63 39 32 136
YK1200X 45 39 8 40
YK550X 59 60 56 240

ARmax

Amax AXYmax

Azmax

Fig. 3-93 Maximum acceleration on end effector attachment

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

7 Limiting the Movement Range with X-Axis


Mechanical Stoppers
(Excluding YK250X, YK350X, YK400X)
In the YK-X Series (excluding YK250X, YK350X, YK400X), the movement range
can be limited by changing the X-axis mechanical stopper positions. (The Y-axis
mechanical stopper positions are fixed and cannot be changed.)
When the robot is shipped from the factory, the movement range is set to the
maximum. If the maximum movement range is too large compared to the actual
work range, or the manipulator might interfere with peripheral units, then the
movement range can be limited as outlined below.
The X-axis mechanical stopper positions may slightly differ depending on ma-
chining precision.

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

7-1 YK500X, YK600X, YK700X, YK800X, YK1000X, YK1200X


To change the X-axis mechanical stopper positions, use the procedure below.

1) Prepare the necessary tools.


Hex wrench set

2) Turn off the robot controller.

3) Place a sign indicating the robot is being adjusted, to keep others from touch-
ing the controller switch.

4) Enter the safeguard enclosure.

5) Remove the X-axis mechanical stoppers installed as shown in Fig. 3-94 to


Fig. 3-96. Then reinstall the mechanical stoppers at the positions that deter-
mine the desired movement range by tightening them to the torque specified
in Table 3-4.

6) Check that the movement range is limited by the mechanical stoppers as


desired.
7) Go outside the safeguard enclosure.

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


Y-axis Mechanical stopper(fixation)

Tapped hole for stopper installation


X-axis Mechanical stopper

Fig. 3-94 Mechanical stopper positions and movement range


(YK500X, YK600X)
123°

93°

°
63
°
33

Y-axis Mechanical stopper(fixation) Tapped hole for stopper installation X-axis Mechanical stopper

Fig. 3-95 Mechanical stopper positions and movement range


(YK700X, YK800X, YK1000X)

3-59
CHAPTER 3 Installation

128°

103°

78 °

°
53

°
28

Y-axis Mechanical stopper(fixation) Tapped hole for stopper installation

X-axis Mechanical stopper

Fig. 3-96 Mechanical stopper positions and movement range


(YK1200X)

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.

2) Remove the cover on the X-axis.

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.

4) Check that the movement range is limited by the mechanical stoppers as


desired.

5) Reattach the cover to the X-axis.

3-61
CHAPTER 3 Installation

93°

65
°

Installation position of
X-axis mechanical stoppers

35
(Remove the cover.) A

°
B


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.)

Tapped hole for stopper installation

Stopper for maximum working envelope

X-axis arm

Stopper

Fig. 3-97 X-axis mechanical stopper positions and movement range

3-62
CHAPTER 3 Installation

8 Limiting the Movement Range with Y-Axis


Mechanical Stoppers (YK550X only)
To change the Y-axis mechanical stopper positions, use the procedure below while
referring to Fig. 3-98.

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.

3) Check that the movement range is limited by the mechanical stoppers as


desired.
X-axis arm

Stopper for maximum working envelope

Tapped hole for stopper installation

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

34
°

Y-axis mechanical
stopper position
63
°

92°

121°

148°

Stopper

Fig. 3-98 Y-axis mechanical stopper positions and movement range

3-63
CHAPTER 3 Installation

9 Working Envelope and Mechanical Stopper


Positions for Maximum Working Envelope
Working envelope and mechanical stopper positions for the maximum working
envelope of each robot are shown in "1-2 External view and dimensions" in Chapter
7.
An example using the YK500X is described below. (Refer to Fig. 7-4.) Other
robot models are the same.

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

4) Robot overrun during impacts with mechanical stopper


A urethane damper is installed to absorb the shock when an impact occurs
with the mechanical stopper, so a certain amount of overrun occurs when the
robot strikes the mechanical stopper. Use caution and take overrun into ac-
count since the end effector may interfere with the robot body and peripheral
equipment or the robot body may interfere with the peripheral equipment.
Maximum overrun amounts are listed below (for normal operation, maxi-
mum load mass, maximum speed).
Z-axis
Robot model X-axis Y-axis
Upper end Lower end
YK250X, YK350X, YK400X 10° 2° 2mm 2mm
YK500X, YK600X 6° 2° 5mm 2mm
YK700X, YK800X, YK1000X 6° 2° 5mm 2mm
YK550X 10° 10° 1mm 4mm
Note: Here, ° (deg.) is the overrun angle at the X-axis and Y-axis joints.

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

4 Setting the Soft Limits ...........................................................4-59


5 Setting the Standard Coordinates ........................................4-62
6 Affixing Stickers for Origin Positions,
Movement Directions and Axis Names .................................4-63
7 Removing the Robot Covers ................................................4-65
8 Adjusting the Timing Belt Tension .........................................4-70
8-1 Adjusting the belt tension (YK250X, YK350X, YK400X) ................ 4-71
8-2 Adjusting the belt tension (YK500X, YK600X) ............................... 4-73
8-3 Adjusting the belt tension (YK700X, YK800X, YK1000X) .............. 4-75
8-4 Adjusting the belt tension (YK1200X) ............................................ 4-77
8-5 Adjusting the Z-axis and R-axis belts (YK550X) ............................ 4-80
(1) Adjusting the Z-axis belt tension ................................................... 4-80
(2) Adjusting the R-axis belt tension ................................................... 4-83
CHAPTER 4 Adjustment

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

3 Adjusting the origin


All models of the YK-X series robots use an absolute type position detector. The
origin position (zero pulse point) can be determined by absolute reset. Once ab-
solute reset is performed, you do not have to repeat absolute reset when turning
the power on next time.
However, absolute reset is required if any of the following cases occur. The robot
is shipped from the factory in condition "c" (below), so please perform absolute
reset after installing the robot. For more details on absolute reset, refer to "Abso-
lute Reset" in Chapter 4 of the "YAMAHA robot controller owner's manual".
a. Absolute-related error occurred on the axis.
b. Power drop was detected in the absolute battery for the driver installed
inside the robot controller.
c. Cable connecting the robot unit to the controller was disconnected.
(This is the status when shipped from the factory.)
d. Robot generation was changed.
e. Parameters were initialized.
f. Axis parameters "Origin shift", "Origin method", "Origin direction" or
"Motor direction" were changed.
g. Motor was replaced. (Motor wiring connector was removed.)
h. Data in the ALL data file (extension: ALL) or parameter file (extension:
PRM) was written into the controller by way of the RS-232C.

The following sections explain how to perform absolute reset.

! 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.

3-1 Absolute reset method

3-1-1 Sensor method (X-axis, Y-axis, and R-axis)


In the sensor method, the target axis is automatically operated for the absolute
reset, and the absolute reset is performed at the position where the proximity
sensor provided on the target axis detects the detection area (dog).
The absolute reset in the sensor method can be executed with the teaching pen-
dant (MPB), RS-232C communication, and dedicated input.

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

3-1-2 Mark method (X-axis, Y-axis, and R-axis)


In the mark method, you move the robot beforehand, to the position where you
want to perform absolute reset and then perform absolute reset there.
Use either of the following 2 methods to move the robot to the position where
you want to perform absolute reset. (See Fig. 4-3.)

(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.

3-1-3 Stroke end method (Z-axis)


In the stroke end method, absolute reset is performed at a position slightly backed
off from the stroke end, after the Z-axis contacts the mechanical stopper and
stroke end is detected.

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

3-2 Machine reference


The YK-X series position detectors are resolvers that have four positions where
absolute reset can be performed per motor revolution.
If the sensor method is used for the absolute reset, the origin position will be set
at the positions where absolute reset can be performed soon after the origin sen-
sor reacts to the dog (the origin signal is detected).
The machine reference means the position relationship of the position where the
robot detects the origin signal to the position where the absolute reset can be
performed soon after detection. (See Fig. 4-1.)
The machine reference is expressed with the ratio of interval A to interval B
shown in Fig. 4-1. Interval A is the minimum distance between the positions
where absolute reset can be performed and interval B is the distance between the
position where the origin signal is detected and the position where absolute reset
can be performed soon after the origin signal detection.
The machine reference value is displayed on the optional MPB screen. (Unit: %)
Machine reference value = B/A × 100(%)

! 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

Origin signal OFF

Resolver
A B

One motor revolution


Positions where absolute reset
can be performed

Machine reference display on MPB screen


MPB
MANUAL >RST. ABS 50% [MG] [S0H0J]

Machine reference (%)

M1= 50 M2= 56 M3= 52

M4= 66

M1 M2 M3 M4 M5

R-axis X-axis Y-axis Z-axis


Fig. 4-1
4-5
CHAPTER 4 Adjustment

3-3 Absolute reset procedures

3-3-1 Sensor method (X-axis, Y-axis, and R-axis)

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) Set the controller to MANUAL mode, if not in MANUAL mode.

4) Press the F13 (LOWER+F3) key to select "RST. ABS".

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.

Origin position at shipment

Return-to-origin is
impossible from this area.

Plus side Minus side

Return-to-origin direction

Fig. 4-2

4-7
CHAPTER 4 Adjustment

3-3-2 Mark method (X-axis, Y-axis, and R-axis)


The absolute reset in the mark method is divided into four types according to the
conditions as shown in Fig. 4-3.
Since each operating procedure is different, refer to the corresponding section in
this manual.

To perform absolute reset using the To perform absolute reset at a position


same positions as the previous different from the previous absolute
absolute reset. reset position.

The servo drive can The servo drive


The origin position The origin position safely guide the robot cannot safely guide
mark can be seen mark cannot be seen arm to the new origin the robot arm to the
from outside the robot from outside the robot position from outside new origin position
movement range. movement range. the robot movement from outside the robot
range. movement range.

Go to "3-3-2-1 Go to "3-3-2-2 Go to "3-3-2-3 Go to "3-3-2-4


Absolute reset Absolute reset Absolute reset Absolute reset
with servo on with servo off with servo on with servo off
(re-reset)" (re-reset)". (new reset)". (new reset)".

Fig. 4-3 Absolute reset flow chart

4-8
CHAPTER 4 Adjustment

3-3-2-1 Absolute reset with servo on (re-reset)

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.

4) Set the controller to MANUAL mode, if not in MANUAL mode.

5) Press the F13 (LOWER+F3) key to select "RST. ABS".

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

7) Do as follows according to the axis that was selected.


(1) X, Y and R axes
1. Jog the robot in steps using the F1 or F2 key so the origin position marks
align with each other. (Robot movement speed can be adjusted with the
F4 or F5 key.)

! 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

3-3-2-2 Absolute reset with servo off (re-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 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.

3) While holding the MPB, enter the safeguard enclosure.

4) Set the controller to MANUAL mode, if not in MANUAL mode.

5) Press the F13 (LOWER+F3) key to select "RST.ABS".

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.

10) Go outside the safeguard enclosure.

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

3-3-2-3 Absolute reset with servo on. (new reset)

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.

4) Set the controller to MANUAL mode, if not in MANUAL mode.

5) Press the F13 (LOWER+F3) key to select "RST.ABS".

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

7) Do as follows according to the axis that was selected.


(1) X, Y and R axes
1. Press the F1 or F2 key to jog the robot in steps to the position where
absolute reset is to be performed. (Robot movement speed is adjustable
with F4 or F5 key.)

! 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.

10) Go outside the safeguard enclosure.

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

3-3-2-4 Absolute reset with servo off. (new 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 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.

3) While holding the MPB, enter the safeguard enclosure.

4) Set the controller to MANUAL mode, if not in MANUAL mode.

5) Press the F13 (LOWER+F3) key to select "RST.ABS".

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.

12) Go outside the safeguard enclosure.

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

Table 4-1 Origin position repeatability tolerance

YK250X, YK350X, YK400X


Axis Origin position repeatability tolerance (° ) Origin position repeatability tolerance (mm)
X-axis ±0.90 ±0.78
Y-axis ±0.90 ±0.78
R-axis ±0.90 ±0.58

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

Origin position sticker

Fig. 4-4 Origin position stickers and slit positions

4-19
CHAPTER 4 Adjustment

Origin position mark


(Setting on the
user side)

Fig. 4-5 Origin position mark setting example YK250X, YK350X, YK400X

4-20
CHAPTER 4 Adjustment

Origin position mark


(Setting on the user side)

Origin position mark


(Setting on the user side)

Fig. 4-6 Origin position mark setting example YK500X, YK600X

4-21
CHAPTER 4 Adjustment

Origin position mark


(Setting on the user side)

Origin position mark


(Setting on the
user side)

Fig. 4-7 Origin position mark setting example YK700X, YK800X, YK1000X

4-22
CHAPTER 4 Adjustment

Slit (Same on opposite side)

Origin position sticker

Origin position sticker

Slit

Details of part A

Fig. 4-8 Origin position mark setting example YK1200X

4-23
CHAPTER 4 Adjustment

3-3-3 Stroke end method (Z-axis)

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) Set the controller to MANUAL mode, if not in MANUAL mode.

4) Press the F13 (LOWER+F3) key to select "RST. ABS".3-4

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

3-4 Changing the origin position and adjusting the machine


reference

! 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

3-4-1 Sensor method

3-4-1-1 YK250X, YK350X, YK400X


1-1 Adjusting the X-axis machine reference

The adjustment method for the X-axis machine reference is as follows.

1) Prepare the necessary tools.


• Hex wrench set

2) Check that no one is inside the safeguard enclosure and then turn on the
controller.

3) Perform the absolute reset from outside the safeguard enclosure.


Refer to "3-3 Absolute reset procedures" for information about the absolute
reset method.

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.

6) Turn off the controller and enter the safeguard enclosure.

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.

10) Tighten the setscrews to fasten the dog ring.

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

1-2 Changing the X-axis origin position

! 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.

The method to change the X-axis origin position is as follows.

1) Prepare the necessary tools.


• Hex wrench set

2) Check that no one is inside the safeguard enclosure and then turn on the
controller.

3) Perform the absolute reset from outside the safeguard enclosure.


Refer to "3-3 Absolute reset procedures" for information about the absolute
reset method.

4) Place a sign indicating that the robot is being adjusted in order to keep others
from operating the controller or operation panel.

5) Turn off the controller and enter the safeguard enclosure.

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.

8) Tighten the setscrews to fasten the dog ring.

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

2-1 Adjusting the Y-axis machine reference

The adjustment method for the Y-axis machine reference is as follows.

1) Prepare the necessary tools.


• Hex wrench set

2) Check that no one is inside the safeguard enclosure and then turn on the
controller.

3) Perform the absolute reset from outside the safeguard enclosure.


Refer to "3-3 Absolute reset procedures" for information about the absolute
reset method.

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.

6) Turn off the controller and enter the safeguard enclosure.

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.

10) Tighten the setscrews to fasten the dog ring.

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

2-2 Changing the Y-axis origin position

! 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.

The method to change the Y-axis origin position is as follows.

1) Prepare the necessary tools.


• Hex wrench set

2) Check that no one is inside the safeguard enclosure and then turn on the
controller.

3) Perform the absolute reset from outside the safeguard enclosure.


Refer to "3-3 Absolute reset procedures" for information about the absolute
reset method.

4) Place a sign indicating that the robot is being adjusted in order to keep others
from operating the controller or operation panel.

5) Turn off the controller and enter the safeguard enclosure.

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.

8) Tighten the setscrews to fasten the dog ring.

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

3-1 Adjusting the R-axis machine reference

The adjustment method for the R-axis machine reference is as follows.

1) Prepare the necessary tools.


• Hex wrench set

2) Check that no one is inside the safeguard enclosure and then turn on the
controller.

3) Perform the absolute reset from outside the safeguard enclosure.


Refer to "3-3 Absolute reset procedures" for information about the absolute
reset method.

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.

6) Turn off the controller and enter the safeguard enclosure.

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.

10) Tighten the setscrews to fasten the dog ring.

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

3-2 Changing the R-axis origin position

! 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.

The method to change the R-axis origin position is as follows.

1) Prepare the necessary tools.


• Hex wrench set

2) Check that no one is inside the safeguard enclosure and then turn on the
controller.

3) Perform the absolute reset from outside the safeguard enclosure.


Refer to "3-3 Absolute reset procedures" for information about the absolute
reset method.

4) Place a sign indicating that the robot is being adjusted in order to keep others
from operating the controller or operation panel.

5) Turn off the controller and enter the safeguard enclosure.

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.

8) Tighten the setscrews to fasten the dog ring.

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-axis dog ring


X-axis dog

X-axis origin sensor

Set screw (One each on opposite sides)

R-axis origin sensor


Y-axis origin sensor
R-axis dog ring R-axis dog Y-axis dog
Y-axis dog ring
w Table 4-2
Axis Movement amount (mm) for 100% of machine reference

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

3-4-1-2 YK500X, YK600X, YK700X,YK800X, YK1000X


1-1 Adjusting the X-axis machine reference

The adjustment method for the X-axis machine reference is as follows.

1) Prepare the necessary tools.


• Hex wrench set

2) Check that no one is inside the safeguard enclosure and then turn on the
controller.

3) Perform the absolute reset from outside the safeguard enclosure.


Refer to "3-3 Absolute reset procedures" for information about the absolute
reset method.

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.

6) Turn off the controller and enter the safeguard enclosure.

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.

10) Tighten the M4 bolts to fasten the dog plate.

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

1-2 Changing the X-axis origin position

! 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.

The method to change the X-axis origin position is as follows.

1) Prepare the necessary tools.


• Hex wrench set

2) Check that no one is inside the safeguard enclosure and then turn on the
controller.

3) Perform the absolute reset from outside the safeguard enclosure.


Refer to "3-3 Absolute reset procedures" for information about the absolute
reset method.

4) Place a sign indicating that the robot is being adjusted in order to keep others
from operating the controller or operation panel.

5) Turn off the controller and enter the safeguard enclosure.

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.

8) Tighten the M4 bolts to fasten the dog plate.

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 between 40 and 60 (recommended range),


then the origin position has been completely changed.
If it is outside the recommended range, then adjust the machine reference by
referring to "1-1 Adjusting the X-axis machine reference".

4-36
CHAPTER 4 Adjustment

2-1 Adjusting the Y-axis machine reference

The adjustment method for the Y-axis machine reference is as follows.

1) Prepare the necessary tools.


• Hex wrench set

2) Check that no one is inside the safeguard enclosure and then turn on the
controller.

3) Perform the absolute reset from outside the safeguard enclosure.


Refer to "3-3 Absolute reset procedures" for information about the absolute
reset method.

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.

6) Turn off the controller and enter the safeguard enclosure.

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.

10) Tighten the setscrews to fasten the dog ring.

! 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

2-2 Changing the Y-axis origin position

! 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.

The method to change the Y-axis origin position is as follows.

1) Prepare the necessary tools.


• Hex wrench set

2) Check that no one is inside the safeguard enclosure and then turn on the
controller.

3) Perform the absolute reset from outside the safeguard enclosure.


Refer to "3-3 Absolute reset procedures" for information about the absolute
reset method.

4) Place a sign indicating that the robot is being adjusted in order to keep others
from operating the controller or operation panel.

5) Turn off the controller and enter the safeguard enclosure.

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.

8) Tighten the setscrews to fasten the dog ring.

! 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.

12) If the machine reference value is between 40 and 60 (recommended range),


then the origin position has been completely changed.
If it is outside the recommended range, then adjust the machine reference by
referring to "2-1 Adjusting the Y-axis machine reference".

4-40
CHAPTER 4 Adjustment

3-1 Adjusting the R-axis machine reference

The adjustment method for the R-axis machine reference is as follows.

1) Prepare the necessary tools.


• Hex wrench set

2) Check that no one is inside the safeguard enclosure and then turn on the
controller.

3) Perform the absolute reset from outside the safeguard enclosure.


Refer to "3-3 Absolute reset procedures" for information about the absolute
reset method.

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.

6) Turn off the controller and enter the safeguard enclosure.

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.

10) Tighten the M4 bolts to fasten the dog ring.

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

3-2 R-axis origin position change


The R-axis origin position cannot be changed on the YK500X, YK600X, YK700X,
YK800X, and YK1000X.

4-42
CHAPTER 4 Adjustment

w
q
w

q
w
q

Table 4-3
Movement amount (mm) for 100% of machine reference

Axis YK500X, YK600X YK700X, YK800X, YK1000X

X 1.23 1.63 (YK1000X : 1.31)

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 origin sensor

Y-axis dog

Y-axis dog ring


R-axis dog
R-axis dog ring
Set screw (One each on opposite sides)

X-axis dog plate


M4 bolts (2 places)

X-axis dog
R-axis origin sensor
M4 bolts (2 places)

X-axis origin sensor

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

1) Prepare the necessary tools.


• Slotted screwdriver
• Hex wrench set
• Plastic hammer

2) Check that no one is inside the safeguard enclosure, and then turn on the
controller.

3) Perform the absolute reset from outside the safeguard enclosure.


Refer to "3-3 Absolute reset procedures" for information about the absolute
reset method.

4) Check that return-to-origin is complete.

5) Turn off the controller.

6) Place a sign indicating the robot is being adjusted, to keep others from
operating the controller switch.

7) Enter the safeguard enclosure.

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.

12) Tighten the set screw of the X-axis origin dog.

4-44
CHAPTER 4 Adjustment

Set screw
Rear cover

X-axis origin dog

Right
Left

Adjustment window
Rubber cap

Fig. 4-11 X-axis origin dog

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.

15) Turn off the controller.

16) Enter the safeguard enclosure.

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 Changing the Y-axis origin position and adjusting the machine


reference value

1) Prepare the necessary tools.


• Hex wrench set

2) Check that no one is inside the safeguard enclosure, and then turn on the
controller.

3) Perform the absolute reset from outside the safeguard enclosure.


Refer to "3-3 Absolute reset procedures" for information about the absolute
reset method.

4) Check that return-to-origin is complete.

5) Turn off the controller.

6) Place a sign indicating the robot is being adjusted, to keep others from
operating the controller switch.

7) Enter the safeguard enclosure.

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.

12) Tighten the set screw of the Y-axis origin dog.

4-46
CHAPTER 4 Adjustment

Set screw

Y-axis origin dog

Left Right

Adjustment window

M16 set screw

Fig. 4-12 Y-axis origin dog

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.

15) Turn off the controller.

16) Enter the safeguard enclosure.

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

3 Changing the R-axis origin position and adjusting the machine


reference value

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.

1) Prepare the necessary tools.


• Phillips screwdriver
• Hex wrench set
• 14mm wrench

2) Check that no one is inside the safeguard enclosure, and then turn on the
controller.

3) Perform the absolute reset from outside the safeguard enclosure.


Refer to "3-3 Absolute reset procedures" for information about the absolute
reset method.

4) After return-to-origin is complete, note the R-axis machine reference value


displayed on the MPB. When this value is within the allowable range (40 to
60%), no adjustment is required. If not, adjust as follows.

5) Turn off the controller.

6) Place a sign indicating the robot is being adjusted, to keep others from
operating the controller switch.

7) Enter the safeguard enclosure.

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

Flat sides on spline shaft

R-axis origin dog

Fig. 4-13 R-axis origin sensor and origin dog


4-48
CHAPTER 4 Adjustment

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

Fig. 4-14 Adjusting the R-axis origin sensor

10) Move the R-axis origin sensor as indicated in NOTE below.

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)

11) Retighten the bolts to secure the installation plate.


Place the 10mm wrench on the flat sides on the spline shaft and turn it to
check that the origin sensor does not touch the origin dog. If the origin sensor
touches the origin dog, adjust the position of the origin sensor so that they do
not interfere with each other.

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

3-4-2 Mark method


In the mark method, the origin position can be changed with the absolute reset at
the desired position.
It is not necessary to adjust the machine reference.
Refer to "Chapter 4, 3-3 Absolute reset procedures" for information about the
absolute reset method with the mark method.

! 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

3-4-3 Stroke end method


The stroke end method is employed on the YK-X series robots for the absolute
reset of the Z-axis.
The origin position of the Z-axis is fixed at the upper end of the Z-axis stroke, and
it cannot be changed.
The machine reference is factory-adjusted at shipment, and readjustment is not
necessary for normal use.
The readjustment in the following procedure is required, however, if the machine
reference exceeds the tolerance range (26 to 74) of the absolute reset for any
reason.

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.

3-4-3-1 YK250X, YK350X, YK400X, YK500X, YK600X, YK700X,


YK800X, YK1000X, YK1200X
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 oper-
ating the controller or operation panel.

3) Perform the Z-axis absolute reset.


To perform the Z-axis absolute reset, see "3-3 Absolute reset procedures" in
Chapter 4.

4) Turn off the controller.

5) Enter the safeguard enclosure.

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.

12) Go outside the safeguard enclosure.

13) Check that no one is inside the safeguard enclosure, and then turn on the
controller.

4-52
CHAPTER 4 Adjustment

14) Perform the Z-axis absolute reset.


To perform the Z-axis absolute reset, see "3-3 Absolute reset procedures" in
Chapter 4.
After absolute reset is complete, use the following procedure to check if the
adjustment machine reference value is within the tolerance range (26 and
74).

! 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.

q Press the MODE key.


w Press the F3 key to set MANUAL mode.
e Press the F13 (LOWER+F3) key to select "RST. ABS ".
r After the Z-axis absolute reset is complete, press the F10 (UPPER+F5) to
display the adjustment machine reference value (%).
If adjustment machine reference value is outside the absolute reset tolerance
range (26 to 74), remove the Z-axis motor again and make fine-adjustment to the
spline shaft height, so that the adjustment machine reference value is within
the absolute reset tolerance range.
Table 4-4
Robot Model L
YK250X, YK350X, YK400X 5mm
YK500X, YK600X 8mm
YK700X, YK800X, 1000X 8mm
YK1200X 21mm

4-53
CHAPTER 4 Adjustment

Z-axis motor
Z-axis motor installation bolt M3×6

Fig. 4-15 YK250X, YK350X, YK400X

Z-axis motor
Z-axis motor installation bolt M5×14

Fig. 4-16 YK500X, YK600X

Z-axis motor
Z-axis motor installation bolt M5×12

Fig. 4-17 YK700X, YK800X, YK1000X

Z-axis motor

Z-axis motor installation bolt M6×20

Fig. 4-18 YK1200X

Z-axis mechanical stopper


L

Fig. 4-19 YK250X to YK1000X Fig. 4-20 YK1200X

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.

3) Perform the absolute reset from outside the safeguard enclosure.


Refer to "3-3 Absolute reset procedures" for information about the absolute
reset method.
To check the machine reference value, refer to step 14) in section 3-4-3-1.

4) After return-to-origin is complete, check the Z-axis machine reference value


displayed on the MPB. When this value is within the allowable range (40 to
60%), no adjustment is required. If not, adjust as follows.
5) Turn off the controller.

6) Place a sign indicating the robot is being adjusted, to keep others from
operating the controller switch.

7) Enter the safeguard enclosure.

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

Upper cover Machine harness


Z-axis motor

Scribed line plate


Screw

Screw R-axis speed


reduction gear
Screw
Screw

Y-axis arm

Z-axis spline
Under cover

Under cover Scribed line

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

4 Setting the Soft Limits


In the YK-X Series, the working envelope during manual and automatic opera-
tion can be limited by setting the plus soft limit [pulse] and minus soft limit
[pulse] on each axis.
The origin point ( 0 [pulse] )is used as the reference to set the soft limits. The
working envelope can be limited by specifying the number of pulses from the 0
pulse position. Refer to the "YAMAHA robot controller owner's manual" for
further details. Also refer to "1-2 External view and dimensions" in Chapter 7 for
the working envelope area.
When performing actual checks of the soft limit settings, operate the robot manu-
ally from outside the safeguard enclosure.

(1) Setting the X-axis and Y-axis soft limits


The soft limits must be set within the movement range limited by the me-
chanical stoppers as explained in Section 7 in Chapter 3 or within the range
where the manipulator does not interfere with the peripheral equipment (but
within maximum working envelope). Set the soft limits with the following
procedure. Also use this procedure when the origin position has been changed.
Likewise, in models where the mechanical stopper position cannot be changed,
reduce the soft limits to narrow the working envelope when the actual work-
ing range of the robot is small or the manipulator interferes with the periph-
eral equipment.

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.

4) Enter the safeguard enclosure while holding the MPB.

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

(2) Setting the Z-axis soft limits


Make this setting from outside the safeguard enclosure.
The Z-axis has mechanical stoppers fixed at the upper and lower ends of the
Z-axis movement range. When the actual working range of the robot is smaller
than the maximum working envelope or the manipulator interferes with the
peripheral equipment, reduce the Z-axis plus (+) soft limit [pulses] to narrow
the working envelope.

(3) Setting the R-axis soft limit


To make this setting, set emergency stop just as for the X-axis and Y-axis, or
be sure to do this from outside the safeguard enclosure. The R-axis has no
mechanical stoppers. When the actual working range of the R-axis is small or
it interferes with the peripheral equipment, reduce the R axis plus (+) soft
limit [pulse] and minus (-) soft limit [pulses] to narrow the working enve-
lope.

! 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

Operation angle/distance vs. number of resolver pulses


X, Y and R-axis speed reduction ratio
Speed ratio Number of resolver pulses per turn (360 degrees)
30 491520
50 819200
80 1310720
100 1638400
105 1720320
121 1982464
Z-axis
Lead Number of resolver pulses per lead movement
10mm 16384
12mm 16384
20mm 16384
30mm 16384

4-61
CHAPTER 4 Adjustment

5 Setting the Standard Coordinates

! 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.

2) Check that the soft limits are correctly set.


If not correctly set, adjust the soft limits while referring to the description of
"4 Setting the Soft Limits" in Chapter 4.

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

6 Affixing Stickers for Origin Positions, Move-


ment Directions and Axis Names
The robot comes packed with stickers showing origin positions, movement direc-
tions and axis names as shown in Fig. 4-23. Using the following procedure, at-
tach these stickers in conspicuous points on the robot after changing the origin
position and installing peripheral equipment.

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

Fig. 4-24 Positions for affixing the stickers (YK500X)

4-64
CHAPTER 4 Adjustment

7 Removing the Robot Covers


To remove the robot cover, follow the procedure below.
1) Prepare the necessary tools.
• Hex wrench set
• Phillips-head screwdriver

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 covers while referring to Fig. 4-25 to Fig. 4-28.


Screws used to fasten each cover are listed in Tables 4-5 to 4-8.

Table 4-5 YK250X, YK350X, YK400X (See Fig. 4-25)


Cover name Screw No. Screw size Qty
Base (robot pedestal) rear cover q M4×6 4
Base (robot pedestal) front cover w M4×6 4
Y-axis arm upper cover e M3×6 2
r M3×10 2
t M3×16 2

Table 4-6 YK500X, YK600X (See Fig. 4-26)


Cover name Screw No. Screw size Qty
Base (robot pedestal) rear cover 1 q M4×6 8
Base (robot pedestal) rear cover 2 w M4×6 4
Base (robot pedestal) front cover e M4×6 8
X-axis arm upper cover r M4×6 2
Y-axis arm upper cover t M3×6 4
y M3×50 4
Y-axis arm under cover u M4×6 4

Table 4-7 YK700X, YK800X, YK1000X (See Fig. 4-27)


Cover name Screw No. Screw size Qty
Base (robot pedestal) rear cover 1 q M4×6 8
Base (robot pedestal) rear cover 2 w M4×6 4
Base (robot pedestal) front cover e M4×6 8
X-axis arm upper cover r M4×8 2
Y-axis arm upper cover t M4×6 4
y M4×50 4
Y-axis arm under cover u M4×6 4 (6 for YK1000X)

Table 4-8 YK1200X (See Fig. 4-28)


Cover name Screw No. Screw size Qty
Base (robot pedestal) rear cover 1 q M4×6 8
Base (robot pedestal) rear cover 2 w M4×6 4
Base (robot pedestal) front cover e M4×6 4
X-axis arm upper cover r M4×6 2
X-axis arm under cover t M4×6 2
Y-axis arm front cover y M4×6 14
Y-axis arm side cover u M4×6 10

4-65
CHAPTER 4 Adjustment

eM3×6 (with washer)

Y-axis upper cover

Base rear cover

wM4×6
qM4×6

Base front cover

rM3×10

tM3×16

Fig. 4-25

4-66
CHAPTER 4 Adjustment

tM3×6 (with washer) rM4×6

Y-axis upper cover

X-axis upper cover

eM4×6

Y-axis under cover


Base rear cover 1 qM4×6
Base front cover

yM3×50
Base rear cover 2 wM4×6
uM4×6

Fig. 4-26

4-67
CHAPTER 4 Adjustment

tM4×6 (with washer) rM4×8

Y-axis upper cover

X-axis upper cover

eM4×6

Y-axis under cover

Base front cover

yM4×50

uM4×6

Base rear cover 1 qM4×6

Base rear cover 2 wM4×6

Fig. 4-27

4-68
CHAPTER 4 Adjustment

rM4×6

y M4×6

Y-axis arm front cover

uM4×6
Y-axis arm side cover

X-axis arm upper cover

X-axis arm under cover


tM4×6

qM4×6
Base rear cover 1
Base front cover

Base rear cover 2 wM4×6


eM4×6

Fig. 4-28

4-69
CHAPTER 4 Adjustment

8 Adjusting the Timing Belt Tension


The YK-X series robots use a timing belt for controlling the movement of the Z
and R axes. If the belt becomes slack, use the following procedure to give proper
tension to the belt.

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

Pulley Belt Pulley

Fig. 4-29 Belt tension adjustment


5
Belt

Push-pull scale
25

55

Nut

Stay Hole

Nut
10

15

Metal plate 3.2mm


thickness

Fig. 4-30 Stay (example)

4-70
CHAPTER 4 Adjustment

8-1 Adjusting the belt tension (YK250X, YK350X, YK400X)

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

(2) R-axis belt adjustment


1. Loosen the bolt w shown in Fig. 4-31.
2. If the load producing the slack specified in Table 4-10 (step 7) above) is
smaller than the specified range, move the R-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 4-10, the adjustment is okay. If not, repeat the above procedure from
steps 1 to 3.

9) After adjustment is complete, tighten the bolt q or w to the torque specified


in Table 4-11.
10) Reattach the upper cover to the Y-axis arm.
Refer to "7 Removing the Robot Covers" in Chapter 4 for attaching the cover.
11) Go outside the safeguard enclosure.
12) Check that no one is inside the safeguard enclosure, and then turn on the
controller.

Z-axis motor

Z-axis belt

R-axis belt
R-axis motor

1M3×6 2M3×6

Tension reduces Tension increases

Fig. 4-31 YK250X, YK350X, YK400X

4-72
CHAPTER 4 Adjustment

8-2 Adjusting the belt tension (YK500X, YK600X)

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.

(1) Z-axis belt adjustment


1. Loosen the bolt q shown in Fig. 4-32.
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.

4-73
CHAPTER 4 Adjustment

(2) R-axis belt adjustment


1. Loosen the bolt w shown in Fig. 4-32.
2. If the load producing the slack specified in Table 4-10 (step 7) above) is
smaller than the specified range, move the R-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 4-10, the adjustment is okay. If not, repeat the above procedure from
steps 1 to 3.

9) After adjustment is complete, tighten the bolt q or w to the torque specified


in Table 4-11.
10) Reattach the upper and under covers to the Y-axis arm.
Refer to "7 Removing the Robot Covers" in Chapter 4 for attaching the cov-
ers.
11) Go outside the safeguard enclosure.
12) Check that no one is inside the safeguard enclosure, and then turn on the
controller.
R-axis belt R-axis motor Z-axis motor

2M4×10 1M5×14

Z-axis belt

Tension reduces Tension increases

Fig. 4-32 YK500X, YK600X

4-74
CHAPTER 4 Adjustment

8-3 Adjusting the belt tension (YK700X, YK800X, YK1000X)

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

(2) R-axis belt adjustment


1. Loosen the bolt w shown in Fig. 4-33.
2. If the load producing the slack specified in Table 4-10 (step 7) above) is
smaller than the specified range, move the R-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 4-10, the adjustment is okay. If not, repeat the above procedure from
steps 1 to 3.

9) After adjustment is complete, tighten the bolt q or w to the torque specified


in Table 4-11.
10) Reattach the upper and under covers to the Y-axis arm.
Refer to "7 Removing the Robot Covers" in Chapter 4 for attaching the cov-
ers.
11) Go outside the safeguard enclosure.
12) Check that no one is inside the safeguard enclosure, and then turn on the
controller.

R-axis belt R-axis motor Z-axis motor


2M4×15 1M5×12

Z-axis belt

Tension reduces Tension increases

Fig. 4-33 YK700X, YK800X, YK1000X

4-76
CHAPTER 4 Adjustment

8-4 Adjusting the belt tension (YK1200X)

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

(2) R-axis belt adjustment


1. Loosen the bolt w shown in Fig. 4-34.
2. If the load producing the slack specified in Table 4-10 (step 7) above) is
smaller than the specified range, move the R-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 4-10, the adjustment is okay. If not, repeat the above procedure from
steps 1 to 3.

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

Install the harness clamp stay so that the R-axis belt


and the harness do not make contact with each other.

Z-axis belt

Tension reduces Tension increases

Fig. 4-34 YK1200X

4-78
CHAPTER 4 Adjustment

Table 4-9 Z-axis belt specifications

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

Table 4-10 R-axis belt specifications

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

Table 4-11 Tightening torque

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

8-5 Adjusting the Z-axis and R-axis belts (YK550X)


The Z-axis and R-axis timing belts of the YK550X use a material that will not
stretch under normal operation. The proper belt tension will be maintained unless
otherwise the position of the Z-axis motor or R-axis speed reduction gear unit is
moved. If for some reason their positions have moved, adjust the belt tension
with the following procedure.

(1) Adjusting the Z-axis belt tension

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.

1) Prepare the necessary tools.


• Hex wrench set
• Phillips screwdriver
• Support stand

2) Turn off the controller.

3) Place a sign indicating the robot is being adjusted, to keep others from
operating the controller switch.

4) Enter the safeguard enclosure.

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.

11) Reattach the covers.

Upper cover Machine harness


Z-axis motor

Screw

Screw R-axis speed


reduction gear
Screw
Screw

Z-axis spline Under cover

Under cover

Fig. 4-35

4-81
CHAPTER 4 Adjustment

Tension adjust bolt

Pull Pull and then


move back

M4 bolt Flange end surface


Scribed line M4 bolt

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

Fig. 4-36 Adjusting the belt tension

4-82
CHAPTER 4 Adjustment

(2) Adjusting the R-axis belt tension


1) Prepare the necessary tools.
• Hex wrench set
• Phillips screwdriver

2) Turn off the controller.

3) Place a sign indicating the robot is being adjusted, to keep others from
operating the controller switch.

4) Enter the safeguard enclosure.

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.

10) Reattach the covers.

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

6 Replacing the Harmonic Grease (YK550X) ..........................5-66


6-1 Replacement period ....................................................................... 5-66
6-2 Basic replacement procedure for harmonic grease and
precautions (Y-axis) ....................................................................... 5-67
6-3 Replacing the X-axis harmonic grease .......................................... 5-72
6-4 Replacing the R-axis harmonic grease .......................................... 5-75

7 Replacing the Grease for RV Speed Reduction Gears


(YK1200X).............................................................................5-77
7-1 Replacement period ....................................................................... 5-77
7-2 Recommended grease................................................................... 5-77
7-3 Replacement procedure................................................................. 5-78
7-3-1 Replacing the X-axis grease ......................................................... 5-79
7-3-2 Replacing the Y-axis grease .......................................................... 5-80
MEMO
CHAPTER 5 Periodic Inspection

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.

Periodic inspection includes:


• Daily inspection
• 6-month inspection
• Replacement of speed reduction gear (harmonic drive)
• Replacing the grease for speed reduction gear (harmonic drive)
• Replacing the grease for RV speed reduction gears

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.

(6) Use only the lubricants specified by YAMAHA or YAMAHA dealers.

(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.)

Check air pressure.


Regulator, joints, air tube, Check for air leaks.
solenoid valve, air cylinder Check drain.
Check air filter for clogging or damage.

Robot exterior Check for damage. (If a damage is found, contact YAMAHA dealer.)

(2) Inspection to be performed with the controller turned on


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.

Checkpoint Procedure

Check if the safeguard enclosure is in place.


Safeguard enclosure Check if emergency stop is triggered when the door is opened.
Check if warning labels are affixed at the entrance and clearly visible.

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

(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.

2) If repair or parts replacement is required for the robot or controller, please


contact your YAMAHA dealer. This work requires specialized technical
knowledge and skill, so do not attempt it by yourself.

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

(1) Inspection to be performed with the controller turned off


1) Turn off the controller.

2) Place a sign showing that 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
Manipulator bolts and screws (Only for
major bolts and screws exposed Check for looseness and tighten if necessary.*1
externally)
Z-axis and R-axis timing belts Check belt tension. (See 8 in Chapter 4.)
Detection areas of the origin sensors of
Clean if it is dirty.
the X-axis, Y-axis, and R-axis
Check for looseness at each terminal and connector on the
Controller
panel. (See 4 in Chapter 3.)
Every 6 month, lubricate the Z-axis ball screw nut with
Grease lubrication of Z-axis ball screw, grease gun, and the linear shaft, spline shaft and ball screw
spline, linear shaft shaft by hand after removing the old grease. The specified
grease is Albania No.2 (SHOWA SHELL SEKIYU KK).
Check for backlash. (If any abnormality is found, contact
Z-axis ball spline, ball screw
YAMAHA dealer.)

*1 Bolt tightening torque


Bolt size Tightening torque (kgf·cm) Tightening torque (N·m)
M3 button head bolt 14 1.4
M4 set screw 20 2.0
M3 20 2.0
M4 46 4.5
M5 92 9.0
M6 156 15.3
M8 380 37
M10 720 71
M12 1310 128
M14 2090 205

5-6
CHAPTER 5 Periodic Inspection

(2) Inspection to be performed with the controller turned on

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

• Check if the fan rotates normally.


• Check if objects blocking the fan are located and remove
• Cooling fan at rear of controller if any are found.
• X-axis motor cooling fan inside robot • Check for abnormal noise from the rotating fan. If
base (pedestal) abnormal noise is heard, visually check and remove the
(YK550X only; see Fig. 5-63) *1 cause. If no cause is found, contact YAMAHA dealer.
• Check for dust on the fan cover. Remove and clean if
necessary.

*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.

2) If repair or parts replacement is required for the robot or controller, please


contact your YAMAHA dealer. This work requires specialized technical
knowledge and skill, so do not attempt it by yourself.

5-7
CHAPTER 5 Periodic Inspection

5 Replacing the Harmonic Drive


The YK-X series robots listed in Table 5-1 use a harmonic drive as the speed
reduction gear for the X, Y and R axes. Harmonic drives need to be replaced after
a specified operation time. Use the guideline explained below to determine the
replacement period and replace the harmonic drive periodically.
Since the YK-X series robots listed in Table 5-1 use long-life harmonic grease, it
is not necessary to replace the harmonic grease.

5-1 Replacement period


The harmonic drive replacement period is determined by the total number of
turns of the wave generator used in the harmonic drive. It is recommended to
replace the harmonic drive when the total number of turns has reached 8.4×108
(at ambient operating temperatures of 0°C to +40°C). This means that the re-
placement period will differ depending on the following operating conditions. If
the robot operation duty ratio is high or the robot is operated in environments at
higher temperatures, the harmonic drive should be replaced earlier.

Replacement period = 8.4×108/(n×60×h×D×N×θ) years


where n : Number of axis movements per minute
θ : Average turn per axis movement
N : Speed reduction 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 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

Table 5-1 Harmonic drive speed reduction ratio


Robot model X-axis Y-axis R-axis
YK250X, YK350X, YK400X 50 50 50
YK500X,YK600X 80 80 50
YK700X,YK800X 80 80 50
YK1000X 100 80 50
YK1200X – – 50
YK550X with high-speed R-axis specifications – – 30

5-8
CHAPTER 5 Periodic Inspection

Table 5-2 Bolt tightening torque


Bolt size Tightening torque (kgf·cm) Tightening torque (N·m)
M3 button head bolt 14 1.4
M4 set screw 20 2.0
M3 20 2.0
M4 46 4.5
M5 92 9.0
M6 156 15.3
M8 380 37
M10 720 71

5-9
CHAPTER 5 Periodic Inspection

5-2 Basic replacement procedure for harmonic drive and precautions


Basic procedures and precautions for replacing the harmonic drive are described
below. Before beginning the replacement work, always be sure to read these re-
placement procedures and caution.

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

5-2-1 YK250X, YK350X, YK400X


The following steps describe procedures and precautions when replacing the har-
monic drives of the YK250X, YK350X and YK400X. (The illustrations show the
YK250X). For the bolt tightening torques in this work, refer to Table 5-2.

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

2) Turn off the controller.

3) Place a sign indicating that the robot is being inspected, to keep others from
operating the controller switch.

4) Enter the safeguard enclosure.

5) Remove the base (robot pedestal) front and rear covers.


Refer to "7 Removing the Robot Covers" in Chapter 4 for removing the covers.

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.

21) Go outside the safeguard enclosure.

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

2) Turn off the controller.

3) Place a sign indicating that the robot is being inspected, to keep others from
operating the controller switch.

4) Enter the safeguard enclosure.

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.)

9) Remove the Y-axis harmonic drive installation bolts (M3×40L, 6 pieces)


M3×40

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

15) Fasten the dog ring on the Harmonic drive.

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

Remove the temporarily tightened bolts when assembling


Keep the circular spline from coming off when assembling

Fit O-ring (supplied) into this groove


Harmonic drive will be damaged if O-ring is caught out of groove.
O-ring : KN3-M257L-000

Apply grease to entire oldham coupling.


Wave generator

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

Apply grease to the thickness equal to the ball diameter.

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

20) Reattach the Y-axis arm upper cover.

21) Go outside the safeguard enclosure.

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

2) Turn off the controller.

3) Place a sign indicating that the robot is being inspected, to keep others from
operating the controller switch.

4) Enter the safeguard enclosure.

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

Spline mount plate

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

Pulley R-axis motor plate

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.)

Wave generator Retaining ring groove

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

Never remove these temporarily tightened bolts.


The axis will otherwise deviate from center.

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.

17) Apply harmonic grease to the circular spline.


See Fig. 5-16 for applying grease properly.

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.

22) Fasten the dog ring on the Harmonic drive.

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).

26) Reattach the Y-axis arm upper cover.

27) Go outside the safeguard enclosure.

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

5-2-2 YK500X, YK600X


The following steps describe procedures and precautions when replacing the har-
monic drives of the YK500X and YK600X. (The illustrations show the YK500X).
For the bolt tightening torques in this work, refer to Table 5-2.

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

2) Turn off the controller.

3) Place a sign indicating that the robot is being inspected, to keep others from
operating the controller switch.

4) Enter the safeguard enclosure.

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

24) Go outside the safeguard enclosure.

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

2) Turn off the controller.

3) Place a sign indicating that the robot is being inspected, to keep others from
operating the controller switch.

4) Enter the safeguard enclosure.

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.

22) Reattach the Y-axis arm upper cover.

23) Go outside the safeguard enclosure.

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

2) Turn off the controller.


3) Place a sign indicating that the robot is being inspected, to keep others from
operating the controller switch.
4) Enter the safeguard enclosure.
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.

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

Apply grease to sufficiently fill in the ball space.


Fit O-ring (supplied) into this groove
Harmonic drive will be damaged if O-ring is
caught out of groove. Apply grease to entire oldham coupling.
O-ring : KN3-M257L-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

Never remove these temporarily tightened bolts.


The axis will otherwise deviate from center.

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.

16) Apply harmonic grease to the circular spline.


See Fig. 5-33 for applying grease properly.

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.)

25) Reattach the Y-axis arm upper cover.

26) Go outside the safeguard enclosure.

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

5-2-3 YK700X, YK800X, YK1000X


The following steps describe procedures and precautions when replacing the har-
monic drives of the YK700X, YK800X and YK1000X. (The illustrations show
the YK700X). For the bolt tightening torques in this work, refer to Table 5-2.

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

2) Turn off the controller.

3) Place a sign indicating that the robot is being inspected, to keep others from
operating the controller switch.

4) Enter the safeguard enclosure.

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

Apply grease to sufficiently fill in the ball space.


Apply grease to the thickness equal to the ball diameter.
Never remove these temporarily tightened bolts.
The axis will otherwise deviate from center.

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.

22) Go outside the safeguard enclosure.

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

2) Turn off the controller.

3) Place a sign indicating that the robot is being inspected, to keep others from
operating the controller switch.

4) Enter the safeguard enclosure.

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.

22) Reattach the Y-axis arm upper cover.

23) Go outside the safeguard enclosure.

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

2) Turn off the controller.


3) Place a sign indicating that the robot is being inspected, to keep others from
operating the controller switch.
4) Enter the safeguard enclosure.
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.

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

Never remove these temporarily tightened bolts.


The axis will otherwise deviate from center.

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.

16) Apply harmonic grease to the circular spline.


See Fig. 5-51 for applying grease properly.

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.

O-ring : KN3-M2159-000 Edge seal


Fastening plate

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.)

24) Reattach the Y-axis arm upper cover.

25) Go outside the safeguard enclosure.

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.

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-25-50 KN6-M1821-001
S90(JIS) KN4-M2143-000 Lower part of harmonic drive
O-ring Rubber wire diameter 1.30mm × Ring inner diameter66.50mm KN4-M257L-000 Supplied with harmonic drive
Rubber wire diameter 1.25mm × Ring inner diameter 37.50mm KN6-M1896-010 Wave generator support bearing section
Edge seal VR32A KN6-M1886-000

2) Turn off the controller.

3) Place a sign indicating that the robot is being inspected, to keep others from
operating the controller switch.

4) Enter the safeguard enclosure.

5) Remove the Y-axis arm front cover.


Refer to "7 Removing the Robot Covers" in Chapter 4 for removing the covers.

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

Spline support shaft


Spline

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

Spline support shaft

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

Fit O-ring (supplied) into this groove


Harmonic drive will be damaged if O-ring is Apply grease to sufficiently fill in the ball space.
caught out of groove. Apply grease to the thickness equal to the
O-ring : KN5-M257L-000 ball diameter.

Circular spline

Never remove these temporarily tightened bolts.


The axis will otherwise deviate from center.

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.

16) Apply harmonic grease to the circular spline.


See Fig. 5-58 for applying grease properly.

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.

O-ring : KN4-M2143-000 Edge seal

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.)

24) Attach the Y-axis arm front cover.

25) Go outside the safeguard enclosure.

26) Check that no one is inside the safeguard enclosure, and then turn on the
controller.
5-64
CHAPTER 5 Periodic Inspection

5-2-5 YK550X with high-speed R-axis specifications: R-axis


The YK550X with high-speed R-axis specifications uses harmonic grease 4B
No.2 only for the R-axis.
For information on how to replace the speed reduction gear, refer to "6-4 Replacing
the R-axis harmonic grease".

5-65
CHAPTER 5 Periodic Inspection

6 Replacing the Harmonic Grease (YK550X)


The YK550X uses a harmonic drive as the speed reduction gear for the X, Y and
R axes. Harmonic grease HC-1A (Harmonic Drive Systems Inc.) is used to
lubricate the harmonic drive. When this grease deteriorates with operating time,
the service life of the harmonic drive may shorten. Use the guideline explained
below to determine the replacement period and replace the grease periodically.

6-1 Replacement period


The harmonic grease replacement period is determined by the total number of
turns of the wave generator used in the harmonic drive. It is recommended to
replace the harmonic grease when the total number of turns has reached 1.5×108
(at ambient operating temperatures of 0°C to +40°C). This means that the
replacement period will differ depending on the following operating conditions.
If the robot operation duty ratio is high or the robot is operated in environments at
higher temperatures, the grease should be replaced earlier.

(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

Replacement period = 1.5×108/(n×60×h×D×N×θ)


= 1.5×108/(10×60×24×240×50×1/4) = 3.47 years
Axis Speed Ratio
X, Y, R 50

5-66
CHAPTER 5 Periodic Inspection

6-2 Basic replacement procedure for harmonic grease and


precautions (Y-axis)
Basic procedures and precautions for replacing the harmonic grease are described
below using the Y-axis of the YK550X as an example. Use basically the same
procedure when replacing the grease the X-axis and R-axis.

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)

2) Turn off the the controller.

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

4) Enter the safeguard enclosure.

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.

6) Remove the four M4 bolts securing 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

Y-axis circular spline

Flexible spline

Washer Y-axis arm

Mark

X-axis arm 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.

Fill all the gear


grooves completely.

Lightly coat the outer


circumference.

(Circular spline) (Flexible spline) (Wave generator)

Fig. 5-61 Applying grease

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.

19) Go outside the safeguard enclosure.

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)

M4 set screw M6 hole

Motor

Wave generator

Key
Motor holder

Fig. 5-62 Wave generator installation position

5-71
CHAPTER 5 Periodic Inspection

6-3 Replacing the X-axis harmonic grease


The following steps explain the procedures for replacing the X-axis harmonic
grease of the YK550X, which differ from the procedures detailed in Section 6-2.
Before starting the replacement job, be sure to read the warning, caution and
procedures described in Section 6-2.

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.

1) Prepare the following tools and items.


• Harmonic grease HC-IA • Waste cloth • Phillips screwdriver
• Cleaning oil (kerosene, etc.)
• Torque wrench (insertion angle 6.35mm, 9.5mm)
• 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)
• Extension bar (insertion angle 6.35mm, length 150mm)
• Extension bar (insertion angle 9.5mm, length 75mm)
• Socket adapter (9.5mm , 6.35mm )

2) Turn off the controller.

3) Place a sign indicating the robot is being inspected, to keep others from
operating the controller switch.

4) Enter the safeguard enclosure.

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)

X-axis motor M5 bolt


Motor holder

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)

M4 set screw M6 hole

Motor

Wave generator

Key
Motor holder

Fig. 5-64 Wave generator installation position

5-74
CHAPTER 5 Periodic Inspection

6-4 Replacing the R-axis harmonic grease


The following steps explain the procedures for replacing the R-axis harmonic
grease of the YK550X, which only differ from the procedures described in Sec-
tion 6-2. Before starting the replacement job, be sure to read the warning, caution
and procedures described in Section 6-2.
In the case of the YK550X with high-speed R-axis specifications, grease replace-
ment is not required because harmonic grease 4B No. 2 is used. When the har-
monic drive replacement period has expired, which can be calculated from the
factors explained in "5-1 Replacement period", replace the harmonic drive while
referring to the procedures described in this section. Always use harmonic grease
4B No. 2.
1) Prepare the following tools and items.
• Harmonic grease (standard R-axis specifications: HC-1A, high-speed R-
axis specifications: 4B No. 2) • Waste cloth
• Phillips screwdriver • Cleaning oil (kerosene, etc.)
• Torque wrench (insertion angle 6.35mm)
• Magic marker
• Ratchet handle (insertion angle 6.35mm)
• Hexagonal socket set (insertion angle 6.35mm)
• Extension bar (insertion angle 6.35mm, length 50mm)
• T wrench (for M5)
2) Turn off the controller.
3) Place a sign indicating the robot is being inspected, to keep others from oper-
ating the controller switch.
4) Enter the safeguard enclosure.
5) Use the same procedure explained in steps 5) and later, in section 6-2. Insert
the wave generator onto the motor shaft so it makes tight contact with the
motor holder as shown in Fig. 5-66, then apply small amounts of "Screw
Lock" (thread sealant) to the two M3 set screws and tighten them to secure
the wave generator.

Motor holder

R-axis motor

Mark

Harmonic drive housing

Mark

Spline

Fig. 5-65 Harmonic drive grease replacement section and position markings
5-75
CHAPTER 5 Periodic Inspection

3.5mm (when fully inserted)

M4 set screw M6 hole

Motor

Wave generator

Motor holder

Fig. 5-66 Wave generator installation position

5-76
CHAPTER 5 Periodic Inspection

7 Replacing the Grease for RV Speed Reduc-


tion Gears (YK1200X)
The YK1200X uses RV speed reduction gears for the X and Y axes. If grease for
RV speed reduction gears deteriorates, this may shorten the service life of RV
speed reduction gears. Replace the grease periodically as explained below.

7-1 Replacement period


The grease replacement period is typically 20,000 hours of operation. However,
if the robot operation duty ratio is higher or the robot is operated in environments
at higher or lower temperatures, the grease should be replaced earlier.

7-2 Recommended grease


Use the following grease.
Daphne Eponex grease EP-0 (Idemitsu Kosan) or equivalent
Replenishment grease amount (for new RV speed reduction gears)
X-axis speed reduction gear 514 cc
Y-axis speed reduction gear 192 cc

! 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

7-3 Replacement procedure

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

7-3-1 Replacing the X-axis grease


1) Prepare the following tools and items.
• Daphne Eponex grease EP-0 • Hex wrench set
• Air tube coupler (PT1/8) • Air tube
• Rag • Grease gun

2) Turn off the controller.

3) Place a sign indicating that the robot is being inspected, to keep others from
operating the controller switch.

4) Enter the safeguard enclosure.

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.

11) Go outside the safeguard enclosure.

12) Check that no one is inside the safeguard enclosure, and then turn on the
controller.
plug Air tube coupler

Grease nipple

Base front cover


X-axis arm top cover Base

Fig. 5-67 Fig. 5-68

5-79
CHAPTER 5 Periodic Inspection

7-3-2 Replacing the Y-axis grease


1) Prepare the following tools and items.
• Daphne Eponex grease EP-0 • Hex wrench set
• Air tube coupler (PT1/8) • Air tube
• Rag • Grease gun

2) Turn off the controller.

3) Place a sign indicating that the robot is being inspected, to keep others from
operating the controller switch.

4) Enter the safeguard enclosure.

5) Remove the X-axis arm under cover.


Refer to "7 Removing the Robot Covers" in Chapter 4 for removing the covers.

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.

11) Go outside the safeguard enclosure.

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 under cover

X-axis arm

Fig. 5-69 Fig. 5-70

5-80
CHAPTER 6

Increasing the robot


operating speed
1 Increasing the robot operating speed .....................................6-1
MEMO
CHAPTER 6 Increasing the robot operating speed

1 Increasing the robot operating speed


The robot operating speed can be increased by the following methods.
Use these methods as needed when programming.

(1) Increasing speed by arch motion


[Also refer to:] Robot controller owner's manual
("Axis parameters" – "Arch position" in Chapter 4)
Programming manual
(ARCH statement in "11. Command statements".)

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

w Arch motion: Using default arch position: (2000 pulses)


From point P1 to P2:
MOVE P, P2, Z=0 M1, M2, M4
Z=0
"Axis parameters" – "Arch position"
M1 (X-axis arch position) = 2000 pulses M3
M2 (Y-axis arch position) = 2000 pulses
M3 (Z-axis arch position) = 2000 pulses P1 P2
M4 (R-axis arch position) = 2000 pulses

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

e Arch motion: Making the arch position value larger


In the arch motion w, making the arch position value larger can further shorten
the cycle time. Since the robot arm moves along a larger arc, use caution to avoid
obstacles if they are located near the arm movement path.
The arch position parameter can be set for each axis.

r Arch motion: changing the arch positions in the program


From point P1 to P2 and then to P3:
ARCH (1) = 10000 ... X-axis arch position (pulses) Arch position can be set for each axis.
ARCH (2) = 20000 ... Y-axis arch position (pulses)
ARCH (3) = 20000 ... Z-axis arch position (pulses)
ARCH (4) = 20000 ... R-axis arch position (pulses)
MOVE P, P2, Z=0
ARCH (1) = 2000 If the same arch position value
ARCH (2) = 2000 (pulses) is used for all axes, you
can write as "ARCH 2000".
ARCH (3) = 2000
ARCH (4) = 2000
MOVE P, P3, Z=100
Since the arch positions can be changed in the program, optimizing the arch po-
sitions can further shorten the cycle time.
Arch position: large
Z=0

Arch position: small


Z=100

P1 P2 P3

6-2
CHAPTER 6 Increasing the robot operating speed

(2) Increasing the speed with the WEIGHT statement


[Also refer to:] Robot controller owner's manual
("Robot parameters" – "Axis tip weight" in Chapter 4)
Programming manual
(WEIGHT statement in "11. Command statements".)

[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

(3) Increasing the speed by the tolerance parameter


[Also refer to:] Robot controller owner's manual
("Axis parameters" – "Tolerance" in Chapter 4)
Programming manual
(TOLE statement in "11. Command statements".)
P2

[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

(4) Increasing the speed by the OUT effective position parameter


[Also refer to:] Robot controller owner's manual
("Axis parameters" – "Out effective Position" in Chapter 4)
Programming manual
(OUTPOS statement in "11. Command statements".)

[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

Chuck starts closing.

OUT effective position

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

1-1 Basic specification

Robot model YK250X YK350X YK400X


Arm length 125mm 225mm 225mm
X-axis
Rotation angle ±115° ±115° ±115°
Axis
Arm length 125mm 125mm 175mm
specifi- Y-axis
Rotation angle ±140° ±140° ±140°
cations
Z-axis Stroke 150mm 150mm 150mm
R-axis Rotation angle ±180° ±180° ±180°
X-axis 200W 200W 200W
Y-axis 100W 100W 100W
Motor
Z-axis 100W 100W 100W
R-axis 100W 100W 100W
XY resultant 4.0m/s 5.0m/s 6.0m/s
Maximum speed Z-axis 1.0m/s 1.0m/s 1.0m/s
R-axis 1020°/s 1020°/s 1020°/s
XY-axes ±0.01mm ±0.01mm ±0.01mm
Repeatability *1 Z-axis ±0.01mm ±0.01mm ±0.01mm
R-axis ±0.005° ±0.005° ±0.005°
Payload 3kg
R-axis tolerable moment of inertia *2 0.05kgm2 (0.5kgfcms2)
User wiring 10cables
User tubing φ4×3
Travel limit 1.Soft limit 2.Mechanical limit (XYZ-axes)
Robot cable 3.5m (option: 5m, 10m)
Weight 15kg 15kg 15kg
*1 At constant ambient temperature (XY)
*2 There are limits to acceleration coefficient settings.

7-1
CHAPTER 7 Specifications

YK550X with high-speed


Robot model YK500X YK600X YK550X
R-axis specifications
Arm length 250mm 350mm 300mm
X-axis
Rotation angle ±120° ±120° ±90°
Axis
Arm length 250mm 250mm 250mm
specifi- Y-axis
Rotation angle ±145° ±145° ±145°
cations
Z-axis Stroke 200,300mm 200,300mm 200mm
R-axis Rotation angle ±180° ±180° ±180°
X-axis 400W 400W 800W
Y-axis 200W 200W 200W
Motor
Z-axis 200W 200W 200W
R-axis 100W 100W 100W
XY resultant 4.9m/s 5.6m/s 6.7m/s
Maximum speed Z-axis 1.7m/s 1.7m/s 2.3m/s
R-axis 876°/s 876°/s 540°/s 1700°/s
XY-axes ±0.02mm ±0.02mm ±0.02mm
Repeatability *1 Z-axis ±0.01mm ±0.01mm ±0.01mm
R-axis ±0.005° ±0.005° ±0.005°
Payload 10kg 5kg
R-axis tolerable moment of inertia *2 0.12kgm2 (1.2kgfcms2) 0.1kgm2 (1.0kgfcms2) 0.05kgm2 (0.5kgfcms2)
User wiring 20cables 20cables
User tubing φ6×3 φ6×2
Travel limit 1.Soft limit 2.Mechanical limit (XYZ-axes)
Robot cable 3.5m (option: 5m, 10m)
Weight 28kg 28kg 46kg
*1 At constant ambient temperature (XY)
*2 There are limits to acceleration coefficient settings.

7-2
CHAPTER 7 Specifications

Robot Model YK700X YK800X YK1000X YK1200X


Arm length 350mm 450mm 550mm 6000mm
X-axis
Rotation angle ±120° ±120° ±120° ±125°
Axis Arm length 350mm 350mm 450mm 600mm
Y-axis
specifi- Rotation angle ±145° ±145° ±145° ±150°
cations Z-axis Stroke 200,400mm 200,400mm 200,400mm 400mm
R-axis Rotation angle ±180° ±180° ±180° ±180°
X-axis 800W 800W 800W 900W
Y-axis 400W 400W 400W 800W
Motor
Z-axis 400W 400W 400W 600W
R-axis 200W 200W 200W 400W
XY resultant 6.7m/s 7.3m/s 8.0m/s 7.4m/s
Maximum speed Z-axis 1.7m/s 1.7m/s 1.7m/s 0.75m/s
R-axis 600°/s 600°/s 600°/s 600°/s
Repeatability *1 X,Y-axes ±0.02mm ±0.02mm ±0.02mm ±0.05mm
Z-axis ±0.01mm ±0.01mm ±0.01mm ±0.02mm
R-axis ±0.005° ±0.005° ±0.005° ±0.005°
Payload 20kg 50kg
R-axis tolerable moment of inertia *2 0.32kgm (3.2kgfcms )
2 2
2.45kgm2(25kgfcms2)
User wiring 20cables
User tubing φ6×3
Travel limit 1.Soft limit 2.Mechanical limit (XYZ-axes)
Robot cable 3.5m,option:5m,10m
Weight 56kg 57kg 58kg 124kg

*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

1-2 External view and dimensions

37 112.2 125 165


45 120
D-sub connector for user wiring

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

User tubing 2 (φ4 red)

User tubing 3 (φ4 blue)


644

576

454

251 250

Z-axis upper end φ5


mechanical stopper 203.5
position
41
5

36

152±2
0
12 -0.018
M8×1.25 Depth15

86
150

45

Z-axis lower end


0 0
mechanical stopper
position
7

Fig. 7-1 YK250X


7-4
CHAPTER 7 Specifications

Interference position
(a) Base flange

1 40

(b) Base rear side

14

11
°


11
0
R25

R86 R125

90°
90°
Manipulator interference area 120

Working envelope

13
145


145
13

R250

5
R7

63°
63°
Manipulator interference area 120

X and Y-axis mechanical stopper positions (maximum working envelope)

D-sub connector for user wiring (No. 1 to 10 usable)

User tubing 1 (φ4 black)

User tubing 2 (φ4 red)


User tubing 3 (φ4 blue)

M4 ground terminal

7-5
CHAPTER 7 Specifications

37 112.2 225 165


45 120
D-sub connector for user wiring

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

User tubing 2 (φ4 red)


User tubing 3 (φ4 blue)
644

576

454

251 250

Z-axis upper end φ5


mechanical stopper 203.5
position
41
5

36

152±2
0
12 -0.018
M8×1.25 Depth15

86
150

45

Z-axis lower end 0 0


mechanical stopper
position
7

Fig. 7-2 YK350X

7-6
CHAPTER 7 Specifications

Interference position
(a) Base flange
(b) Base rear side

11


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

X and Y-axis mechanical stopper positions (maximum working envelope)

D-sub connector for user wiring (No. 1 to 10 usable)


User tubing 1 (φ4 black)

User tubing 2 (φ4 red)


User tubing 3 (φ4 blue)

M4 ground terminal

7-7
CHAPTER 7 Specifications

37 166.1 225 165


45 120
D-sub connector for user wiring

0
(No. 1 to 10 usable)

R5
175
55

100
120
140
74

4-φ9
135 15 Use M8 bolt for installation

User tubing 1 (φ4 black) 165

User tubing 2 (φ4 red)


User tubing 3 (φ4 blue)
644

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

Z-axis lower end


mechanical stopper position

Fig. 7-3 YK400X

7-8
CHAPTER 7 Specifications

Interference position
(a) Base flange
(b) Base rear side

11


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

X and Y-axis mechanical stopper positions (maximum working envelope)

User tubing 1 (φ4 black) D-sub connector for user wiring (No. 1 to 10 usable)

User tubing 2 (φ4 red)


User tubing 3 (φ4 blue)

M4 ground terminal

7-9
CHAPTER 7 Specifications

47 250 250 122.5

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

Z-axis 300mm stroke 876

790

Z-axis 200mm stroke 741

667

2×2-M4×0.7 561
Depth10
(Same on opposite side)
36

363 364

Z-axis upper end 54 20


mechanical stopper φ7 318
position
282
8
48

41

237±2
0
φ18 -0.018

M12×1.75 Depth20
200
300

91
Z-axis stroke 200mm
Working envelope
15
0 0
12

Z-axis stroke 300mm


Working envelope
Z-axis lower end
mechanical stopper position
12

Fig. 7-4 YK500X

7-10
CHAPTER 7 Specifications

Interference position
(a) Base flange
(b) Base rear side
(c) Base

12


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


R1

1( 00
12

c) a)
42

4(
R5

R4
100

50
R2
R9
5

147°
147°
Manipulator interference area

X and Y-axis mechanical stopper positions (maximum working envelope)

M4 ground terminal

User tubing 1 (φ6 black)


User tubing 2 (φ6 red)
User tubing 3 (φ6 blue)
D-sub connector for user wiring
(No. 1 to 20 usable)

73
55 53
35

0 0
2

7-11
CHAPTER 7 Specifications

47 250 350 122.5

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

Z-axis 200mm stroke 741

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

Z-axis stroke 300mm


Working envelope
Z-axis lower end
mechanical stopper
position
12

Fig. 7-5 YK600X

7-12
CHAPTER 7 Specifications

Interference position
(a) Base flange
(b) Base rear side
(c) Base

12


12

00
a)

R1
6(

R2

R6
33
10

04
(c
R

)
50
R2

b)
8(
R7

145°
145°
Working envelope

12

R1


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

User tubing 1 (φ6 black)


User tubing 2 (φ6 red)
User tubing 3 (φ6 blue)
D-sub connector for user wiring
(No. 1 to 20 usable)

73
55 53
35

0 0
2

7-13
CHAPTER 7 Specifications

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)

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

Z-axis 400mm stroke 956

877

Z-axis 200mm stroke 756

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

Z-axis stroke 400mm


Working envelope
Z-axis lower end
mechanical stopper
position
12

Fig. 7-6 YK700X

7-14
CHAPTER 7 Specifications

Interference position
(a) Base flange
(b) Base rear side
(c) Base

12
R1

00
R2
25


12

R7
(c a)

10
) 5(
R9

5 0
R3
b)
0(
R6

145°
145°

Working envelope

12
R1

00

14


R1
12

(c a)
R7
99

) 3(
R8
100

50
R3
R1
45

147° 147°
Manipulator interference area

X and Y-axis mechanical stopper positions (maximum working envelope)

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

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)

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

Z-axis 400mm stroke 956

877

Z-axis 200mm stroke 756

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

Z-axis stroke 400mm


Working envelope
Z-axis lower end
mechanical stopper
position
12

Fig. 7-7 YK800X

7-16
CHAPTER 7 Specifications

Interference position
(a) Base flange
(b) Base rear side
(c) Base

12
0


0
)

R8
(a

17
12

R2
43

4(
R1

59
c)
50
R3

b)
0 8(
R1

145°
Working envelope 145°

12
00


R8
12

R1 R2 )
47 (a
62 31
(c) R1

50
R3

b)
6(
R9

147°
147°

X and Y-axis mechanical stopper positions (maximum working envelope)

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

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)

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

Z-axis 400mm 956


stroke

877

Z-axis 200mm 756


stroke

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

Z-axis lower end


mechanical stopper
position
12

Fig. 7-8 YK1000X

7-18
CHAPTER 7 Specifications

Interference position
(a) Base flange
(b) Base rear side
(c) Base

12
00

a)


R1
12
R2 R3 0(
30 15 20
( R
c)

50
R4

)
(b
65
R1

145° 145°
Working envelope

12
0

00


12

R3 )
R1

00 (a
R2 84
15
(c) R1
50
R4

(b)
49
R1

147°
147°

X and Y-axis mechanical stopper positions (maximum working envelope)

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

70 600 600 210


D-sub connector for user wiring

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

Fig. 7-9 YK1200X

7-20
CHAPTER 7 Specifications

Interference position
(a) Base flange
(b) Base rear side
(c) Base

R1

12


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 °

X and Y-axis mechanical stopper positions (maximum working envelope)

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

41 240 300 201


159
Fan inlet

01
R1
R57
250

140
70
70
82

User tubing 1 (φ6 black) 4-φ12


Fan outlet Use M10 bolt for installation
User tubing 2 (φ6 blue) 140

D-sub connector for user wiring (No. 1 to 20 usable)

(When Y-axis maximum working envelope is set to 940mm.)


909

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

326±2 Use caution to avoid interference of load


with robot cable, user wiring or tubing
User tubing 2 (φ6 blue)
200

User tubing 1 (φ6 black)


Fan position
172
Z-axis lower end
mechanical stopper 104
position Area to mechanical stopper
5

(cannot be used) D-sub connector for user wiring


44
16 (No. 1 to 20 usable)
0 0
M4 ground terminal

Fig. 7-10 YK550X

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

Details of manipulator tip

7-23
CHAPTER 7 Specifications

1-3 Robot inner wiring diagram


Machine harness

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 origin sensor

X-axis motor
IO

User tubing
X-axis resolver

R-axis origin sensor Y-axis origin sensor XP XP


XM XM User IO connector
YM YM
YP YP
XORG

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

Fig. 7-11 YK250X, YK350X, YK400X

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 origin sensor

R-axis origin sensor Y-axis arm


IO
Y-axis origin sensor
X-axis arm
X-axis motor XORG

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

Fig. 7-12 YK500X, YK600X, YK700X, YK800X, YK1000X, YK1200X

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

Y-axis origin sensor


R-axis origin sensor

M4 ground terminal

X-axis origin sensor


XORG

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)

Fig. 7-13 YK550X

7-26
CHAPTER 7 Specifications

1-4 Wiring table


Robot cable wiring table
Signal Connector No Connection No Connector Color Wire
Resolver S2 1 1 Blue 0.15sq
S4 2 2 Orange Twisted pair
S1 3 3 Green 0.15sq
XP
S3 4 4 Brown Twisted pair
R1 5 5 Gray 0.15sq
R2 6 6 Red Twisted pair
DG 7 7 Green 0.3sq
Resolver S2 1 19 Black 0.15sq
S4 YP 2 20 Yellow Twisted pair
S1 3 21 Pink 0.15sq
XY
S3 4 22 Purple Twisted pair
R1 5 23 White 0.15sq
R2 6 24 Blue/Red Twisted pair
DG 7 25 Green 0.3sq
FG FG 1 18 Orange/White 0.15sq
36 Green/White 0.15sq

HLIM 10 Green 0.3sq


GND24 11
HLIM 28 Green 0.3sq
GND24 29
Origin Sensor GND 3 13 Yellow/Black 0.15sq
ORG XORG 2 12 Pink/Black Twisted pair
24V 1 9 Purple/White 0.15sq
Origin Sensor 24V 1 27 White/Blue Twisted pair
ORG YORG 2 30 Blue/Red2 0.15sq
GND 3 31 Orange/White2 Twisted pair
U 1 2 Black 0.75sq
XM XM
V 2 3 Red 0.75sq
W 3 4 White 0.75sq
FG Round terminal 1 Yellow/Green 0.75sq
U 1 2 Yellow 0.75sq
YM YM
V 2 3 Brown 0.75sq
W 3 4 Blue 0.75sq

7-27
CHAPTER 7 Specifications

Signal Connector No Connection No Connector Color Wire


Resolver S2 1 1 Blue 0.15sq
S4 2 2 Orange Twisted pair
S1 3 3 Green 0.15sq
ZP
S3 4 4 Brown Twisted pair
R1 5 5 Gray 0.15sq
R2 6 6 Red Twisted pair
DG 7 7 Green 0.3sq
Brake MB+ 1 14 Black 0.15sq
ZBK
MB- 2 16 Yellow Twisted pair
15 Pink 0.15sq
ZR
17 Purple Twisted pair
Resolver S2 1 19 White 0.15sq
S4 RP 2 20 Blue/Red Twisted pair
S1 3 21 Orange/White 0.15sq
S3 4 22 Green/White Twisted pair
R1 5 23 Brown/White 0.15sq
R2 6 24 Gray/White Twisted pair
DG 7 25 Green 0.3sq
FG FG 1 18 Red/White 0.15sq
36 Black/White 0.15sq

HLIM 10 Green 0.3sq


GND24 11
HLIM 28 Green 0.3sq
GND24 29
Origin Sensor 24V 1 27 White/Blue 0.15sq
ORG RORG 2 30 Blue/Red2 0.15sq
GND 3 31 Orange/White2 Twisted pair
U 1 2 Black 0.75sq
ZM ZM
V 2 3 Red 0.75sq
W 3 4 White 0.75sq
FG Round terminal 1 Yellow/Green 0.75sq
U 1 2 Yellow 0.75sq
RM RM
V 2 3 Brown 0.75sq
W 3 4 Blue 0.75sq

7-28
CHAPTER 7 Specifications

Machine harness wiring table


(YK250X, YK350X, YK400X)
Y-axis arm side Base side
Signal Connector No Connection No Connector Color Wire
Y-axis Resolver S2 1 1 Brown 0.2mm2
S4 2 2 White Twisted pair
S1 3 3 Red 0.2mm2
S3 YP 4 4 YP White Twisted pair
R1 5 5 Orange 0.2mm2
R2 6 6 White Twisted pair
DG 7 7 Green Shield
Z-axis Resolver S2 1 1 Brown 0.2mm2
S4 2 2 Black Twisted pair
S1 3 3 Red 0.2mm2
S3 ZP 4 4 ZP Black Twisted pair
R1 5 5 Orange 0.2mm2
R2 6 6 Black Twisted pair
DG 7 7 Green Shield
R-axis Resolver S2 1 1 Brown 0.2mm2
S4 2 2 Gray Twisted pair
S1 3 3 Red 0.2mm2
S3 RP 4 4 RP Gray Twisted pair
R1 5 5 Orange 0.2mm2
R2 6 6 Gray Twisted pair
DG 7 7 Green Shield
Y-axis motor U 1 1 Brown
V YM 2 2 YM Red 0.75mm2
W 3 3 Orange
Z-axis motor U 1 1 Blue
V ZM 2 2 ZM Purple 0.75mm2
W 3 3 Gray
R-axis motor U 1 1 Black
V RM 2 2 RM White 0.75mm2
W 3 3 Red
Z-axis brake 1 1 1 Purple
ZBK ZBK 0.3mm2
Z-axis brake 2 2 2 Gray

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

Machine harness wiring table


(YK500X, YK600X, YK700X, YK800X, YK1000X, YK1200X)
Y-axis arm side Base side
Signal Connector No Connection No Connector Color Wire
Y-axis Resolver S2 1 1 Brown 0.2mm2
S4 2 2 White Twisted pair
S1 3 3 Red 0.2mm2
S3 YP 4 4 YP White Twisted pair
R1 5 5 Orange 0.2mm2
R2 6 6 White Twisted pair
DG 7 7 Green Shield
Z-axis Resolver S2 1 1 Brown 0.2mm2
S4 2 2 Black Twisted pair
S1 3 3 Red 0.2mm2
S3 ZP 4 4 ZP Black Twisted pair
R1 5 5 Orange 0.2mm2
R2 6 6 Black Twisted pair
DG 7 7 Green Shield
R-axis Resolver S2 1 1 Brown 0.2mm2
S4 2 2 Gray Twisted pair
S1 3 3 Red 0.2mm2
S3 RP 4 4 RP Gray Twisted pair
R1 5 5 Orange 0.2mm2
R2 6 6 Gray Twisted pair
DG 7 7 Green Shield
Y-axis motor U 1 1 Brown
V YM 2 2 YM Red 0.75mm2
W 3 3 Orange
Z-axis motor U 1 1 Blue
V ZM 2 2 ZM Purple 0.75mm2
W 3 3 Gray
R-axis motor U 1 1 Black
V RM 2 2 RM White 0.75mm2
W 3 3 Brown
Z-axis brake 1 1 1 White
ZBK ZBK 0.3mm2
Z-axis brake 2 2 2 Black

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

4-axis machine harness wiring table


(YK550X)
Y-axis arm side Base side Y-axis arm side Base side
Signal Connector No Connection No Connector Color Signal Connector No Connection No Connector Color
Y-axis Resolver S2 1 1 Brown +24V 1 1 Brown
S4 2 2 White Y-axis origin ORG YORG 2 2 YORG Red
S1 3 3 Red 0V 3 3 Orange
S3 YP 4 4 YP White +24V 1 1 White
R1 5 5 Orange R-axis origin ORG RORG 2 2 RORG Black
R2 6 6 White 0V 3 3 Brown
DG 7 7 Green Z-axis Brake 1 1 1 Red
ZBK ZBK
Z-axis Resolver S2 1 1 Brown Z-axis Brake 2 2 2 Orange
S4 2 2 Black Frame ground 1 FG Green
S1 3 3 Red 1 1 Brown
S3 ZP 4 4 ZP Black 2 2 Red
R1 5 5 Orange 3 3 Orange
R2 6 6 Black 4 4 Blue
DG 7 7 Green 5 5 Purple
R-axis Resolver S2 1 1 Brown 6 6 Gray
S4 2 2 Gray 7 7 White
S1 3 3 Red 8 8 Black
S3 RP 4 4 RP Gray 9 9 Brown
R1 5 5 Orange 10 10 Red
R2 6 6 Gray User signal line IO 11 11 IO Orange
DG 7 7 Green 12 12 Blue
Y-axis motor U 1 1 Brown 13 13 Purple
V YM 2 2 YM Red 14 14 Gray
W 3 3 Orange 15 15 White
Z-axis motor U 1 1 Blue 16 16 Black
V ZM 2 2 ZM Purple 17 17 Brown
W 3 3 Gray 18 18 Red
R-axis motor U 1 1 White 19 19 Orange
V RM 2 2 RM Black 20 20 Blue
W 3 3 Brown Shield 25 25 Green
Frame ground FG 1 Round terminal Green Frame ground 1 FG Green
Protective ground Round terminal Round terminal Yellow Green

7-31
CHAPTER 7 Specifications

Motor wiring table


Signal Color Connection No. Connector

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

PE Yellow Green 1 Round terminal

BK Yellow 1
Brake ZBK (Z-axis motor only)
BK Yellow 2

Origin sensor wiring table


Signal Color Connection No. Connector
+24V Brown 1
ORG Black 2 XORG, YORG, RORG
0V Blue 3

Fan wiring table


Signal Connection No Connector Color
+24V 1 Red
FAN stop signal 2 FAN Yellow
0V 3 Black

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.

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