Ykx Series

YAMAHA SCARA ROBOT
User’s Manual ENGLISH

E
E35-Ver. 1.08
Before using the robot
(Be sure to read the following notes.)
At this time, our thanks for your purchase of this YAMAHA YK-XG series SCARA
robot.
1. 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 of the YK-XG series robots is adjusted to the robot arm ex-
tended position at the factory prior to shipment, so the reference or standard coor-
dinates are temporarily set. 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-XG series robots only require the absolute reset to be performed once
when the robot is introduced. Once the absolute reset is performed, you do not
need to reperform it when the power is turned on next time. Set the origin
position while referring to absolute reset methods in "3. Adjusting the origin"
in Chapter 4 of this manual and in "Absolute Reset" of the "YAMAHA Robot
Controller User's Manual". Setting of standard coordinates is not required in
the above case. To set the standard coordinates with high accuracy, refer to "5.
Setting the Standard Coordinates" in Chapter 4 of this manual and "Setting the
Standard Coordinates" in the "YAMAHA Robot Controller User's Manual". If
the standard coordinate settings are incorrect, robot malfunctions (vibration,
excessive noise) may occur.
! CAUTION
Never enter the robot movement range once the robot servo is turned on as
this is extremely hazardous.
[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-XG series robots only require the absolute reset to be performed once
when the robot is introduced. Once the absolute reset is performed, you do not
need to reperform it when the power is turned on next time. Set the origin
position while referring to absolute reset methods in "3. Adjusting the origin"
in Chapter 4 of this manual and in "Absolute Reset" of the "YAMAHA Robot
Controller User's Manual". Set the origin position with the absolute reset.
! CAUTION
Never enter the robot movement range once the robot servo is turned on as
this is extremely hazardous.
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 User'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 (RCX142)
17.81 : D?.ABS.battery wire breakage
17.83 : D?.Backup position data error 1
17.85 : D?.Backup position data error 2
17.92 : D?.Resolver disconnected during power off
17.93 : D?.Position backup counter overflow
etc.
2. If the X, Y or R axis rotation angle is small.

If the X, Y or R axis rotation angle is smaller than 5° so that it always moves in
the same position, an oil film is difficult to be formed on the joint support bear-
ing, possibly leading to damage to the bearing. In this type of operation, add a
movement so that the joint moves through 90° or more, about 5 times a day.
3. Do not remove the Z-axis upper-end mechanical stopper

Removing or moving the upper-end mechanical stopper attached to the Z-axis
spline can damage the Z-axis ball screw. Never remove or move it.
Introduction
The YAMAHA YK-XG series robots are SCARA type industrial robots devel-
oped based on years of YAMAHA experience and achievements in the automa-
tion field as well as efforts to streamline our in-house manufacturing systems.
The YK-XG 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-XG series robots can
be used for a wide range of assembly applications such as installation and inser-
tion of various parts, application of sealant, and packing operations.
This instruction manual describes the safety measures, handling, adjustment and
maintenance of YK-XG 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 the YK500XG, YK600XG, YK600XGH, YK700XG,

YK800XG, YK900XG, and YK1000XG. For details on specific operation and
programming of the robot, refer to the separate "YAMAHA Robot Controller
User'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 ................................................................................................1-16
CHAPTER 2 Functions
1 Robot Manipulator ........................................................................................2-1
2 Robot Controller ...........................................................................................2-3
3 Robot initialization number list .....................................................................2-4
CHAPTER 3 Installation
1 Robot Installation Conditions .......................................................................3-1
1-1 Installation environments ........................................................................................... 3-1
1-2 Installation base ........................................................................................................ 3-2
2 Installation ....................................................................................................3-4
2-1 Unpacking ................................................................................................................. 3-4
2-2 Checking the product ................................................................................................ 3-5
2-3 Moving the robot ........................................................................................................ 3-6
2-3-1 Moving the YK500XG, YK600XG, YK600XGH, YK700XG, YK800XG, YK900XG,
YK1000XG ................................................................................................................... 3-6
2-4 Installing the robot ..................................................................................................... 3-8
3 Protective Bonding .......................................................................................3-9

4 Robot Cable Connection ............................................................................ 3-11
5 User Wiring and User Tubing .....................................................................3-12
6 Attaching The End Effector ........................................................................3-16
6-1 R-axis tolerable moment of inertia and acceleration coefficient .............................. 3-16
6-1-1 Acceleration coefficient vs. moment of inertia (YK500XG) ........................................ 3-17
6-1-2 Acceleration coefficient vs. moment of inertia (YK600XG) ........................................ 3-17
6-1-3 Acceleration coefficient vs. moment of inertia (YK600XGH) ..................................... 3-18
6-1-4 Acceleration coefficient vs. moment of inertia (YK700XG, YK800XG) ...................... 3-18
6-1-5 Acceleration coefficient vs. moment of inertia (YK900XG, YK1000XG) .................... 3-19
6-2 Equation for moment of inertia calculation .............................................................. 3-20
6-3 Example of moment of inertia calculation ................................................................ 3-23
6-4 Attaching the end effector ....................................................................................... 3-25
6-5 Gripping force of end effector .................................................................................. 3-29
7 Limiting the Movement Range with X-Axis Mechanical Stoppers ..............3-30

7-1 YK500XG, YK600XG, YK600XGH, YK700XG, YK800XG, YK900XG, YK1000XG ... 3-31
8 Working Envelope and Mechanical Stopper Positions for Maximum Working

Envelope ....................................................................................................3-33
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 Stroke end method (Z-axis) ......................................................................................... 4-3
3-2 Machine reference ..................................................................................................... 4-4
3-3 Absolute reset procedures ........................................................................................ 4-5
3-3-1 Sensor method (X-axis, Y-axis, and R-axis) ................................................................ 4-5
3-3-2 Stroke end method (Z-axis) ......................................................................................... 4-7
3-4 Changing the origin position and adjusting the machine reference ........................... 4-8
3-4-1 Sensor method ............................................................................................................ 4-9
3-4-1-1 YK500XG, YK600XG, YK600XGH, YK700XG, YK800XG, YK900XG, YK1000XG ..... 4-9
3-4-2 Stroke end method .................................................................................................... 4-27
3-4-2-1 YK500XG, YK600XG, YK600XGH, YK700XG, YK800XG, YK900XG, YK1000XG ... 4-27
4 Setting the Soft Limits ................................................................................4-31

5 Setting the Standard Coordinates ..............................................................4-34
5-1 Standard coordinate setting using a standard coordinate setup jig (option) ........... 4-35
6 Affixing the Stickers for Movement Directions and Axis Names ................ 4-38
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 .....................................................................5-9
5-1 Replacement period .................................................................................................. 5-9
5-2 Basic replacement procedure for harmonic drive and precautions ......................... 5-10
5-2-1 YK500XG, YK600XG, YK600XGH, YK700XG, YK800XG, YK900XG, YK1000XG ... 5-12
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 Robot inner wiring diagram ....................................................................................... 7-2
1-3 Wiring table ............................................................................................................... 7-3
MEMO
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 ....................................................................................................1-16
MEMO
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
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 for the loca-
tions 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.
DANGER
Serious injury or death
will result from impact
with moving robot.
• Keep outside of guard
during operation.
• Lock out power before
approaching robot.
■Fig. 1-1 Warning label 1

(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 for the loca-
tions 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 hands. Keep hands away from robot arms.
1-2
WARNING
Moving parts can
pinch or crush.
Keep hands away
from robot arms.
(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 for the loca-
tions of warning labels.
• Be sure to read the warning label and this manual carefully and make you
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 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 user's manual and all warning labels before installation or operation.
WARNING
Improper Installation or operation
can result in serious injury or
death. Read user's(owner's)
manual and all warning labels
before operation.

(4) Do not remove the Z-axis upper-end mechanical stopper
Removing or moving the upper-end mechanical stopper attached to the Z-
axis spline can damage the Z-axis ball screw. Never remove or move it.
! CAUTION
Do not remove this part. Damage to the ball screw will result.
1-3
(5) 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.
(6) 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.
(7) 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.
(8) 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.
1-4
(9) 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.
(10) 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.
(11) 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.
(12) 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.
1-5
(13) 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.
(14) 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 Con-
troller User's Manual".
(15) 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.
If the following damages or troubles exist These dangers can happen

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
(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 controller, wait for a while and
check that the temperature has cooled.
1-6
(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 safeguard enclosure.
(18) Protective bonding
WARNING
Be sure to ground the robot and controller to prevent electrical shock.
(19) 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.
(20) Do not use the robot for tasks requiring motor thrust.
! CAUTION
Avoid using the YK-XG series robots for tasks which make use of motor thrust
(press-fitting, burr removal, etc.). These tasks may cause malfunctions of the
robot.
(21) If the X, Y or R axis rotation angle is small
! CAUTION
If the X, Y or R axis rotation angle is smaller than 5° so that it always moves in
the same position, an oil film is difficult to be formed on the joint support bear-
ing, possibly leading to damage to the bearing. In this type of operation, add a
movement so that the joint moves through 90° or more, about 5 times a day.
1-7
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-XG 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
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 range is the area lim-
ited by mechanical stoppers.
• The movement ranges of the X-axis arm can be limited as needed by use of
mechanical stoppers.
• 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.
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
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
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
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) Teaching
For items 1) to 3), follow the precautions and procedure for each section. To
perform item 4), 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
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
11 Warranty
The YAMAHA robot and/or related product you have purchased are warranted
against the defects or malfunctions as described below.
Warranty description : If a failure or breakdown occurs due to defects

in materials or workmanship in the genuine
parts constituting this YAMAHA robot and/or
related product within the warranty period, then
YAMAHA will repair or replace those parts free
of charge (hereafter called "warranty repair").
Warranty Period : The warranty period ends when any of the fol-
lowing applies:
(1) After 18 months (one and a half year) have
elapsed from the date of shipment
(2) After one year has elapsed from the date of
installation
(3) After 2,400 hours of operation
Exceptions to the Warranty : This warranty will not apply in the following
cases:
(1) Fatigue arising due to the passage of time,
natural wear and tear occurring during op-
eration (natural fading of painted or plated
surfaces, deterioration of parts subject to
wear, etc.)
(2) Minor natural phenomena that do not affect
the capabilities of the robot and/or related
product (noise from computers, motors,
etc.).
(3) Programs, point data and other internal data
that were changed or created by the user.
Failures resulting from the following causes are not covered by warranty repair.
1) Damage due to earthquakes, storms, floods, thunderbolt, fire or any other

natural or man-made disasters.
2) Troubles caused by procedures prohibited in this manual.
3) Modifications to the robot and/or related product not approved by
YAMAHA or YAMAHA sales representatives.
4) Use of any other than genuine parts and specified grease and lubricants.
5) Incorrect or inadequate maintenance and inspection.
6) Repairs by other than authorized dealers.
1-14
YAMAHA MOTOR CO., LTD. MAKES NO OTHER EXPRESS OR IMPLIED

WARRANTIES, INCLUDING ANY IMPLIED WARRANTY OF
MERCHANTABILITY OR FITNESS FOR ANY PARTICULAR PURPOSE.
THE WARRANTY SET FORTH ABOVE IS EXCLUSIVE AND IS IN LIEU
OF ALL EXPRESSED OR IMPLIED WARRANTIES, INCLUDING WARRAN-
TIES OF MERCHANTABILITY, FITNESS FOR A PARTICULAR PURPOSE,
OR WARRANTIES ARISING FROM A COURSE OF DEALING OR USAGE
OF TRADE.
YAMAHA MOTOR CO., LTD. SOLE LIABILITY SHALL BE FOR THE DE-
LIVERY OF THE EQUIPMENT AND YAMAHA MOTOR CO., LTD. SHALL
NOT BE LIABLE FOR ANY CONSEQUENTIAL DAMAGES (WHETHER
ARISING FROM CONTRACT, WARRANTY, NEGLIGENCE OR STRICT
LIABILITY). YAMAHA MOTOR CO., LTD. MAKES NO WARRANTY WHAT-
SOEVER WITH REGARD TO ACCESSORIES OR PARTS NOT SUPPLIED
BY YAMAHA MOTOR CO., LTD.
1-15
12 CE Marking
When the YAMAHA robots are exported to or used in EU (European Union)
countries, refer to the separate "YAMAHA Robot Controller User's Manual" or
"CE marking manual" for related information about CE marking.
1-16
CHAPTER 2
Functions
1 Robot Manipulator ............................................................................................2-1

2 Robot Controller ...............................................................................................2-3
3 Robot initialization number list .........................................................................2-4
MEMO
CHAPTER 2 Functions
1 Robot Manipulator
The YK-XG 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-XG 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 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
User tubing 1 (φ6 black)
Eyebolt installation position

User tubing 2 (φ6 red)
User tubing 3 (φ6 blue)

D-sub connector for user wiring (No.1 to 20)
Machine harness
Ball screw
Y-axis motor
R-axis motor Y-axis arm
Y-axis mechanical stopper X-axis speed reduction gear

X-axis arm
X-axis movable mechanical stopper
R-axis speed
Warning label 1
reduction gear
Warning label 2
on opposite side Serial label
Warning label 4 Z-axis motor
User tubing 1 (φ6 black)
Y-axis speed reduction gear User tubing 2 (φ6 red) D-sub connector for user wiring
Warning label 3 User tubing 3 (φ6 blue) (No.1 to 20)
Z-axis spline
X-axis motor
End effector attachment M4 ground terminal
Robot cable
Tapped hole and screw for user
Fig. 2-2 YK500XG, YK600XG, YK600XGH, YK700XG, YK800XG, YK900XG, YK1000XG
2-2
CHAPTER 2 Functions
2 Robot Controller
The YK-XG series robot comes supplied with a robot controller RCX142. For
more details, refer to the separate "YAMAHA Robot Controller User's Manual".
MOTOR
PWR MPB
OP.1 OP.3
RCX142
MODEL.
SRV SER. NO.
MANUFACTURED
XM ERR FACTORY AUTOMATION EQUIPMENT MADE IN JAPAN
ROB
I/O CAUTION
READ INSTRUCTION
MANUAL
XY
YM
COM BATT
ROB XY
I/O
ZR
ZR
OP.2 OP.4
RGEN
ZM
STD.DIO
P
SAFETY N
RM ACIN
200-230V~
50-60Hz
MAX.2500VA
RCX142
Fig. 2-3 Robot controller
2-3
CHAPTER 2 Functions
3 Robot initialization number list

The YK-XG series robots are initialized for optimum setting (default setting)
according 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
origin" in Chapter 4 and make sure you thoroughly understand the proce-
dure.
• When the controller is initialized, the "ARM LENGTH" and "OFFSET PULSE"
settings in the axis parameters will be erased, making the standard coordi-
nate 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 "OFF-
SET PULSE" settings before initializing, and re-enter their settings after ini-
tialization is complete.
Robot initialization number Model name

2117 YK500XG Z200
2118 YK500XG Z300
2119 YK600XG Z200
2120 YK600XG Z300
2121 YK600XGH Z200
2122 YK600XGH Z400
2123 YK700XG Z200
2124 YK700XG Z400
2125 YK800XG Z200
2126 YK800XG Z400
2127 YK900XG Z200
2128 YK900XG Z400
2129 YK1000XG Z200
2130 YK1000XG Z400
2-4
CHAPTER 3
Installation
1 Robot Installation Conditions ...........................................................................3-1

1-1 Installation environments ................................................................................................ 3-1
1-2 Installation base .............................................................................................................. 3-2
2 Installation ........................................................................................................3-4
2-1 Unpacking....................................................................................................................... 3-4
2-2 Checking the product ...................................................................................................... 3-5
2-3 Moving the robot ............................................................................................................. 3-6
2-3-1 Moving the YK500XG, YK600XG, YK600XGH, YK700XG, YK800XG, YK900XG,
YK1000XG ........................................................................................................................ 3-6
2-4 Installing the robot .......................................................................................................... 3-8
3 Protective Bonding ...........................................................................................3-9

4 Robot Cable Connection ................................................................................ 3-11
5 User Wiring and User Tubing .........................................................................3-12
6 Attaching The End Effector ............................................................................3-16
6-1 R-axis tolerable moment of inertia and acceleration coefficient ................................... 3-16
6-1-1 Acceleration coefficient vs. moment of inertia (YK500XG) .............................................. 3-17
6-1-2 Acceleration coefficient vs. moment of inertia (YK600XG) .............................................. 3-17
6-1-3 Acceleration coefficient vs. moment of inertia (YK600XGH) ........................................... 3-18
6-1-4 Acceleration coefficient vs. moment of inertia (YK700XG, YK800XG) ............................ 3-18
6-1-5 Acceleration coefficient vs. moment of inertia (YK900XG, YK1000XG) .......................... 3-19
6-2 Equation for moment of inertia calculation ................................................................... 3-20
6-3 Example of moment of inertia calculation ..................................................................... 3-23
6-4 Attaching the end effector ............................................................................................. 3-25
6-5 Gripping force of end effector ....................................................................................... 3-29
7 Limiting the Movement Range with X-Axis Mechanical Stoppers ..................3-30

7-1 YK500XG, YK600XG, YK600XGH, YK700XG, YK800XG, YK900XG, YK1000XG ..... 3-31
8 Working Envelope and Mechanical Stopper Positions for Maximum Working

Envelope ........................................................................................................3-33
MEMO
1 Robot Installation Conditions
1-1 Installation environments

Be sure to install the robot in the following environments.
Setting environments 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 or liquid.
Avoid installation near objects causing electromagnetic interference,
electrostatic discharge or 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 User'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.
• This robot was not designed for operation in environments where inflamma-
ble or explosive substances are present. Do not use the robot in environ-
ments containing inflammable gas, dust or liquids. Explosions or fire could
otherwise result.
• Avoid using the robot in locations subject to electromagnetic interference,
electrostatic discharge or radio frequency interference. Malfunction may oth-
erwise occur.
• Do not use the robot in locations subject to excessive vibration. Robot instal-
lation bolts may otherwise become loose causing the manipulator to fall over.
3-1
1-2 Installation base
WARNING
• Install the robot on a horizontal surface, with the base mount section facing
down. If installed by other methods with the base mount section not facing
down, grease might leak from the reduction gear unit.
• 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
damage to the robot.
! CAUTION
• The manipulator positioning might decrease if the installation surface preci-
sion is insufficient.
• 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.
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
YK500XG 1416 144 178 18 134 14
YK600XG 1476 150 178 18 134 14
YK600XGH 2125 217 395 40 205 21
YK700XG 2479 253 395 40 239 24
YK800XG 2561 261 395 40 239 24
YK900XG 2494 254 395 40 165 17
YK1000XG 2427 248 395 40 165 17
3-2
Fxmax
Load Fzmax
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. For machining dimensions
and positions, refer to the external view and dimensions shown in the catalog
or website (www.yamaha-motor.co.jp/global/industrial/robot).
4) Securely fix the installation base on the floor with anchor bolts.
3-3
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 folklift that require
a license, only properly qualified personnel may operate it. The equipment and
tools used for moving the robot should be serviced daily.
The YK-XG 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.
Robot manipulator
Robot controller and accessories
Arm clamping stay

(Used only for transportation.
Remove after installation.)
YK500XG, YK600XG, YK600XGH, YK700XG, YK800XG, YK900XG, YK1000XG

Fig. 3-2 Packed state
3-4
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 : RCX142
Robot : YK500XG, YK600XG, YK600XGH, YK700XG, YK800XG,
YK900XG, YK1000XG
Standard
Warning label ( × 1)
CD-ROM User's Manual

or
User's Manual
Standard coordinate setting jig
(option)
OP.1
OP.3 RCX1
42 Robot manipulator
YK-XG series
MODEL.
NO.
SER. IN JAPAN
TURED MADE
MANUFAC N EQUIPMENT
AUTOMATIO
FACTORY
ION
CAUT
MPB
MOTOR
PWR INSTRU
READ L
CTION
D-sub connector/hood ( × 2)
MANUA
SRV
ERR
XM ROB
I/O
T
XY BAT
XY
YM
COM
ZR
N
RGE
ROB
I/O OP.4
OP.2 P
ZR N
.DIO
STD
ACIN
ZM
SAF
ETY
L
N
A B Origin position stickers
X Y
-230V~
200 60Hz
RM
50- 500VA
X.2 Z R
Eyebolts
MA
( × 2)
RCX142controller
Option
OP, DIO connector
MPB programming unit Extension IO connector
Fig. 3-3 Product configurations
3-5
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 YK500XG, YK600XG, YK600XGH, YK700XG,

YK800XG, YK900XG, YK1000XG
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 YK500XG) correctly and safely, follow the
procedure below. (See Fig. 3-4.) Use the same procedure to move other robots.
1) Lower the Z-axis to a point approximately 24mm (35mm for YK600XGH or
longer arm robots) lower than the origin position. Then turn off the controller
and unplug the robot cable from the controller. (The Z-axis is fixed to the
base with an arm clamp stay at the factory prior to shipment.)
2) Remove the bolts on the X-axis arm.
3) Fold the X and Y-axis arms as shown in the drawing, and clamp the Y axis
arm to the robot base by using the stay, bolts and washers (2 washers for
YK500XG and YK600XG; 1 washer for YK600XGH or longer arm robots)
that come with the robot.
If the arms cannot be folded in the carrying position due to the X-axis
mechanical stoppers, then remove them. (When the robot is shipped, the
mechanical stoppers are installed to provide the maximum movement range.)
3-6
4) Screw the two eyebolts through washers into the upper surface of the X-axis arm.
5) Wind the robot cable around the upper part of the robot base so that it does
not hang up on the base mount, then fasten the cable end with adhesive tape.
6) Prepare two looped ropes with the same length to allow a good lifting balance,
then pass each rope through each eyebolt and catch it on the hoist hook.
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
installation 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 rope, eyebolts and arm clamp stay. Screw the bolts into the upper
surface of the X-axis. (Always attach these bolts to protect the eyebolt hole
threads.) Be sure to keep the eyebolts, arm clamp stay, bolts and pallet, since
they may be used to move the robot again.
Washers (under stay)

Bolt
Bolt M16×25 Hoist hook

(supplied with YK500XG, YK600XG)
Screw, or bolt and nut Bolt M20×25
(4 pieces supplied) (supplied with YK600XGH or longer arm robots) Rope
Tightening torque 71Nm (720kgfcm)
Arm clamp stay (supplied)
Bolts (M4×8) 2 pieces (supplied)

Tightening torque 4.5Nm (46kgfcm)
Eyebolt
Pallet (supplied with the robot)
Washer
45° or more
Fig. 3-4
3-7
2-4 Installing the robot

Install the robot securely with the four hex socket head bolts as shown in Fig. 3-5.
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
YK500XG, YK600XG M10 71Nm (720kgfcm)
YK600XGH, YK700XG, YK800XG, YK900XG, YK1000XG M12 128Nm (1310kgfcm)
Depth of tapped holes in installation base:

Iron installation base Bolt diameter × 1.5 or more
Aluminum installation base Bolt diameter × 3 or more
Recommended bolt JIS B 1176 hex socket head bolt, or equivalent
Strength class JIS B 1051 12.9, or equivalent
Hex socket head bolt
Installation base
Fig. 3-5 Installing the robot
3-8
3 Protective Bonding
WARNING
• Be sure to ground the robot and controller to prevent electrical shock.
• 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. 3-6 for example of the YK500XG.)
(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-XG 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 User'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.
3-9
Ground symbol
M4 Ground terminal
Fig. 3-6 Ground terminal
3-10
4 Robot Cable Connection

The robot cable is pre-connected to the YK-XG series robot. For details on con-
nections to the robot controller, refer to Fig. 3-7 and the "YAMAHA Robot Con-
troller User's Manual". After making connections, check the operation while re-
ferring 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 con-
troller.
• In the RCX142 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.
• 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.
• Lay out the cables so that they do not obstruct the movement of the manipu-
lator. Determine the robot work area in which the robot cables will not inter-
fere with the load or workpiece picked up by the manipulator. If the robot
cables interfere with the movable parts of the robot, the cables may be dam-
aged causing malfunction and hazardous situations. Refer to the external
view and dimensions shown in the catalog or website (www.yamaha-
motor.co.jp/global/industrial/robot).
• 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.
Controller side connector

Robot side connector RCX142
XM XM
YM YM
ZM ZM
RM RM
ROB I/O
Robot cable XY
XY
ROB I/O
ZR
ZR
Fig. 3-7 Robot cable connections

3-11
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-XG 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

YK500XG, YK600XG, YK600XGH, YK700XG, YK800XG, YK900XG, YK1000XG 20 wires φ6, 3 tubes
(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 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. For the locations, refer
to the external view and dimensions shown in the catalog or website
(www.yamaha-motor.co.jp/global/industrial/robot).
3-12
3) Signal wiring connections in the machine harness
1. YK500XG, YK600XG
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 Brown
14 14 Red
15 15 Orange
16 16 Blue
17 17 Violet
18 18 Grey
19 19 White
20 20 Black
21 21
22 22
23 23
24 24
Shield 25 25 Green
Flame Ground 1 FG Green
(Robots models with non-standard specifications

may have different wiring colors.)
3-13
4) As shown in Fig. 3-8, 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
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)
YK500XG, YK600XG, YK600XGH, YK700XG, YK800XG, YK900XG, YK1000XG

Fig. 3-8
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.
• 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.
• Avoid fastening the user cable or tube with the machine harness, as this may
lead to harness breakage and malfunction.
• Make sure that the user cable attached to the D-sub connector for user wir-
ing and the tube attached to the bulkhead union for user tubing will not inter-
fere with the robot movement, entangle around the robot or flap around dur-
ing operation. Wiring and tubing might then be damaged causing malfunc-
tion of the robot.
• 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.
3-14
! 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.
• Be sure to use the D-sub connector and hood which are supplied with the
robot. Using other types may result in contact failure.
D-sub connectors (supplied with robot)

Robot model D-sub connector on arm side D-sub connector on base side Hood
YK500XG, YK600XG, YK600XGH,

DB-25P-NR DB-25S-NR DB-C2-J9R
YK700XG, YK800XG, YK900XG, YK1000XG
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.
3-15
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. 3-9 to
Fig. 3-13 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: YK500XG
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 0.1kgm2 (1.0kgfcmsec2). 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 62%, as can be seen from Fig. 3-9.
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 User'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 calcu-
lated value smaller than the actual moment of inertia is set, residual vibra-
tions may occur. If this happens, reduce the acceleration coefficient param-
eter even further.
! CAUTION
• The robot must be operated with correct tolerable moment of inertia and
acceleration coefficients according to the manipulator tip mass and moment
of inertia. 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.
• 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
appropriate level.
• If the moment of inertia is too large, vibration may occur on the Z-axis de-
pending on its operation position. If this happens, reduce the Z-axis accel-
eration to an appropriate level.
3-16
6-1-1 Acceleration coefficient vs. moment of inertia (YK500XG)

AX, AY, AR (%)
0.04 (0.4)
100
80
60
40
20
0 0.05 0.1 0.15 0.2 0.25 0.3 Ir (kgm2)

0 0.5 1.0 1.5 2.0 2.5 3.0 Jr (kgm2)
Fig. 3-9 m=1 to 10kg
6-1-2 Acceleration coefficient vs. moment of inertia (YK600XG)

AX, AY, AR (%)
0.03 (0.3)
100
80
60
40
20
0 0.05 0.1 0.15 0.2 0.25 0.3 Ir (kgm2)

0 0.5 1.0 1.5 2.0 2.5 3.0 Jr (kgm2)
Fig. 3-10 m=1 to 10kg
3-17
6-1-3 Acceleration coefficient vs. moment of inertia

(YK600XGH)
AX, AY, AR (%)
0.03 (0.3)
100
80
60
40
20
0
0.2 0.4 0.6 0.8 1.0 Ir (kgm2)
0 2.0 4.0 6.0 8.0 10.0 Jr (kgfcmsec2)
Fig. 3-11 m=1 to 20kg

(YK700XG, YK800XG)
AX, AY, AR (%)
0.02 (0.2)
100
80
60
40
20
0 0.2 0.4 0.6 0.8 1.0 Ir (kgm2)

0 2.0 4.0 6.0 8.0 10.0 Jr (kgfcmsec2)
Fig. 3-12 m=1 to 20kg
3-18

(YK900XG, YK1000XG)
AX, AY, AR (%)
0.07 (0.7)
100
80
60
40
20
0
0.2 0.4 0.6 0.8 1.0 Ir (kgm2)
0 2.0 4.0 6.0 8.0 10.0 Jr (kgfcmsec2)
Fig. 3-13 m=1 to 20kg
3-19
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 (kgfcmsec2) = 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. 3-14 is as follows:
This is used as an approximate equation when x is larger than the object size.
I= mx2 (kgm2)
2
J= Wx (kgfcmsec2)
g
... (Eq. 3.1)
x
g : Gravitational acceleration (cm/sec2)

m : Mass of material particle (kg)
W : Weight of material particle (kgf)
Fig. 3-14
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. 3-15 is given below.
ρπ D 4 h 2
I= = mD (kgm2)
32 8
ρπ D 4 h 2
J= = WD (kgfcmsec2)
32g 8g
... (Eq. 3.2)
h
ρ : Density (kg/m , kg/cm )

3 3

m : Mass of cylinder (kg)
W : Weight of cylinder (kgf) D
Fig. 3-15
3-20
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. 3-16 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 ( + ) (kgfcmsec2)
16g 4 3 4g 4 3
... (Eq. 3.3)
ρ : Density (kg/m3, kg/cm3)

m : Mass of cylinder (kg) D
W : Weight of cylinder (kgf)
h
2
Fig. 3-16
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. 3-17 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= = (kgfcmsec2)
12g 12g
... (Eq. 3.4)
c 1/2a
b
a
m : Mass of prism (kg)
W : Weight of prism (kgf)
Fig. 3-17
3-21
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. 3-18, is
given as follows.
ρπD 4 h ρπD 2 hx2 2

I= + = mD + mx2 (kgm2)
32 4 8 Center line
ρπD 4 h ρπD 2 hx 2
J= + Rotation center
32g 4g
2 2
= WD +
Wx
(kgfcmsec2)
8g g h
... (Eq. 3.5)

g : Gravitational acceleration (cm/sec2) D
x
m : Mass of cylinder (kg)
W : Weight of cylinder (kgf)
Fig. 3-18
In the same manner, the moment of inertia of a cylinder as shown in Fig. 3-19
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
= ( + ) + (kgfcmsec )
4g 4 3 g
... (Eq. 3.6) D
Fig. 3-19
In the same manner, the moment of inertia of a prism as shown in Fig. 3-20 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 (kgfcmsec2)
12g g c
x
... (Eq. 3.7) b
a
m : Mass of prism (kg)

W : Weight of prism (kgf)
Fig. 3-20
3-22
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. 3-21. The moment of
inertia is calculated with the following three factors, assuming that the load mate-
rial is steel and its density ρ is 0.0078kg/cm3.
R-axis
Stay 2cm
2cm
2cm
1cm
4cm 10cm
1cm
6cm
Chuck
Workpiece
4cm
2cm
Fig. 3-21
1) Moment of inertia of the stay
From Fig. 3-22, 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. 3-22
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 (kgfcmsec2)
12 × 980 980
3-23
2) Moment of inertia of the chuck
10cm R-axis
When the chuck form resem- 2cm
bles that shown in Fig. 3-23,

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. 3-23
12 × 980
0.37 × 102
+
980
= 0.038 (kgfcmsec2)
3) Moment of inertia of workpiece
10cm R-axis
When the workpiece form
resembles that shown in Fig.
3-24, 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. 3-24
8 × 980 980
= 0.010 (kgfcmsec2)
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 (kgfcmsec2)
3-24
6-4 Attaching the end effector
WARNING
• Before attaching the end effector, be sure to turn off the controller.
• 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.
The user's end effector that attaches to the robot 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. 3-27. Refer to Fig. 3-25 for details on the end effector attach-
ment of each robot model. Refer to Fig. 3-3 for the depth of tapped hole and
recommended type of tap bolt. When checking end effector operation, refer to "6
Trial Operation" in Chapter 1.
3-25
Never loosen this bolt.
40
End effector attachment area Spline shaft (hollow diameter φ14)
φ20 h7 0
-0.021
M16×2, depth 20
YK500XG, YK600XG
Never loosen this bolt.

45
Spline shaft (hollow diameter φ18)
End effector attachment area

φ25 h7 0
-0.021
M20×2.5, depth 20
YK600XGH, YK700XG, YK800XG, YK900XG, YK1000XG

Fig. 3-25
WARNING
• The tapped hole (see Figs. 3-25) provided on the lower part of the end effec-
tor attachment should be used only for preventing the end effector from com-
ing loose.
• Do not fasten the end effector just by using this tapped hole. If the end effec-
tor is fastened only with this tapped hole, it may come loose from the attach-
ment during robot operation and fly off resulting in accidents or injuries.
3-26
Table 3-1
FXYmax FZmax FRmax MRmax Mmax

Robot Model N kgf N kgf N kgf Nm kgfm Nm kgfm
YK500XG 173 18 134 14 506 52 24 2.6 15 1.5
YK600XG 173 18 134 14 506 52 24 2.6 15 1.5
YK600XGH 489 49 214 22 696 71 56 5.7 26 2.7
YK700XG 489 49 214 22 696 71 56 5.7 26 2.7
YK800XG 489 49 191 19 696 71 56 5.7 24 2.4
YK900XG 443 46 191 19 696 71 56 5.7 24 2.4
YK1000XG 443 46 191 19 696 71 56 5.7 24 2.4
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.
• 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.
End effector
Stay
FRmax Mmax
MRmax
FxYmax
Fzmax
Fig. 3-26 Maximum load applied to end effector attachment
Table 3-2
Tightening torque Hole diameter
Bolts Used Number of bolts
Robot Model Nm kgfcm (mm)
+0.021
YK500XG, YK600XG M6 or lager 2 or more 15.3 156 20 0
+0.021
YK600XGH, YK700XG, YK800XG, YK900XG, YK1000XG M8 or lager 2 or more 37.0 380 25 0
Table 3-3
Iron material base Bolt diameter 1.5 or more
Depth of tapped hole
Aluminum material base Bolt diameter 3.0 or more
JIS B 1176 hex socket head bolt, or equivalent
Recommended bolt
(Strength class: JIS B 1051 12.9, or equivalent)
3-27
Hole diameter
Bolt
Slot
Spline shaft
End effector or stay
Fig. 3-27
3-28
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 opera-
tion can be calculated from the acceleration applied to the end effector attach-
ment. The maximum acceleration 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 3-4 Maximum acceleration during robot operation

Robot Model Amax(m/sec2) AXYmax(m/sec2) Azmax(m/sec2) ARmax(rad/sec2)
YK500XG 98 48 57 280
YK600XG 104 41 57 280
YK600XGH 78 60 38 176
YK700XG 96 60 38 176
YK800XG 101 51 38 176
YK900XG 95 51 38 176
YK1000XG 95 51 38 176
ARmax
Amax AXYmax (Tangential acceleration)

(centrifugal acceleration)
Azmax
Fig. 3-28 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.
3-29
7 Limiting the Movement Range with X-Axis

Mechanical Stoppers
In the YK-XG Series, the movement range can be limited by changing the X-axis
mechanical stopper positions. (See Fig. 3-29.) 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 out-
lined below. The X-axis mechanical stopper positions may slightly differ depending
on machining 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.)
3-30
7-1 YK500XG, YK600XG, YK600XGH, YK700XG, YK800XG,

YK900XG, YK1000XG
To change the X-axis mechanical stopper positions, for example, from the maxi-
mum movement range (132°) to 87°, use the following procedure.
1) Prepare a 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 screw plug, X-axis mechanical stopper bolt and washer as shown
in Fig. 3-30. Then reinstall the mechanical stopper bolt and washer at the
position that determines the desired movement range by tightening the bolt
to the torque specified in Table 3-5.
Reinstall the screw plug you removed, into the position where the X-axis
stopper bolt was installed.
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 3-5
Robot Model Bolt size Tightening torque (kgfcm) Tightening torque (Nm)
YK500XG,YK600XG M8 380 37.2
YK600XGH, YK700XG, YK800XG,
M10 459 45.0
YK900XG, YK1000XG
Use only YAMAHA genuine bolts or JIS B 1176 hex socket head bolts
(strength class: JIS B 1051 12.9).
3-31
Y-axis mechanical stopper
X-axis movable mechanical stopper
43° 12°
87° 132°
Fig. 3-29 X-axis movable mechanical stopper position
Screw plug X-axis stopper bolt Washer : YK500XG, YK600XG (1 washer)

YK600XGH, YK700XG YK800XG, YK900XG, YK1000XG (2 washers)
Fig. 3-30 Changing the X-axis mechanical stopper position
3-32
8 Working Envelope and Mechanical Stopper

Positions for Maximum Working Envelope
Working envelope of each robot and mechanical stopper positions for the maxi-
mum working envelope are shown in Fig. 3-31 to Fig. 3-37.
Z300mm stroke 775
Z200mm stroke 675
Z-axis upper-end
137.6 ±2 mechanical stopper position
8mm rise during Z-axis return-to-origin
200
0 0
300
10
Z-axis lower end

mechanical stopper position
10
14
7°
5°
5°
14
R1
14
147°
05
R8
R5
8
R5
(a)
130
17
2 (a
0°
132
)
°
00
7
00
(d
132
R
13
R1
(d)
°
4
)
R71
°
R6
165
165
260
260
R300 R300
(b)
55
R R
R
25 2
b)
25
R2
5(
5
(c
5
R5
)
(c
)
100
114°
114° 288
113° 113°
100
288
Working envelope Maximum movement range
Interference position (a) Base front panel X-axis mechanical stopper: 132° Interference position (a) Base front panel
(b) Base side panel Y-axis mechanical stopper: 147° (b) Base side panel
(c) Base rear panel Do not operate the robot in (c) Base rear panel
(d) Base corners an area outside the working envelope. (d) Base corners
Fig. 3-31 YK500XG
3-33
Z300mm stroke 775
Z200mm stroke 675
137.6 ±2 Z-axis upper-end

200
0 0
300
10
Z-axis lower end

10
14
5°
5°
14
7°
14
14
7°
R8
R6
R9
5 (a
80
R6
130
°
)
00
130
132
2°
7(
(d
R1
00
70
)
13
6
a)
R7
R1
d)
°
6(
R6
220
c)
0( c)
0(
220
R8 R8
b)
6(
b)
R4
R300
6(
R300
R4
270
270
135°
135
° ° 134
134 °
Working envelope
Interference position (a) Base front panel Maximum movement range Interference position (a) Base front panel
(b) Base side panel X-axis mechanical stopper: 132° (b) Base side panel
(c) Base rear panel Y-axis mechanical stopper: 147° (c) Base rear panel
(d) Base corners Do not operate the robot in (d) Base corners
an area outside the working envelope.
Fig. 3-32 YK600XG
3-34
Z400mm stroke 990
Z200mm stroke 790
208.7±2
Z-axis upper-end
6mm rise during
200
Z-axis return-to-origin
0 0
12
400
Z-axis lower end mechanical stopper position

12
15
0°
R14
2°
0°
R1
15
15
15
8 (a
(d)
2°
1(
R6
R )
42
60 (d
16
)
a)
00
13
0
°
R2
8
132
0
°
4 1
130
R1
R1
132
R2
0°
°
400
400
R400
R4
R5 00
)
R63 (b
R400
2(
R
(b)
c)
46
(c
R70
200 200
97° 97° 96° 96°
Working envelope
Fig. 3-33 YK600XGH
3-35
Z400mm stroke 990
Z200mm stroke 790
208.7±2
Z-axis upper-end
200
0 0
12
400

12
15
0°
15
2°
15
2°
0°
15
R7
R9
00
°
d)
13
8
°
130
132
R
132
3(
R8
(a)
70
0°
05 6( 95 d)
R7
3(
0
R2 a) R1 R6
)
(c
2
R3
202
202
R400
300
300
R30 (b) R30 (b

)
R3
R3 R
0 32 (
0
200
200
R4
00
c)
280 280
124° 124° 124° 124°

Working envelope
Fig. 3-34 YK700XG
3-36
Z400mm stroke 990
Z200mm stroke 790
208.7±2
Z-axis upper-end
200
0 0
12
400

12
15
2°
0°
2°
15
15
15
0°
R8
00
07
R1
R2
°
13
132
130
00
132
94
0°
)
(d )
(
R1
°
R8 (d
a)
R8 5 4(
00 R7 a) 61
R
c)
202
202
2(
250
250
R30 (b) R3 R30 (b)
R400
R3
R3
200 200 0
0
R400
R3
2(
c)
280 280
°
41 °
141 141 141
1 ° °
Working envelope
Fig. 3-35 YK800XG
3-37
Z400mm stroke 990
Z200mm stroke 790
208.7±2 Z-axis upper-end

200
0 0
12
400

12
15
0°
0° 2° 15
2°
15 15
R90
R90
0
R1 R1
13
°
52
52 36
130
132
)
132
0°
(d
(a )
R2
(a (d
38
)
0
) 6
°
12
R2
10
R
R76 R5
(b) 7 (b)
00 00
R4 R4
R5
R4
7(
1
c)
(c
)
° 150
150 ° 2°
15
2°
15
Working envelope
Fig. 3-36 YK900XG
3-38
Z400mm stroke 990
Z200mm stroke 790
208.7±2 Z-axis upper-end

200
0 0
12
400

12
0°
15 2° 15
15
0° 15 2°
R10
(d)
R10
00
R
R191
R2
)
00
22
0(d
15
9
13
°
(a
(a
R18
130
132
°
)
)
0°
132
R32
) 3 R31
R165 (b 00 (b) 0
R4 R149
R400
R1
R1
34
20
(
(c
c)
° 150
150 ° ° 15
152 2°
Working envelope
Fig. 3-37 YK1000XG
3-39
Here, working envelope and mechanical stopper positions for the maximum work-
ing envelope of a robot are described using the YK500XG as an example.
Refer to Fig. 3-31 YK500XG. Other robot models are the same.
1) X and Y axes
1. Do not attempt operation outside the working envelope. On the YK-XG
series, the origin can be set at a discrete position. The working envelope
described in this manual is an area with the robot frontal reference when
no load is applied.
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", "c" and
"d" are the respective interference positions with the base front panel, base
side panel, base rear panel, and base corners. Be careful not to allow the
robot load to interfere with any part of the robot.
The Z-axis spline may touch the base or the Y-axis arm may touch the
wire harness before the robot strikes the X-axis or Y-axis mechanical stop-
pers, so use caution.
3. Interference positions where a load might touch the robot within the maxi-
mum movement range and their radii are shown in the figure. Here, "a",
"b", "c" and "d" are the respective interference positions with the base
front panel, base side panel, base rear panel and the base corners. The Z-
axis spline may touch the base or the Y-axis arm may touch the wire har-
ness before the robot strikes the X-axis or Y-axis mechanical stoppers, so
use caution.
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.
3-40
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 payload, maximum speed).
Robot model X-axis Y-axis Z-axis

Upper end Lower end
YK500XG,YK600XG 9° 12° 5mm 5mm
YK600XGH, YK700XG to YK800XG 9° 12° 5mm 5mm
Note: Here, ° (deg.) is the overrun angle at the X-axis and Y-axis joints.
(1) If the X-axis, Y-axis or Z-axis mechanical stopper is deformed or dam-

aged by impacts, please contact our sales office or dealer. Using the de-
formed or damaged mechanical stopper is dangerous, so it must be re-
placed.
(2) When the robot strikes the X-axis or Y-axis mechanical stopper or an-
other 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 happens, please contact our sales office or dealer.
3-41
MEMO
3-42
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 Stroke end method (Z-axis) ............................................................................................... 4-3
3-2 Machine reference .......................................................................................................... 4-4
3-3 Absolute reset procedures.............................................................................................. 4-5
3-3-1 Sensor method (X-axis, Y-axis, and R-axis) ...................................................................... 4-5
3-3-2 Stroke end method (Z-axis) ............................................................................................... 4-7
3-4 Changing the origin position and adjusting the machine reference ................................ 4-8
3-4-1 Sensor method .................................................................................................................. 4-9
3-4-1-1 YK500XG, YK600XG, YK600XGH, YK700XG, YK800XG, YK900XG, YK1000XG ............ 4-9
3-4-2 Stroke end method .......................................................................................................... 4-27
3-4-2-1 YK500XG, YK600XG, YK600XGH, YK700XG, YK800XG, YK900XG, YK1000XG .......... 4-27
4 Setting the Soft Limits ....................................................................................4-31

5 Setting the Standard Coordinates ..................................................................4-34
5-1 Standard coordinate setting using a standard coordinate setup jig (option)................. 4-35
6 Affixing the Stickers for Movement Directions and Axis Names .....................4-38
MEMO
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
3 Adjusting the origin

All models of the YK-XG series robots use an absolute type position detector.
The origin position (zero pulse point) can be determined by absolute reset. Once
absolute 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 follow-
ing 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 abso-
lute reset, refer to "Absolute Reset" in Chapter 4 of the "YAMAHA Robot Con-
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 equip-
ment after the setup is complete.
• 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.
• The standard coordinate and point data must be reset when the origin posi-
tion is changed.
• Make point data setting after changing the origin position. After changing the
origin position, do not use the previous point data.
There are three absolute reset methods for the YK-XG 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.
4-2
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 pendant (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 operation.
(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 me-
chanical stopper or a peripheral device. Since a mechanical stopper is not pro-
vided in the R-axis, the wiring and piping installed on the end effecter may be
wound up by the operation.
3-1-2 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
4-3
3-2 Machine reference

The YK-XG 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 sensor 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 (unit: %) is
displayed on the optional MPB screen.
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 ma-
chine reference must be readjusted. For information on how to adjust the ma-
chine reference, refer to "3-4 Changing the origin position and adjusting the
machine reference" in Chapter 4. When the temperature of the robot joint sec-
tions is high immediately after the robot has been operated, the machine refer-
ence value might be outside the specified range (40 to 60%). When checking or
adjusting the machine reference 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
4-4
3-3 Absolute reset procedures
3-3-1 Sensor method (X-axis, Y-axis, and R-axis)
WARNING
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 User's Manual" for information on operating the robot controller.
1) Check that no one is inside the safeguard enclosure and then turn on the
controller.
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, 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).
4-5
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 Chang-
ing the origin position and adjusting the machine 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
4-6
3-3-2 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 User's Manual" for information on operat-ing the robot controller.
controller.
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 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 absolute reset is complete, check that the adjustment machine refer-
ence value displayed on the MPB is within the absolute reset tolerance range
(33 to 67).
! CAUTION
Use the following procedure to display the adjustment machine reference
value. When adjusting the machine reference value, always check the ad-
justment machine reference value with this procedure.
(1) Press the MODE key.

(2) Press the F3 key to enter MANUAL mode.
(3) Press the F13 key (LOWER+F3) to select "ABS Reset".
(4) After the Z-axis absolute reset is complete, press the F10 (UPPER+F5) key
to display the adjustment machine reference value (%).
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,
make the necessary adjustments by referring to "3-4 Changing the origin
position and adjusting the machine reference" in Chapter 4.
4-7
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
performed, the machine reference must be adjusted, and the standard coor-
dinate and point data must be reset.
• If any machine reference is adjusted, the origin position may change. Before
the adjustment, mark off the reference mark at the current origin position on
the main body of the robot. After the machine reference is adjusted, be sure
to check that the origin position has not deviated. If the origin position changes
after the machine reference has been adjusted, then the standard coordi-
nate and point data must be reset.
4-8
3-4-1 Sensor method
3-4-1-1 YK500XG, YK600XG, YK600XGH, YK700XG, YK800XG,

YK900XG, YK1000XG
1-1 Adjusting the X-axis machine reference
! CAUTION
The origin position may change due to machine reference adjustment. If it oc-
curs, you must set point data again.
The adjustment method for the X-axis machine reference is as follows.
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) Remove the cover.
9) Scribe a mark on the position of the X-axis origin sensor stay.
10) Using the hex wrench, loosen the two bolts securing the X-axis origin sensor
stay. (See Fig. 4-3.)
! CAUTION
The bolts only need to be loosened, and do not need to be completely re-
moved.
4-9
11) Move the X-axis origin sensor stay in the following manner and then secure
it with the bolts.
NOTE
• When the machine reference is less than 40%, move the stay in direction q:
See Fig. 4-3 (b).
• When the machine reference is more than 40%, move the stay in direction w:
See Fig. 4-3(b).
As an approximate guide, a 1mm movement equals to 100%.
12) Go out of the safeguard enclosure, and check that no one is inside the safe-
guard enclosure. Then turn on the controller.
14) After the absolute reset is completed, read the machine reference value dis-
played on the MPB.
15) 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.
16) Reattach the cover after the adjustment is complete.

X-axis origin dog
Fig. 4-3 (a)
4-10
X-axis origin sensor stay
X-axis origin sensor
Cover
Bolt
Fig. 4-3 (b)
4-11
1-2 Changing the X-axis origin position
The X-axis origin position can be changed to any position in the range from the
front position of the X-axis arm base to a maximum of 120° clockwise and
counterclockwise at 30° intervals, by changing the positions of the dog and the
mounting bolt for the X-axis speed reduction unit as shown in Fig. 4-4.
! CAUTION
• The dog and bolt might come off and cause the joint to lock up unless you
apply "Screw Lock" to them and tighten to the specified torque.
The following describes the method for changing the X-axis origin position, for
example, to a position 90° counterclockwise.
1) Prepare the necessary tools.
• Hex wrench set • Torque wrench
• Phillips screwdriver • Screw Lock (thread sealant)
• Phillips screwdriver bit • Hex bit
controller.
reset method.
6) Remove the cover. (See Fig. 4-5 (a).)
7) Using the hex wrench, loosen the two bolts securing the X-axis origin sensor stay.
8) Remove the X-axis origin sensor stay.
9) Remove the dog and hex nut through the elongated hole.
We recommend using the Phillips screwdriver bit and wrench to remove the
dog since it is secured with "Screw Lock".
10) Rotate the X-axis arm 90° counterclockwise. (See Fig. 4-5 (b).)
11) Remove the bolt located opposite the elongated hole.
12) Apply "Screw Lock" to the dog and nut, insert them into the tapped hole where
the bolt was attached, and tighten to the specified torque. (See Fig. 4-5 (c).)
13) Return the X-axis arm to the current origin position. (See Fig. 4-5 (d).)
14) Apply "Screw Lock" to the bolt, insert it into the tapped hole where the dog
was attached, and tighten to the specified torque.
4-12
15) Temporarily fasten the X-axis origin sensor stay using the bolts. At this point,
check that the sensor does not interfere with other parts while turning the X-
axis arm by hand.
played on the MPB.
mended range), then the origin position has been correctly changed. Fully
tighten the bolts to secure the X-axis origin sensor stay. If it is outside the
recommended value, then adjust the machine reference by referring to "1-1
Adjusting the X-axis machine reference".
Dog Mounting bolt for X-axis speed reduction unit
X-axis origin position adjustable range
0°
12
°
°90
60
Factory-preset
30°
X-axis origin position

6030°
°
90
°
12
0°
Fig. 4-4
4-13
Elongated hole
Hex nut
Dog
X-axis origin sensor stay
Cover
Bolt
Fig. 4-5 (a)
X-axis arm
Bolt
Fig. 4-5 (b)
4-14
Hex nut
Dog
Robot model Dog Tightening torque (kgfcm) Tightening torque (cNm)

YK500XG,YK600XG M4×30 16 160
M5×40 32 320
YK900XG, YK1000XG
Recommended "Screw Lock": LOCTITE 262 (made by Henkel Corporation)
Fig. 4-5 (c)

Bolt
Robot model Bolt Tightening torque (kgfcm) Tightening torque (Nm)
YK500XG,YK600XG M4×30 46 4.5
M5×40 92 9.0
YK900XG, YK1000XG
Fig. 4-5 (d)

4-15
2-1 Adjusting the Y-axis machine reference
! CAUTION
The origin position may change due to machine reference adjustment. If it oc-
curs, you must set point data again.
The adjustment method for the Y-axis machine reference is as follows.
controller.

reset method.
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.
9) Scribe a mark on the position of the Y-axis origin sensor stay.
10) Using the hex wrench, loosen the two bolts securing the Y-axis origin sensor
! CAUTION
moved.
4-16
11) Move the Y-axis origin sensor stay in the following manner and then secure it
with the bolts.
NOTE
See Fig. 4-6.
See Fig. 4-6.
As an approximate guide, a 0.8mm movement equals to 100%.
played on the MPB.
4-17
Y-axis origin dog
Bolt
Y-axis origin sensor stay
q Cover
Y-axis origin sensor
Fig. 4-6
4-18
2-2 Changing the Y-axis origin position
The Y-axis origin position can be changed to any position in the range from the
front position of the Y-axis arm and X-axis arm to a maximum of 120° clockwise
and counterclockwise at 30° intervals, by changing the positions of the dog and
the mounting bolt for the Y-axis speed reduction unit as shown in Fig. 4-7.
! CAUTION
• The dog and bolt might come off and cause the joint to lock up unless you
apply "Screw Lock" to them and tighten to the specified torque.
The following describes the method for changing the Y-axis origin position, for
example, to a position 90° counterclockwise.
1) Prepare the necessary tools.
• Hex wrench set • Torque wrench
• Phillips screwdriver • Screw Lock (thread sealant)
• Phillips screwdriver bit • Hex bit
controller.
reset method.
6) Remove the cover. (See Fig. 4-8 (a).)
7) Using the hex wrench, loosen the two bolts securing the Y-axis origin sensor stay.
8) Remove the Y-axis origin sensor stay.
9) Remove the dog and hex nut through the elongated hole. (See Fig. 4-8 (b).)
We recommend using the Phillips screwdriver bit and wrench to remove the
dog since it is secured with "Screw Lock".
10) Rotate the Y-axis arm 90° counterclockwise. (See Fig. 4-8 (c).)
11) Remove the bolt located opposite the elongated hole.
12) Apply "Screw Lock" to the dog and nut, insert them into the tapped hole where
the bolt was attached, and tighten to the specified torque. (See Fig. 4-8 (d).)
13) Return the Y-axis arm to the current origin position. (See Fig. 4-8 (e).)
14) Apply "Screw Lock" to the bolt, insert it into the tapped hole where the dog
was attached, and tighten to the specified torque.
4-19
15) Temporarily fasten the Y-axis origin sensor stay using the bolts. At this point,
check that the sensor does not interfere with any parts while turning the Y-
axis arm by hand.
played on the MPB.
mended range), then the origin position has been correctly changed. Fully
tighten the bolts to secure the Y-axis origin sensor stay. If it is outside the
recommended value, then adjust the machine reference by referring to "2-1
Adjusting the Y-axis machine reference".
Y-axis origin position adjustable range
0°
12
°
90
Factory-preset
°
60
Y-axis origin position
Dog
30°
30°
60
°
Mounting bolt for Y-axis speed reduction unit

90
°
12
0°
Fig. 4-7
4-20
Bolt
Y-axis origin sensor stay
Elongated hole
Cover
Fig. 4-8 (a)
4-21
Dog
Hex nut
Fig. 4-8 (b)
Y-axis arm
Bolt
X-axis arm
Fig. 4-8 (c)
4-22
Dog
Robot model Dog Tightening torque (kgfcm) Tightening torque (cNm)

YK500XG,YK600XG M3×30 9 90
M4×30 16 160
YK900XG, YK1000XG
Hex nut
Fig. 4-8 (d)
Bolt
Robot model Bolt Tightening torque (kgfcm) Tightening torque (Nm)

YK500XG,YK600XG M3×30 20 2.0
M4×30 46 4.5
YK900XG, YK1000XG
Fig. 4-8 (e)
4-23
3 Adjusting the R-axis machine reference
The adjustment method for the R-axis machine reference is as follows.
controller.

reset method.
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.
9) Scribe a mark on the position of the R-axis origin sensor stay.
10) Using the hex wrench, loosen the two bolts securing the R-axis origin sensor
! CAUTION
moved.
11) Move the R-axis origin sensor stay in the following manner and then secure
it with the bolts.
NOTE
See Fig. 4-9.
See Fig. 4-9.
As an approximate guide, a 1.9mm movement equals to 100%.
4-24
played on the MPB.
4-25
R-axis origin dog
R-axis origin sensor stay
Bolt
Cover
R-axis origin sensor
Fig. 4-9
4-26
3-4-2 Stroke end method

The stroke end method is employed on the YK-XG 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 read-
justment in the following procedure is required, however, if the machine refer-
ence exceeds the tolerance range (33 to 67) of the absolute reset for any reason.
! CAUTION
The origin position may change due to machine reference adjustment. If it occurs,
you must set point data again.
3-4-2-1 YK500XG, YK600XG, YK600XGH, YK700XG, YK800XG,

YK900XG, YK1000XG
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. Make a note of the Z-axis machine reference value.
! CAUTION
Use the following procedure to display the adjustment machine reference
value.
When adjusting the machine reference value, always check the adjustment
machine reference value with this procedure.
(1) Press the MODE key.

(2) Press the F3 key to enter MANUAL mode.
(3) Press the F13 key (LOWER+F3) to select "ABS Reset".
(4) After the Z-axis absolute reset is complete, press the F10 (UPPER+F5) key
to display the adjustment machine reference value (%).
4) Turn off the controller.

The Z-axis motor brake is now working at the origin position.
4-27
6) Remove the cover. (See Fig. 4-10.)
WARNING
If the ball screw comes off the Z-axis motor, the Z-axis drops causing a hazard-
ous situation. Always prop up the Z-axis with a support stand or the like.
7) Prop the spline or end effector with a support stand to prevent the Z-axis
from dropping.
8) Lift up the Z-axis lower end damper. If this is difficult, insert a screwdriver
between the damper and the holder, and pry up the damper. (See Fig. 4-11 (a).)
9) Put a mark to indicate the current flange position with respect to the motor
shaft. Fit the spanner (wrench) to the flat surfaces of the flange and loosen
the bolts. This allows the ball screw to rotate freely independent of the Z-axis
motor.
10) Rotate the flange with respect to the motor shaft. (See Fig. 4-11 (b).)
Rotating the flange 30 degrees changes the machine reference value by 33%.
The machine reference value decreases by rotating the flange clockwise as
viewed from top, while it increases by rotating the flange counterclockwise.
Determine the flange position based on the Z-axis machine reference value
you made a note of, so that the machine reference value is within 33 to 67%.
11) Tighten the bolts a little at a time in a diagonal pattern. The tightening torque
should be 2.0Nm (20kgfcm). The bolts can be inserted into 10 holes among
12 through-holes.
controller.
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, check that the adjustment machine
reference value is within the tolerance range (33 and 67). If the adjustment
machine reference value is outside the tolerance range (33 to 67), then repeat
the procedure from 4) to readjust it.
4-28
15) When the machine reference value is within the tolerance range, lower the Z-
axis lower end damper until it makes tight contact with the holder and then
reattach the cover.
Rear cover
Cover
Fig. 4-10
4-29
Ball screw
Z-axis lower end damper
M3×12
Bolt
Flat surface
Z-axis motor shaft

(located under the flange)
Flange
Mark
Fig. 4-11 (a)
Counterclockwise
Clockwise
Fig. 4-11 (b)
4-30
4 Setting the Soft Limits

In the YK-XG 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 Us-
er's Manual" for further details. Also refer to the external view and dimensions in
the catalog or website (www.yamaha-motor.co.jp/global/industrial/robot) for the
working envelope area. When performing actual checks of the soft limit settings,
operate the robot manually 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.
controller.
2) Press the emergency stop button on the MPB to set emergency stop.
Refer to the "YAMAHA Robot Controller User's Manual" for further details
on emergency stop and canceling emergency stop.
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 enclo-
sure. Refer to the "YAMAHA Robot Controller User's Manual" for further
details on soft limit settings.
4-31
! 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 posi-
tion).
(2) Setting the Z-axis soft limits

Make this setting from outside the safeguard enclosure. The Z-axis has me-
chanical 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 maxi-
mum working envelope or the manipulator interferes with the peripheral equip-
ment, 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.
4-32
(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
YK500XG, YK600XG 80 80 20mm 30
YK600XGH, YK700XG, YK800XG, YK900XG, YK1000XG 80 80 20mm 50
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
4-33
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.
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.
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 "Setting
the Standard Coordinates" as explained in the "YAMAHA Robot Controller
User's Manual".
Never enter within the robot movement range. The next section, "5-1 Stand-
ard coordinate setting using a standard coordinate setup jig (option)", de-
scribes how to set the standard coordinates more accurately using an optional
setup jig.
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.
4-34
5-1 Standard coordinate setting using a standard coordinate

setup jig (option)
+Y direction
+X direction
Fig. 4-12
controller.
2) Press the emergency stop button on the MPB to set emergency stop.
Refer to the "YAMAHA Robot Controller User'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
operating the controller or operation panel.
4) Enter the safeguard enclosure while holding the MPB.
5) Position the robot arms as shown in Fig. 4-13 and remove the screw.
6) Position the robot arms so that you can easily insert the sleeve into the hole,
and insert the sleeve into the hole. Then tighten the bolt just enough to hold
the sleeve. (See Fig. 4-14.)
7) Turn the X and Y-axis arms so that they are nearly straight. (See Fig. 4-15.)
Remove the cover and plate.
8) Position the Y-axis arm so that you can easily insert the pin into the sleeve
through the elongated hole in the Y-axis arm. (See Fig. 4-16.)
Secure the pin with the bolt. Tighten the bolt just enough to hold the pin.
9) Enter "MANUAL>POINT" mode. Lightly apply a clockwise torque to the Y-

axis to unload it while holding the X-axis arm, and make a note of the Y-axis
position pulse value displayed on [POS].
10) Lightly apply a counterclockwise torque to the Y-axis to unload it while holding
the X-axis arm, and make a note of the Y-axis position pulse value displayed
on [POS].
11) Move the X-axis arm in the direction that you want to set as the + direction of
the X-axis as shown in Fig. 4-12. At this point, make a note of the X-axis
position pulse value displayed on [POS].
4-35
12) Enter the following values in M1 and M2 for "11. Arm length [mm]" of axis
parameters.
M1 (X-axis arm length) M2 (Y-axis arm length)

YK500XG 200.00 300.00
YK600XG 300.00 300.00
YK600XGH 200.00 400.00
YK700XG 300.00 400.00
YK800XG 400.00 400.00
YK900XG 500.00 400.00
YK1000XG 600.00 400.00
13) Enter the following values in "12. Offset pulse" of axis parameters.
M1= X-axis position pulse value you made a note of in step 11)
M2= Y-axis position pulse value you made a note of in step 9) + Y-axis position pulse value you made a note of in step 10)
2
Round off the decimal part of the M2 value.
14) After entering the parameters, remove the pin, bolt, and sleeve.
Reattach the cover, plate and screw.
Screw
Fig. 4-13
4-36
Bolt
Sleeve
Hole
Fig. 4-14
Bolt
Plate
Cover
Bolt
Fig. 4-15
Clockwise
Y-axis arm
Bolt
Pin
Counterclockwise
Elongated hole
X-axis arm
Sleeve
Fig. 4-16
4-37
6 Affixing the Stickers for Movement Directions

and Axis Names
The robot comes packed with stickers showing origin positions, movement direc-
tions and axis names as shown in Fig. 4-17. Using the following procedure, at-
tach these stickers in conspicuous points on the robot after changing the origin
position and installing peripheral equipment.
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 User's Manual".
ating the controller switch.
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. 4-18)
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
Z R
(a) Origin position stickers (b) Direction of movement and
axis name stickers
Fig. 4-17
4-38
-
R Z
- + +
- +
Y
End effector End effector

- +
X
Fig. 4-18
4-39
MEMO
4-40
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 .........................................................................5-9
5-1 Replacement period ....................................................................................................... 5-9
5-2 Basic replacement procedure for harmonic drive and precautions .............................. 5-10
5-2-1 YK500XG, YK600XG, YK600XGH, YK700XG, YK800XG, YK900XG, YK1000XG ........ 5-12
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-XG series robots.
Periodic inspection includes:

• Daily inspection
• 6-month inspection
• Replacement of speed reduction gear (harmonic drive)
Make sure that you thoroughly understand details of the inspection and follow
the procedures and precautions explained in this chapter.
5-1
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 Con-
5-2
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
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

controller.
operating the controller, programming unit or operation panel.
3) Check the following points from outside the safeguard enclosure.
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
(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
4 Six-Month Inspection
Take the following precautions when performing 6-month inspection.
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 and spline 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.
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
and ball spline will shorten.
(1) Inspection to be performed with the controller turned off

2) Place a sign showing that the robot is being inspected, to keep others from
5-5
3) Enter the safeguard enclosure and check the following points.
Manipulator bolts and screws (Only for

major bolts and screws exposed Check for looseness and tighten if necessary.*1
externally)
Detection areas of the origin sensors of
the X-axis, Y-axis, and R-axis Clean if it is dirty.
Check for looseness at each terminal and connector on the

Controller
panel. (See 4 in Chapter 3.)
Lubricate the Z-axis spline shaft and ball screw nut after
Grease lubrication of Z-axis ball screw
removing the old grease. The specified grease is Alvania
and spline
S2 (SHOWA SHELL SEKIYU KK). (See Fig. 5-1.)
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 (kgfcm) Tightening torque (Nm)
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 459 45.0
M12 1310 128
M14 2090 205
5-6
Supply grease through the grease nipple.
Apply grease to the groove.
Cover
Lower the spline and apply grease to the groove.
Fig. 5-1
5-7
(2) Inspection to be performed with the controller turned on
WARNING
• The robot controller must be installed outside the safeguard enclosure, to
prevent a hazardous situation in which you or anyone enter the safeguard
enclosure to inspect the controller while it is turned on.
• 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.
controller.
operating the controller, programming unit or operation panel.
3) Check the following points from outside the safeguard enclosure.
• Check if the fan rotates normally.

• Check if objects blocking the fan are located and remove
if any are found.
• Check for abnormal noise from the rotating fan. If
• Cooling fan at rear of controller
abnormal noise is heard, visually check and remove the
cause. If no cause is found, contact YAMAHA dealer.
• Check for dust on the fan cover. Remove and clean if
necessary.
(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.
5-8
5 Replacing the Harmonic Drive

The YK-XG 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-
XG series robots listed in Table 5-1 use long-life harmonic grease, it is not neces-
sary 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 YK500XG 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
YK500XG, YK600XG 80 80 30
YK600XGH, YK700XG, YK800XG, YK900XG, YK1000XG 80 80 50
Table 5-2 Bolt tightening torque

Bolt size Tightening torque (kgfcm) Tightening torque (Nm)
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
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 auto-
matic 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 tem-
perature has cooled.
• 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, apply-
ing 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.
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.
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.
! CAUTION
The harmonic drive service life may shorten if the grease recommended by
YAMAHA is not used.
5-10
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.
• Since a positional shift occurs after replacing the harmonic drive, it is neces-
sary to make absolute reset, standard coordinate setting and point data set-
ting again.
5-11
5-2-1 YK500XG, YK600XG, YK600XGH, YK700XG, YK800XG,

YK900XG, YK1000XG
The following steps describe procedures and precautions when replacing the har-
monic drives of the YK500XG and YK600XG. (The illustrations show the
YK500XG). For the bolt tightening torques in this work, refer to Table 5-2. Use
only YAMAHA genuine bolts or JIS B 1176 hex socket head bolts (strength class:
JIS B 1051 12.9).
1. X-axis
1) Prepare the following tools and items.
• Harmonic grease 4B No.2
• Waste cloth (rag)
• Phillips screwdriver
• Hex wrench set
• Screw Lock (thread sealant)
• Ratchet handle
• Hexagonal socket set
• Torque wrench (with ratchet)
• Replacement parts (See table below.)
• Hexagon long bit
<YK500XG, YK600XG>
For M6: installation diameter, 9.53 | outer diameter, 17 or less| 83 mm
(approx.) at full length
<YK600XGH to YK1000XG>
For M5: installation diameter, 9.53 | outer diameter, 17 or less| 128mm
(approx.) at full length
• Hexagon bit
<YK500XG, YK600XG>
For M4: installation diameter, 6.35
<YK600 to YK1000XG>
For M5: installation diameter, 9.53
YK500XG, YK600XG
Replacement parts
Parts name Type No. YAMAHA Parts No. Note
Harmonic drive SHG-25-80 KBF-M2110-000
q S90(JIS) KN4-M2143-000 Top of harmonic drive
O-ring w Rubber wire diameter 1.78mm × Ring inner diameter 66.4mm 90990-17J030 Base (robot pedestal)
e Rubber wire diameter 1.30mm × Ring inner diameter 66.50mm KN5-M257L-000 Supplied with harmonic drive

Replacement parts
q S511(JIS) KN5-M2159-000 Top of harmonic drive
O-ring w Rubber wire diameter 1.50mm × Ring inner diameter 82.00mm 90990-17J035 Base (robot pedestal)
e Rubber wire diameter 1.50mm × Ring inner diameter 87.50mm KN5-M2199-000 Supplied with harmonic drive
5-12
3) Place a sign indicating that the robot is being inspected, to keep others from
5) Remove the base front and rear covers. (See Fig. 5-2.)
6) Unplug the connectors on the X-axis motor power wire XM and resolver
wire XP in the base. Also disconnect the X-axis motor ring-tongue terminal.
! CAUTION
Carefully remove the motor not to pinch fingers between the motor and the
base. An O-ring w is placed between the motor mating end face and the base.
Replace this O-ring with a new one. (See Fig. 5-4 and Fig. 5-6.)
On the YK600XGH and YK700XG to YK1000XG, an O-ring is placed between
the motor flange end face and the base.
7) Remove the bolts securing the motor by using a hexagon long bit and ratchet
handle, while holding the motor not to let it drop (see Fig 5-3). Items in
parentheses ( ) apply to the YK600XGH, and YK700XG to YK1000XG.
8) Pull the motor out of the base while turning the X-axis arm.
9) Remove the wave generator from the motor shaft.

The wave generator is secured with a set screw (1 piece) and keyway (see
Fig. 5-6). A spacer and bolts need to be removed for YK600XGH and
YK700XG to YK1000XG.
! CAUTION
A spacer is inserted between the wave generator and the motor, so be careful
not to lose it. No spacer is used there for the YK600XGH, and YK700XG to
YK1000XG.
WARNING
• When you remove the X-axis arm installation bolts in the next step, the X-
axis arm may come off causing a hazardous situation. Be especially careful
to keep the arm from falling when a heavy tool is attached to the arm tip. (See
Fig. 5-4.)
• 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
"5-2-1" for removing the Y-axis arm.
10) Remove the X-axis arm installation bolts by using a hexagon bit and ratchet
handle. (See Fig. 5-4).
5-13
11) Remove the X-axis arm and place it where it will not obstruct the work.
12) Remove the bolts securing the X-axis harmonic drive and also remove the
panhead bolt along with the nut. (See Fig. 5-5.)
13) Remove the X-axis harmonic drive from the X-axis arm.
! CAUTION
An O-ring q is fitted to the X-axis arm. Replace this O-ring with a new one.
14) Fit a new O-ring q coated with harmonic grease into the O-ring groove of
the X-axis arm (See Fig. 5-5.). Grease to the O-ring is to prevent the O-ring
from coming off, so a small amount is enough.
Apply small amounts of "Screw Lock" to the bolts you removed earlier and
tighten them to secure the new harmonic drive to the X-axis arm. Also return
the panhead bolt and nut to the original position and secure them (See Fig. 5-
5.). Apply small amounts of "Screw Lock" to the panhead bolt. See 1-2 in 3-
4-1-1 for the panhead bolt tightening and tighten the bolt to the specified
torque.
! CAUTION
Do not allow the O-ring to get caught out of the groove during reassembly. A
problem 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. 5-7 for applying grease properly.
16) Fit a new O-ring e coated with harmonic grease into the O-ring groove of
the harmonic drive. Apply small amount of "Screw Lock" to the positioning
bolts, then fix the harmonic drive to the base with 16 pieces of bolt by using
hexagon bit and torque wrench (see Fig. 5-5 and Fig. 5-7). Tighten the bolts
to the specified torque.
! CAUTION
groove.
17) 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 set
screw (1 piece) you removed earlier and tighten it to secure the wave genera-
tor onto the motor shaft (see Fig. 5-6). For 600XGH and YK700XG to
YK1000XG, the wave generator need to be fixed with M5 bolts and spacers
prior to this step.
5-14
18) Place a new O-ring w in the cylindrical section of the base and push the O-
ring to the top end face. (See Fig. 5-4.)
! CAUTION
groove.
19) Push the X-axis motor into the base while moving the X-axis arm by hand.
Push the X-axis motor into the base while moving the X-axis arm by hand.
Uniformly tighten the four bolts by using the hexagon long bit and torque
wrench, while moving the X-axis arm 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. (See Fig. 5-3.)
20) Reattach the connectors on the X-axis motor power wire XM and resolver
wire XP. (See Fig. 5-2.) Also reattach the X-axis motor ring-tongue terminal.
21) Reattach the base (robot pedestal) front and rear covers.
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.
Cover
Cover The ring terminal for

the X-axis motor is
located behind the cover.
Disconnect the terminal.
Fig. 5-2
5-15
Base
M6×16
(M5×16)
X-axis motor
Fig. 5-3
5-16
M4×18
(M5×40)
O-ring w
O-ring w
YK500XG, YK600XG YK600XGH, YK700XG, YK800XG, YK900XG, YK1000XG

Fig. 5-4
5-17
O-ring q
M5 nut
(M6 nut) Harmonic drive
M4×30 (M5×40)
M4×30L (M5×40L) panhead bolt

O-ring e supplied with harmonic drive
During reassembly, reattach
this bolt to the same position
on the X-axis arm as before.
Fig. 5-5
M5×16 (YK600XG, YK700XG to YK1000XG only)
Spacer
M4 setscrew Wave generator
(supplied with harmonic drive) (Harmonic drive) Wave generator
(Harmonic drive)
M4 setscrew
(supplied with harmonic drive)
Motor mating end face
Motor flange end face

Motor flange end face
Do not remove this spacer.

Fig. 5-6
5-18
Apply grease to sufficiently fill in the ball space.
Wave generator
Apply grease to entire oldham coupling.

Apply grease to entire inner surface to
the thickness equal to ball diameter.
Fit O-ring (supplied) into this groove. Flexible spline
Circular spline
Never remove these temporarily tightened bolts.

The axis will otherwise deviate from center.
Fig. 5-7
5-19
2. Y-axis
• Hex wrench set
• Torque wrench
YK500XG, YK600XG
Replacement parts
q Rubber wire diameter 1.78mm × Ring inner diameter 72.75mm KN4-M257K-000 Lower part of harmonic drive
O-ring w Rubber wire diameter 1.50mm × Ring inner diameter 49.00mm KN3-M2143-000 For motor
e Rubber wire diameter 0.99mm × Ring inner diameter 53.28mm KN3-M2144-000 Supplied with harmonic drive

Replacement parts
Harmonic drive SHG-25-80 KBP-M2510-000
q S90(JIS) KN4-M2143-000 Lower part of harmonic drive
O-ring w Rubber wire diameter 1.78mm × Ring inner diameter 66.40mm 90990-17J030 For motor
e Rubber wire diameter 1.3mm × Ring inner diameter 66.50mm KN5-M257L-000 Supplied with harmonic drive
6) Unplug the connectors on the Y-axis motor power wire YM and resolver wire
YP in the Y-axis arm. Also disconnect the Y-axis motor ring-tongue terminal.
7) Remove the bolts securing the Y-axis motor, and slowly pull out the Y-axis
motor while turning the Y-axis joint. (See Fig. 5-9.)
Items in parentheses ( ) apply to the YK600XGH and YK700XG to
YK1000XG.
! CAUTION
An O-ring w is fitted to the motor. Replace this O-ring with a new one.
(See Fig. 5-12.)
5-20
8) Remove the wave generator from the motor shaft. The wave generator is
secured with a set screw (1 piece) and keyway. (See Fig. 5-12.)
WARNING
When you remove the Y-axis arm installation bolts in the next step, the Y-axis
arm may come off causing a hazardous situation. Be especially careful to keep
the arm from falling when a heavy tool is attached to the arm tip.
(See Fig. 5-10.)
9) Remove the Y-axis arm installation bolts. (See Fig. 5-10.)
10) Remove the Y-axis arm and place it where it will not obstruct the work.
! CAUTION
An O-ring e is fitted to the upper surface of the harmonic drive, so be careful
not to let it drop into the peripheral unit. (See Fig. 5-11.)
11) Remove the bolts securing the Y-axis harmonic drive and also remove the
panhead bolt along with the nut. (See Fig. 5-11.)
12) Remove the Y-axis harmonic drive from the top of the X-axis arm.
! CAUTION
An O-ring q is fitted to the upper surface of the X-axis arm. Replace this O-ring
with a new one.
13) Fit a new O-ring q coated with harmonic grease into the O-ring groove of
the X-axis arm. (See Fig. 5-11.)
14) Place the new harmonic drive on the X-axis arm and secure it with the bolts
you removed earlier. At this point, apply small amounts of "Screw Lock" to
those bolts and uniformly tighten them. Also return the panhead bolt and nut
to the original position and secure them. Apply small amounts of "Screw
Lock" to the panhead bolt. See 2-2 in 3-4-1-1 for the panhead bolt tightening
and tighten the bolt to the specified torque.
! CAUTION
groove.
15) Fit a new O-ring e coated with harmonic grease into the O-ring groove of
the harmonic drive. (Fig. 5-11.)
5-21
16) Secure the Y-axis arm to the harmonic drive with the bolts you removed earlier.
At this time keep the Y-axis arm level by two people so as not to apply a
moment to the Y-axis. One person supports the tip of the Y-axis arm. The
other person secures the Y-axis arm.
Apply small amounts of "Screw Lock" to the 16 bolts and tighten them uni-
formly to secure the Y-axis arm. (See Fig. 5-10.) Tighten the bolts to the
specified torque.
! CAUTION
groove.
17) Apply harmonic grease to the new wave generator and flexible spline.
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 set screw (1 piece)
you removed earlier and tighten it to secure the wave generator (See Fig. 5-
12.). On the YK600XGH and YK700XG to YK1000XG, do not forget to
insert a spacer.
19) Fit a new O-ring w to the motor and place the motor in the Y-axis arm while
turning the Y-axis joint. Then tighten the bolts you removed earlier to
temporarily secure the motor to the Y-axis arm. (See Fig. 5-9.)
On the YK600XGH and YK700XG to YK1000XG, fit the new O-ring w into
the groove in the Y-axis arm. (See Fig. 5-12.)
! CAUTION
problem will occur if the robot is operated with the O-ring left caught out of
groove.
20) Uniformly tighten the four bolts temporarily fastened in the previous step
while turning the Y-axis joint. If any jamming or catching is felt at this time,
then reassemble from the beginning.
21) Reattach the connectors on the Y-axis motor power wire YM and resolver
wire YP. (See Fig. 5-8.) Also reattach the Y-axis motor ring-tongue terminal.
22) Reattach the cover.
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
Cover
Cover
Y-axis arm
Disconnect this Y-axis motor

ring-tongue terminal located inside the cover.
Fig. 5-8
Y-axis motor
M5×12 (M6×16)
Fig. 5-9
5-23
M3×16 (M4×18)
X-axis arm
Fig. 5-10
5-24
O-ring e
M3×30 (M4×30)
M3×30L (M4×30L) panhead bolt

During reassembly, reattach
this bolt to the same position
on the X-axis arm as before.
Harmonic drive M4 nut (M5 nut)
O-ring q
Fig. 5-11
O-ring w
M3 setscrew Wave generator

(supplied with harmonic drive) (Harmonic drive)
YK500XG, YK600XG
Fig. 5-12
5-25
M4 setscrew
O-ring w
Wave generator
(Harmonic drive)
Do not forget to insert a spacer.

Fig. 5-12
5-26
3. R-axis
• Hex wrench set
• Torque wrench
• Hook wrench
YK500XG, YK600XG
Replacement parts
Harmonic drive SHF-17-30 KBF-M1821-000
q Rubber wire diameter 1.78mm × Ring inner diameter 63.22mm KN4-M1896-000 Lower part of harmonic drive
w Rubber wire diameter 0.80mm × Ring inner diameter 45.40mm KN3-M257L-000 Supplied with harmonic drive
O-ring e Rubber wire diameter 1.00mm × Ring inner diameter 35.3mm 90990-17J031 Spline nut
r Rubber wire diameter 1.00mm × Ring inner diameter 46.00mm 90990-17J032 Y-axis arm
t Rubber wire diameter 0.60mm × Ring inner diameter 22.00mm 90990-17J033 Wave generator
Edge seal V-25A (N+C) KBF-M1886-000 FORSHEDA

Replacement parts
Harmonic drive SHF-20-50 KBP-M1821-000
q S71(JIS) KN3-M2159-000 Lower part of harmonic drive
w Rubber wire diameter 0.99mm × Ring inner diameter 53.28mm KN3-M2144-000 Supplied with harmonic drive
O-ring e Rubber wire diameter 1.00mm × Ring inner diameter 43.00mm 90990-17J036 Spline nut
r Rubber wire diameter 1.30mm × Ring inner diameter 53.00mm 90990-17J038 Y-axis arm
t Rubber wire diameter 0.5mm × Ring inner diameter 28.00mm 90990-17J037 Wave generator
Edge seal V-28A (N+C) KBP-M1886-000 FORSHEDA

Unplug the connectors on the R-axis motor power wire RM and resolver
wire RP in the Y-axis arm. Also disconnect the R-axis motor ring-tongue
terminal.
WARNING
The Z-axis will slide down when the bearing mounting bolts are removed in the
next step, causing a hazardous situation. Prop the Z-axis with a support stand
before loosening these bolts. (See Fig. 5-14.)
5-27
6) Remove the bolts securing the bearing to the upper end of the spline and
remove the spline and bearing from the holder. (See Fig. 5-14.)
7) Fit the spanner or wrench to the flat surfaces at the bottom of the spline to
grip it, and loosen and remove the U-nut on top of the spline with the hook
spanner. Then remove the bearing and bearing mount plate. (See Figs. 5-15
and 5-16.)
At this point, be careful to keep the spline shaft from coming off the spline
nut.
8) Remove the bolts securing the spline nut and remove the spline nut.
(See Fig. 5-16.)
! CAUTION
An O-ring e is fitted to the shaft. Replace this O-ring with a new one. Also
replace the V-ring with a new one. Do not remove the sleeve. (See Fig. 5-16.)
9) Remove the bolts securing the R-axis motor and pull out the R-axis motor
while turning the R-axis. (See Fig. 5-17.)
! CAUTION
An O-ring r is placed between the R-axis motor flange and the Y-axis arm.
Replace this O-ring with a new one. (See Fig. 5-17.)
10) Loosen the two setscrews for the wave generator.

Pull the wave generator out of the R-axis motor shaft. (See Fig. 5-20.)
! CAUTION
An O-ring t is placed between the R-axis motor shaft and the wave generator.
Replace this O-ring with a new one. (See Fig. 5-20.)
11) Remove the bolts securing the harmonic drive and remove the harmonic drive.
(See Fig. 5-18.)
! CAUTION
An O-ring w is fitted to the harmonic drive. Replace this O-ring with a new one.
(See Fig. 5-18.)
12) Remove the shaft mounting bolts from the harmonic drive and also remove
the panhead bolt along with the nut. Then remove the shaft.
On the YK600XGH and YK700XG to YK1000XG, remove the dog and bolt.
(See Fig. 5-19 (b).)
! CAUTION
An O-ring q is placed between the harmonic drive and shaft. Replace this O-
ring with a new one. (See Fig. 5-19 (a) (b).)
5-28
13) Apply the harmonic grease to the new wave generator. See Fig. 5-21 for
applying the grease.
14) Fit the O-ring t to the inner side of the new wave generator. Insert the wave
generator into the inner end of the R-axis motor shaft and secure it with the
two setscrews. (See Fig. 5-20.)
15) Apply harmonic grease to the circular spline.

16) Fit a new O-ring q coated with harmonic grease into the groove of the shaft.
tighten them to secure the new harmonic drive. Also return the panhead bolt
and nut to the original position and secure them. Apply small amounts of
"Screw Lock" to the panhead bolt. The panhead bolt tightening torque should
be 90cNm (9kgfcm). On the YK600XGH and YK700XG to YK1000XG,
also apply "Screw Lock" to the dog mounting bolt and tighten it to a torque
of 2.0Nm (20kgfcm). (See Fig. 5-19 (b).)
! CAUTION
groove.
17) Fit the O-ring w coated with harmonic grease into the O-ring groove of the
new harmonic drive. (See Fig. 5-18.)
tighten them to secure the new harmonic drive to the Y-axis arm from the top
of the Y-axis arm. (See Fig. 5-18.)
! CAUTION
groove.
18) Fit the new O-ring r coated with harmonic grease into the O-ring groove of
the Y-axis arm.
Insert the R-axis motor into the Y-axis arm while turning the R-axis. Then
tighten the bolts to secure the R-axis motor while turning the R-axis. (See
Fig. 5-17.)
! CAUTION
groove.
5-29
19) Fit the new O-ring e coated with harmonic grease into the groove at the
bottom of the shaft. Attach a new V-ring to the top of the sleeve and secure
the spline nut to the shaft with the bolts you removed earlier. (See Fig. 5-16.)
! CAUTION
groove.
20) Insert the bearing mount plate and bearing onto the spline from the top, and
tighten the U-nut to secure the bearing. (Utilize the flat surfaces when
tightening the U-nut like you did to loosen it.) On the YK600XGH and
YK700XG to YK1000XG, do not forget to insert a spacer. (See Fig. 5-15.)
21) Insert the spline and bearing through the holder and secure them with the
bolts you removed earlier. (See Fig. 5-14.)
22) Reconnect the R-axis motor power wire RM and resolver wire RP.
Also reconnect the R-axis motor ring-tongue terminal.
23) Reattach the cover.
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.
5-30
Cover
Cover
Disconnect this R-axis motor

ring-tongue terminal located inside the cover.
Fig. 5-13
Holder
Bearing mount plate
M5×14
Spline
Fig. 5-14
5-31
U-nut
U-nut
Spacer
Bearing
Bearing
Flat surface
Flat surface
Bearing mount plate Bearing mount plate
M5×14

Fig. 5-15
V-ring
Degrease and make it tight contact with sleeve.
Shaft
O-ring e
Sleeve
Do not remove this sleeve from spline nut.
M4×10
(M5×14) Spline nut
Fig. 5-16
5-32
R-axis motor
M5×14
(M6×16)
O-ring r
Fig. 5-17
5-33
M3×14
(M3×16)
O-ring w
Fig. 5-18
5-34
M3×25
O-ring w
M3×30L panhead bolt
Harmonic drive
M4 nut
O-ring q
Shaft
YK500XG, YK600XG
Fig. 5-19 (a)
5-35
M3×25
O-ring w
M3×30
Dog
Harmonic drive
O-ring q
Shaft

Fig. 5-19 (b)
5-36
R-axis motor
O-ring t
Wave generator
(Harmonic drive)
M4 setscrew
(M3 set screw)
Tightening torque
YK500XG, YK600XG: 7kgfcm (0.7Nm)
YK600XGH to YK1000XG: 17kgfcm (1.7Nm)
Fig. 5-20
5-37
Apply grease only to

ball parts.
Wave generator ball
• Apply grease to fill the space around the ball.
Do not apply grease thicker

than 0.5mm to the area above
the end face seal lip.
End face seal lip

• Apply slight amount of grease to
the lip only.
• Remove all grease that remain
inside the lip.
Harmonic grease
• Apply grease every around.
• Be cautious about the amount
of grease; amounts of the grease
applying to the area above and
below the end face seal lip are
different.
Below the end face seal lip, apply grease as thick as

the diameter of the wave generator ball.
Fig. 5-21
5-38
CHAPTER 6
Increasing the robot

operating speed
1 Increasing the robot operating speed ...............................................................6-1
MEMO
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 user'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
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 pa-
rameter 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
(2) Increasing the speed with the WEIGHT statement

("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
(3) Increasing the speed by the tolerance parameter

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

("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 posi-
tion 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 Robot inner wiring diagram............................................................................................. 7-2
1-3 Wiring table ..................................................................................................................... 7-3
MEMO
1 Manipulator
1-1 Basic specification

Robot model YK500XG YK600XG Robot model YK500XG YK600XG
Arm length 200mm 300mm Repeatability *1 XY-axes ±0.01mm ±0.01mm
X-axis
Rotation angle ±130° ±130° Z-axis ±0.01mm ±0.01mm
Axis
Arm length 300mm 300mm R-axis ±0.005° ±0.005°
specifi- Y-axis
Rotation angle ±145° ±145° Payload 10kg
cations
Z-axis Stroke 200, 300mm 200, 300mm R-axis tolerable moment of inertia *2 0.30kgm2 (3.0kgfcms2)
R-axis Rotation angle ±360° ±360° User wiring 20 cables
X-axis 400W 400W User tubing φ6×3
Y-axis 200W 200W Travel limit 1.Soft limit 2.Mechanical limit (XYZ-axes)
Motor
Z-axis 200W 200W Robot cable 3.5m (option: 5m, 10m)
R-axis 200W 200W Weight 30kg 31kg
XY resultant 7.6m/s 8.4m/s
Maximum 2.3m/s (200mm stroke Z-axis)
Z-axis
speed 1.7m/s (300mm stroke Z-axis)
R-axis 1700°/s 1700°/s
*1 At constant ambient temperature (XY)
*2 There are limits to acceleration coefficient settings.
Robot model YK600XGH YK700XG YK800XG YK900XG YK1000XG

Arm length 200mm 300mm 400mm 500mm 600mm
X-axis
Rotation angle ±130° ±130° ±130° ±130° ±130°
Axis Arm length 400mm 400mm 400mm 400mm 400mm
specifi- Y-axis
cations Rotation angle ±150° ±150° ±150° ±150° ±150°
Z-axis Stroke 200, 400mm 200, 400mm 200, 400mm 200, 400mm 200, 400mm
R-axis Rotation angle ±360° ±360° ±360° ±360° ±360°
X-axis 750W 750W 750W 750W 750W
Y-axis 400W 400W 400W 400W 400W
Motor
Z-axis 400W 400W 400W 400W 400W
R-axis 200W 200W 200W 200W 200W
XY resultant 7.7m/s 8.4m/s 9.2m/s 9.9m/s 10.6m/s
2.3m/s (200mm stroke Z-axis)
Maximum speed Z-axis
1.7m/s (400mm stroke Z-axis)
R-axis 1020°/s 1020°/s 1020°/s 1020°/s 1020°/s
XY-axes ±0.02mm ±0.02mm ±0.02mm ±0.02mm ±0.02mm
Repeatability *1 Z-axis ±0.01mm ±0.01mm ±0.01mm ±0.01mm ±0.01mm
R-axis ±0.005° ±0.005° ±0.005° ±0.005° ±0.005°
Payload 20kg
R-axis tolerable moment of inertia *2 1.0kgm2 (10.0kgfcms2)
User wiring 20 cables
User tubing φ6×3
Travel limit 1.Soft limit 2.Mechanical limit (XYZ-axes)
Robot cable 3.5m (option: 5m, 10m)
Weight 48kg, 50kg 50kg, 52kg 52kg, 54kg 54kg, 56kg 56kg, 58kg
*1 At constant ambient temperature (XY)
*2 There are limits to acceleration coefficient settings.
Noise level
Maximum sound pressure level of the robot (when there is 10dB Position where the maximum sound
or larger difference from the back ground sound pressure level) pressure is measured
1 meter apart from the back of the robot,
78.4dB
1.6m height from the floor surface.
Note: The noise level can be higher when the robot is set nearby the objects that cause sound reflection.
7-1
1-2 Robot inner wiring diagram
User tubing
Machine harness
User IO connector
IO
RORG RORG ZP ZP YORG YORG

RP RP ZBKG ZBKG YP YP
R-axis resolver Y-axis resolver
R-axis motor RM RM ZM ZM YM YM Y-axis motor
Round terminal
R-axis origin sensor Y-axis origin sensor
X-axis arm
Z-axis motor
Y-axis arm
Z-axis brake
Z-axis resolver
X-axis origin sensor
X-axis motor
XORG
X-axis resolver
XP XP
XM XM
YM YM
XORG
ZM ZM
RM RM User tubing
YP YP
ZP ZP
IO User IO connector
RP RP
YORG YORG
XM
ZORG
YM
RORG RORG
ZBK ZBK ZM
FG FG
RM
FG
XY
ZR
Robot cable
Round terminal M4 ground terminal
YK500XG,YK600XG, YK600XGH, YK700XG, YK800XG, YK900XG, YK1000XG
Fig. 7-1
7-2
1-3 Wiring table

Robot cable wiring table
Signal Connector No Connection No Connector Color Wire

Resolver S2 1 1 Orange-1-Red 0.15sq
S4 2 2 Orange-1-Black Twisted pair
S1 3 3 Gray-1-Red 0.15sq
XP
S3 4 4 Gray-1-Black Twisted pair
R1 5 5 Sky blue-2-Red 0.15sq
R2 6 6 Sky blue-2-Black Twisted pair
DG 7 7 Green 0.3sq
S4 YP 2 20 Orange-2-Black Twisted pair
S1 3 21 Bright green-2-Red 0.15sq
XY
S3 4 22 Bright green-2-Black Twisted pair
R1 5 23 Pink-2-Red 0.15sq
R2 6 24 Pink-2-Black Twisted pair
DG 7 25 Green 0.3sq
FG FG 1 18 Gray-2-Red 0.15sq
36 Gray-2-Black 0.15sq
HLIM 10 Green 0.3sq

GND24 11
HLIM 28 Green 0.3sq
GND24 29
Origin Sensor GND 3 13 Sky blue-3-Red 0.15sq
ORG XORG 2 12 Sky blue-3-Black Twisted pair
24V 1 9 Pink-3-Red 0.15sq
Origin Sensor 24V 1 27 Pink-3-Black Twisted pair
ORG YORG 2 30 Bright green-1-Red 0.15sq
GND 3 31 Bright green-1-Black 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
7-3

S4 2 2 Orange-1-Black Twisted pair
S1 3 3 Gray-1-Red 0.15sq
ZP
S3 4 4 Gray-1-Black Twisted pair
R1 5 5 Sky blue-2-Red 0.15sq
R2 6 6 Sky blue-2-Black Twisted pair
DG 7 7 Green 0.3sq
Brake MB+ 1 14 Pink-1-Red 0.15sq
ZBK
MB- 2 16 Pink-1-Black Twisted pair
15 Sky blue-1-Red 0.15sq
ZR
17 Sky blue-1-Black Twisted pair
S4 RP 2 20 Orange-2-Black Twisted pair
S1 3 21 Bright green-2-Red 0.15sq
S3 4 22 Bright green-2-Black Twisted pair
R1 5 23 Pink-2-Red 0.15sq
R2 6 24 Pink-2-Black Twisted pair
DG 7 25 Green 0.3sq
FG FG 1 18 Gray-2-Red 0.15sq
36 Gray-2-Black 0.15sq
HLIM 10 Green 0.3sq

GND24 11
HLIM 28 Green 0.3sq
GND24 29
Origin Sensor 24V 3 13 Sky blue-3-Red 0.15sq
ORG ZORG 2 12 Sky blue-3-Black Twisted pair
GND 1 9 Pink-3-Red 0.15sq
Origin Sensor 24V 1 27 Pink-3-Black Twisted pair
ORG RORG 2 30 Bright green-1-Red 0.15sq
GND 3 31 Bright green-1-Black 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
7-4
Machine harness wiring table (YK500XG, YK600XG, YK600XGH,

YK700XG, YK800XG, YK900XG, YK1000XG)
Y-axis arm side Base side
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
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
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
7-5
Motor wiring table

Signal Color Connection No. Connector
S2 Blue 1
S4 Blue Black 2
S1 Brown 3
S3 Brown Black 4 XP,YP,ZP,RP
Resolver
R1 Red 5
R2 Black 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 Blue 2
Origin sensor wiring table

Signal Color Connection No. Connector
+24V Brown 1
ORG Black 2 XORG, YORG, RORG
0V Blue 3
7-6
MEMO
User's Manual
SCARA Robot YK-XG series

Jul. 2008
Ver. 1.08
This manual is based on Ver. 1.08 of Japanese manual.
© 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
reliable. 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.

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YAMAHA SCARA ROBOT

User’s Manual ENGLISH

2. Affixing the origin position sticker

2. If the X, Y or R axis rotation angle is small.

3. Do not remove the Z-axis upper-end mechanical stopper

This manual describes the YK500XG, YK600XG, YK600XGH, YK700XG,

YAMAHA MOTOR CO., LTD.

CHAPTER 1 Using the Robot Safely

3 Protective Bonding .......................................................................................3-9

7 Limiting the Movement Range with X-Axis Mechanical Stoppers ..............3-30

8 Working Envelope and Mechanical Stopper Positions for Maximum Working

4 Setting the Soft Limits ................................................................................4-31

CHAPTER 6 Increasing the robot operating speed

Using the Robot Safely

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

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

2 Essential Caution Items

(1) Observe the following cautions during automatic operation.

■Fig. 1-1 Warning label 1

■Fig. 1-3 Warning label 3

■Fig. 1-4 Warning label 4

(5) Do not use the robot in environments containing inflammable

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

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

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

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

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

If the following damages or troubles exist These dangers can happen

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

(18) Protective bonding

(19) Be sure to make correct parameter settings.

(21) If the X, Y or R axis rotation angle is small

3 Special Training for Industrial Robot Opera-

4 Robot Safety Functions

(5) Z-axis (vertical axis) brake

5 Safety Measures for the System

7 Work Within the Safeguard Enclosure

(1) Check the following before starting automatic operation.

9 Adjustment and Inspection

10 Repair and Modification

Warranty description : If a failure or breakdown occurs due to defects

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

YAMAHA MOTOR CO., LTD. MAKES NO OTHER EXPRESS OR IMPLIED

1 Robot Manipulator ............................................................................................2-1

Fig. 2-1 Manipulator movement

User tubing 1 (φ6 black)

Eyebolt installation position

User tubing 3 (φ6 blue)

Y-axis mechanical stopper X-axis speed reduction gear

End effector attachment M4 ground terminal

Tapped hole and screw for user

Fig. 2-2 YK500XG, YK600XG, YK600XGH, YK700XG, YK800XG, YK900XG, YK1000XG

3 Robot initialization number list

Robot initialization number Model name

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

3 Protective Bonding ...........................................................................................3-9

7 Limiting the Movement Range with X-Axis Mechanical Stoppers ..................3-30

8 Working Envelope and Mechanical Stopper Positions for Maximum Working

1 Robot Installation Conditions

1-1 Installation environments