YR-MA02010-A10

Operating and maintenance

instructions

MA2010
Created on: 12/2014
Revision: 4
Document number: E1101000192GB04 Author: WOE

Changes made in revision:

Rev. 1: Revised version of the original HW1482758.0 in YEU-R style (08/2014)
Rev. 2: Revised version of the table: Forces and moments of the robot (11/2014)
Rev. 3: Revised version of the original HW1482758.2 (Chapter "Internal user I/O wiring
harness and air lines" as well as chapter "Spare parts") (11/2014)
Rev. 4: Revision of the chapter "Technical data"

© Copyright 2014
This documentation – also in part – may be reproduced or made available to third parties only with the
express approval of YASKAWA Europe "Robotics Division GmbH".
We have checked the content of this publication for compliance with the hardware described.
Nevertheless, discrepancies cannot be ruled out. Therefore, we cannot guarantee full compliance.
However, the information given in this publication is checked regularly and any necessary corrections
will be made in subsequent editions.
Subject to technical modifications.
 Table of contents

Table of contents

1 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.1 Notes for safe operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 5
1.2 Frequently used terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 5
1.3 Target group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 6
1.4 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 6
1.5 Improper use. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 6
1.6 About this manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 7
1.7 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 8
1.8 Manufacturer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.9 Authorized representative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

2 Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.1 Checking the scope of delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.2 Position type plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

3 Transportation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.1 Transporting method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.1.1 Using a crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.1.2 Using a forklift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.2 Shipping brackets and bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

4 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.1 Installing protective equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.2 Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4.3 Installation example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

5 Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5.1 Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5.2 Cable connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5.2.1 Connecting the robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
5.2.2 Connecting the robot control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5.2.3 Connecting the programming pendant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

6 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
6.1 Parts and work axis label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
6.2 Robot base dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
6.3 Dimensions and defined working area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
6.4 Adjustable working area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
6.5 Stopping Angle and Time at the Emergency Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
6.5.1 Stop category 0. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
6.5.2 Stop category 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

7 Allowable load for wrist axis and wrist flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

7.1 Wrist flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
7.2 Maximum load of the S-axis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
7.3 Optimal robot performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
7.4 Allowable Wrist Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
7.5 Maximum capacity load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

3
Table of contents

8 Internal cables and compressed air lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

9 Maintenance and inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

9.1 Inspection schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
9.2 Note on battery unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
9.2.1 Changing battery unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
9.2.2 Battery pack connector (including warning note) . . . . . . . . . . . . . . . . . . . . . . . . 56
9.2.3 Note on maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
9.3 Instructions on grease replenishment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
9.3.1 Grease replenishment/exchange for S-axis reduction gear unit. . . . . . . . . . . . . 59
9.3.2 Grease replenishment/exchange for L-axis reduction gear unit . . . . . . . . . . . . . 60
9.3.3 Grease replenishment/exchange for U-axis reduction gear unit. . . . . . . . . . . . . 61
9.3.4 Grease replenishment/exchange for R-axis gear . . . . . . . . . . . . . . . . . . . . . . . . 62
9.3.5 Grease replenishment/exchange for B- and T-axes gear . . . . . . . . . . . . . . . . . . 63
9.3.6 Replenishment/Exchange for R-axis cross roller bearings . . . . . . . . . . . . . . . . . 65
9.4 Home position calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
9.4.1 Register all axes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
9.4.2 Register individual axes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
9.4.3 Changing absolute data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
9.4.4 Clearing absolute data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
9.5 Setting the second home position (check point) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
9.5.1 Purpose of position check operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
9.5.2 Procedure for the second home position setting . . . . . . . . . . . . . . . . . . . . . . . . 73
9.5.3 Procedure after alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

10 Recommended spare parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

11 Parts lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
11.1 S-axis unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
11.2 L-axis unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
11.3 U-axis drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
11.4 R-axis unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
11.5 Wrist unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
11.6 Gear unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

4
 General

1 General
1.1 Notes for safe operation

DANGER!
Indicating immediate danger at high risk, hazard that can cause death or serious bodily
injuries if no precautions are taken.

WARNING!
Indicating possible medium risk hazard situation which can cause death or serious bodily
injuries if it is not avoided.

CAUTION!
Indicating potentially dangerous situation with low risk of minor or moderate bodily injuries
result if it is not avoided. This signal word can also be used for property damage warnings.

NOTICE
Indicates important background information and application advice.

1.2 Frequently used terms

The YASKAWA robot is a product of YASKAWA Electric Corporation, and is provided by
default with the robot controller, the programming pendant and robot cable.
The terms are designated as follows in this manual:

Definitions Used
Control Robot controller
Industrial robot Robot
Programming pendant / teach box Programming pendant
Supplying cable between robot and robot Cable
controller
Robot, robot controller and cable Robot system
Yaskawa Electric Corporation YEC
YASKAWA Robotics Division YEU-R
Move, calibrate and setup of the robot Teachen
Movement sequences of the robot JOBs
Technical customer service TCS

1 -5
General

1.3 Target group

This manual is directed at users with the following knowledge:
• Advanced knowledge of mechanical engineering
• Advanced knowledge of electrical engineering
• System knowledge of the robot controller
• Specially trained staff

NOTICE
According to the international DIN EN ISO 10218-1 standard, operators of a robot system
must receive training before they operate the robot.
For optimal use of our products, we recommend our customers to take part in a training
session at the YASKAWA Academy. For information on the training programme, please visit
www.yaskawa.eu.com or contact our branch offices directly.

1.4 Intended use

Typical applications:
• Flange-mounting tools
• Installation of spot welding guns
• Installation of arc welding equipment
• Installation of grippers
• Machining and transporting workpieces or products

1.5 Improper use

Any use that deviates from the intended use shall be regarded as impermissible misuse.
This includes:
• Transport of people and animals
• Use as ascending aid.
• Use outside the permissible operating limits.
• Use in environments with risk of explosion (except for ATEX-approved robots).
• Overload
• Use without protective equipment.

NOTICE
Modifications to the robot, e.g. drilling holes or similar modifications, can damage parts.
This will be regarded as improper use (i.e. use that deviates from the intended use) and will
lead to loss of warranty and liability claims as well as loss of the declaration of incorporation.

CAUTION!
The robot system is an incomplete machine.
The robot system may be put into operation only after it has been determined that the
incomplete or complete machine in which the robot system is being installed:
 Corresponds to the provisions of the Machinery Directive.
 Complies with all relevant (harmonized) standards.
 Corresponds to the state of the art.

1 -6
 General

1.6 About this manual

• This instruction manual is intended to explain mainly on the mechanical part of the robot
for the application to the actual operation and for proper maintenance and inspection.
It describes on safety and handling, details on specifications, necessary items on
maintenance and inspection, to explain operating instructions and maintenance
procedures. Be sure to read and understand this instruction manual thoroughly before
installing and operating the robot.
• To ensure correct and safe operation, read the robot control operating instructions
(basic information, installation and wiring and system setup).
• In order to illustrate details clearly, some drawings are shown with the protective covers
or shields removed. All protective covers and shields must be mounted before the robot
is operated.
• The drawings and figures in this manual are representative illustrations. They may differ
from the product delivered.
• YEU-R reserves the right to make technical changes. These changes may include
product improvements, modifications or changes in specifications
• If your copy of the operating and maintenance instructions is damaged or lost, please
contact the local YASKAWA branch office to order a new copy. The official branch
offices are listed on the last page. Please mention the manual number in your order.
• YASKAWA Europe GmbH is not responsible for damage caused due to unauthorized
modification of the painting robot track. If any impermissible modifications are made to
the system and to the robot, all warranty and liability claims as well as the declaration
of incorporation will expire.

1 -7
General

1.7 Safety

REMOTE TEACH
START HOLD
1
PLAY

JOB EDIT DISPLAY UTILITY

JOB CONTENT
-TEST01 S:0000
CONTROL GROUP:R1 TOOL:
0000 NOP
0001 SET B000 1
0002 SET B001 0
0003 MOVJ VJ=80.00
0004 MOVJ VJ=80.00
0005 DOUT OT#(10) ON
0006 TIMER T=3.00
0007 MOVJ VJ=80.00
0008 MOVJ VJ=100.00
0009 MOVJ VJ=100.00
0010 MOVJ VJ=100.00
0011 MOVJ VJ=100.00
MOVJ VJ=0.78

Main Menu Short Cut Turn on servo power

LAYOUT TOOL SEL GO BACK

DIRECT
COORD OPEN
Multi PAGE AREA
ENTRY
SERVO
SELECT
MAIN SIMPLE ON CANCEL
MENU MENU READY ASSIST

SERVO ON
X- X+ X- X+
S- S+ R- R+
HIGH
SPEED
Y- Y+ Y- Y+
L- L+ B- B+
FAST
Z- Z+ MANUAL SPEED
Z- Z+
U- U+ T- T+
SLOW
E- E+ 8- 8+

INTER 7 8 9 TEST
SHIFT
SHIFT
LOCK START

ROBOT INFORM 4 5 6 BWD FWD

LIST

EX.AXIS
WELD 1 2 3 DELETE INSERT
ON/OFF

MOTION 0 . -
AUX MODIFY ENTER
TYPE

Fig. 1-1: Programming pendant

1 Emergency stop button

WARNING!
Death or injury because of danger of crushing
If the emergency stop button does not function properly, the robot cannot be stopped in the
event of an emergency.
 The robot should not be used if the emergency stop button does not function.
 Before operating the manipulator check the emergency stop button. The SERVO power
must be deactivated immediately when the emergency stop button is pressed (see Fig.
1-3: "Emergency stop button") on the programming pendant.
 When the SERVO power is turned OFF, the "SERVO ON" LED (see Fig. 1-2: "LED
SERVO ON") on the programming pendant.

SERVO ON
Fig. 1-2: LED SERVO ON

Fig. 1-3: Emergency stop button

1 -8
 General

WARNING!
Death or injury because of danger of crushing
Before you release the emergency stop button (see Fig. 1-4: "Release of emergency stop
button by turning") note the following:
 Make sure that there is no one within the maximum working range of the robot.
 Clear the cell of all items which could collide with the robot.
 Now you can switch ON the servo voltage by pressing the hold-to-run button on the
programming pendant.

Fig. 1-4: Release of emergency stop button by turning

WARNING!
Death or injury because of danger of crushing
if anyone enters the working area of the robot during operation or any problems occur,
always press the emergency stop button immediately. This is located on the programming
pendant (see Fig. 1-1: "Programming pendant").
Observe the following precautions when performing teaching operations within the
operating range of the robot:
 View the Robot from the front whenever possible.
 Always follow the prescribed operating procedure (see the instructions on robot control
as well as the operating instructions on "Handling" or "Universal Application").
 An area must be left clear so that the operator can retreat to it in case of emergency.

The following inspection procedures must be performed prior to teaching the robot. If
problems are found, correct them immediately, and be sure that all other necessary
processing has been performed.
• Check for problems in robot movement.
• Check the connectors for tight fit and all cables for damage.
• Hang the programming pendant back on the robot controller after use.
• Make sure that the key for the operating mode selector switch (Teach/Automatic) of the
programming pendant is kept by a skilled person who has been specially trained.
• The key may be inserted in the key switch of the programming pendant only during
teach operation; after the teach operation it must be immediately removed and kept in
a safe place.

1 -9
General

1.8 Manufacturer
Address:
YASKAWA ELECTRIC CORPORATION
2-1 KUROSAKISHIROISHI
YAHATANISHI-KU
KITAKYUSHU
JAPAN

1.9 Authorized representative

Address:
YASKAWA Europe GmbH
Robotics Division
Yaskawastr. 1
85391 Allershausen
Germany

1 - 10
 Supply

2 Supply
2.1 Checking the scope of delivery
The standard delivery includes the following items:

1 2

DX200

MOTOMAN
MANU AL

4 5

Fig. 2-1: Scope of supply

1 Programming pendant 4 The present assembly instructions

2 Robot controller 5 Cable
3 Robot

2 - 11
Supply

2.2 Position type plate

Verify whether the serial number of the robot, the robot controller and the programming
pendant with the delivery. The serial number can be found on the type plate as shown
below.

S/N.

YASAKAW DX200
Part No.
Power Supply Peak kVA
AC 400/415/440 Average kVA
Serial No.
Date/Signature
Type ERDR-
Robot Type
Robot Order No.
Robot Serial No.

YASKAWA ELECTRIC CORPORATION

2-1 SHIROISHI KUROSAKI, YAHATANISHILU KITAKYUSYU, JAPAN

YASKAWA Europe „Robotics Division“ GmbH

Yaskawastr. 1, D-85391 Allershausen
DX200

Fig. 2-2: Position type plate

NOTICE
Please contact the local YASKAWA branch office if the serial numbers do not match the
information on the delivery note.

2 - 12
 Transportation

3 Transportation
CAUTION!
Personal injury or damage to property
The system consists of precision components. If this precaution is not taken, performance
may be impaired.
 A crane or forklift may only be operated by authorised personnel. The same applies to
the use of slings.
 Avoid strong vibrations or impacts during transportation.
 No external forces may be exerted on the robot controller.

3.1 Transporting method

CAUTION!
Damage to persons and damage to property due to external force influences
 External forces must not be exerted on the robot or the motors.

• Check that the eyebolts are securely fastened.

• The robot weights approximately 280 kg. Use load carrying devices strong enough to
withstand the weight.
• The transport safety devices support the robot; therefore, use them exclusively for the
transport of the robot.
• Before transport, be sure to mount the shipping bolts and brackets to the robot.

3 - 13
Transportation

3.1.1 Using a crane

Adequate load handling devices must be used to transport the robot. Make sure that the
robot is lifted as shown in the diagram "Transport by crane".

2 A

A B
3

Fig. 3-1: Transport with crane

1 Shipping bracket and bolts 3 2 screws M12 x 30

2 View A

3 - 14
 Transportation

3.1.2 Using a forklift

If the robot is transported using a forklift, it should be fixed on a pallet with transport securing
devices and shipping bolts as shown in the figure below "Transport using a forklift". Make
sure that the forklift and the transportation route have sufficient bearing capacity.
Always take due care when transporting the robot.

%&
%&
1
%&

Fig. 3-2: Using a forklift

1 4 screws M16 3 Forklift claw entries

2 Palette

3 - 15
Transportation

3.2 Shipping brackets and bolts

The robot is equipped with transport securing devices and shipping bolts to reduce external
forces to a minimum during transport.
• The shipping brackets and bolts are painted yellow.
• The shipping bracket will be fastened by 2 screws M12.

2 3 4

Fig. 3-3: Shipping brackets and bolts

1 Shipping brackets 3 2 screws M12 x 30

2 Side view 4 Front view

NOTICE
Before turning ON the power, check to be sure that the shipping bolts and brackets are
removed.
After removing the transport securing devices and the shipping bolts, keep them at a safe
place. The transport securing devices and shipping bolts will be required again if the system
is transported again.

NOTICE
Before turning ON the power, check to be sure that the rubber buffer are removed.
After removing the rubber pads, keep them at a safe place. The rubber pads will be required
again if the system is transported again.

For transportation purposes the robot is fitted in the range A and B with a rubber buffer
(see Fig. 3-4: "Damping material for transport").

Fig. 3-4: Damping material for transport

3 - 16
 Installation

4 Installation
CAUTION!
Personal injury and damage to property
The following precautions must be taken.
 Check that the robot controller is complete and not damaged.
 Do not put into operation a robot controller that is damaged or incomplete.
 Check that all transport safety devices and transport screws have been removed.

4.1 Installing protective equipment

To ensure safe operation, the following procedures are to be taken into account.

DANGER!
Personal injury and material damage
The robot system must not be operated without protective devices. Starting up without
appropriate protective measures can lead to death of people, serious bodily harm or
damage to property.
Install following safeguardings:
 Separating protection devices
 Non-contact protection devices
 Enclosures
 Marked areas
 Signs
 Emergency stop button
 Display elements

NOTICE
Operator's responsibility
The operator of a robot or a robot system must ensure that all specifications and
requirements of the standards DIN EN ISO 10218-1 and DIN EN ISO 10218-2 are met.
In the first instance, the following must be observed:
 Preparing a risk assessment
 The installation of protective devices
 Regular training of the employees
 Regular inspection of all protective devices
 Checking for compliance with intended use

4 - 17
Installation

4.2 Location
When installing a robot, it is necessary to satisfy the undermentioned environmental
conditions:
• Ambient temperature: from 0° C to + 45° C.
• Air humidity: 20% to 80% relative humidity (non-condensing).
• No corrosive gases, liquids or explosive gases. No water, oil, dust and free from
excessive electrical noise (plasma).
• Free from excessive vibration (Vibration acceleration: 4.9 m/s² [0.5 G] or less).
• Maximum unevenness of the support surface of the robot base: 0.5 mm.

4.3 Installation example

1. At the first setout, anchor the baseplate firmly onto the floor.
2. The robot base is tapped for 4 mounting holes. Fix the robot base with the screws M16
(Strength category 12.9) Minimum length: 50 mm.
3. Next, fix the Robot base to the base plate. Tighten the hexagon head bolts and anchor
bolts securely so that they will not work loose during operation (see figure „Mounting the
robot on the Baseplate“).

4 - 18
 Installation

1 2

25
5
6

7 375
4
335

316 200±0.1
60
10 9
200±0.1

335
375
292

170±0.1

60
8
260±0.1

Fig. 4-1: Mounting the robot on the base plate

1 Screws 6 at least 25 mm
2 Spring washer 7 Anchor bolt (M16 or greater)
3 Washer 8 2 holes Ø 12 H7
4 Robot base 9 4 holes Ø 18
5 Base plate 10 adhesive

4 - 19
Installation

520

x)
25

(4
335

36
580
335

260
520
80

8x)
260
24 (

580

Fig. 4-2: Base plate

Horizontal direction Vertical direction

Force FH Moment MH Force FV Moment MV
Emergency stop 8820 N 6370 Nm 10290 N 13720 Nm
Acceleration 2940 N 1915 Nm 3430 N 5145 Nm
Deceleration
Tab. 4-1: Forces and moments of the robot

MV

FV

MH

FH

Fig. 4-3: Robot Force and Torque

4 - 20
 Installation

Types of Mounting
The robot can be mounted in the following positions:

1 2 3 4

Fig. 4-4: Types of Mounting

1 0° = standing (standard) 3 180° = hanging from the ceiling

2 90°= hanging on the wall 4 10° - 90° = mounted on an angle

Suspended mounting
Suspended mounting differs from assembly in a standing position in the following points.
• S-axis working range
• Fixing the robot base

NOTICE
For suspended mounting in any position, please contact the local YASKAWA branch office.

S-axis working range

For the wall-mounted type, the S-axis movable range is ±30° (the range is adjusted prior to
the shipment).
B-Axis operating range
For ceiling-mounted type, the B-axis operating range is -90° to +135° (The range is
adjusted prior to the shipment).

Fastening the robot base

With suspended mounting, the robot must be fastened with 4 screws M16 (Strength
category 12.9). Use a torque of 400 Nm in tightening the screws.

Precaution against falling

In case of suspended mounting, take measures to prevent the robot from falling down.

NOTICE
If the setup is changed, please contact the local YASKAWA branch office.

4 - 21
Wiring

5 Wiring
DANGER!
Danger to life due to electric shock, risk of fire due to short circuit.
Wiring must be performed by authorized or certified personnel.
Follow the instructions given below before wiring.
 Make sure that the earthing resistance does not exceed 0.1 Ω.
 Turn OFF the main power supply.
 Put up the warning sign prescribed, e.g. "Do not turn the power on!".
 Install a switch-on guard as prescribed.

5.1 Grounding
Follow electrical installation standards and wiring regulations for grounding. The cable
cross-section must be 6 mm² or more.
With regard to the direct connection of the earthing cable, see Fig. 5-1: "Grounding
method".

NOTICE
Note on earthing connection!
Never use the earthing cable together with another earthing cable, e.g.
 Of a different electrical consumer
 Of a different motor-driven consumer
 Welding devices etc.

Where metal ducts, metallic conduits, or distributing racks are used for cable laying,
grounding should be performed in accordance with applicable electrical installation
standards.

Fig. 5-1: Grounding method

1 M8 screw for earthing is supplied with the robot (at least 6 mm² protective earth con-
ductor).

5 - 22
 Wiring

5.2 Cable connections

YASAKAW DX200
Part No.
Power Supply Peak kVA
AC 400/415/440 Average kVA
Serial No.
Date/Signature
Type ERDR-
Robot Type
Robot Order No.
Robot Serial No.

YASKAWA ELECTRIC CORPORATION

2-1 SHIROISHI KUROSAKI, YAHATANISHILU KITAKYUSYU, JAPAN

YASKAWA Europe „Robotics Division“ GmbH

Yaskawastr. 1, D-85391 Allershausen

DX200

Fig. 5-2: Connecting the robot system

Two cables are delivered with the robot (refer to Fig. 5-3: "Robot cable").
• Encoder cable (1BC)
• Power cable (2BC)
Before connecting the robot cable, check the marking on the robot cable and the
connections on the connector plate of the robot (see the following diagram "Robot cable").
Connect the cables to the connections on the robot base and on the robot controller (see
the following chapter on "robot connection" and "robot controller connection").

2 1

1BC
X11

1BC

X11 1BC

1BC
3

2 1
2BC
X21

2BC

X21 2BC

2BC
4

Fig. 5-3: Robot cable

1 Robot control side 3 Encoder cable (1BC)

2 Robot side 4 Power cable (2BC)

5 - 23
Wiring

5.2.1 Connecting the robot

1. Check the encoder cable (1BC) and the power cable (2BC).
2. Connect the encoder cable (1BC) to the connector plate of the robot.
3. Connect the power cable(2BC) to the connector plate of the robot.
Make sure that you hear each locking clip snap into place (clicking sound).

1BC 2BC 3BC

Fig. 5-4: Connector plate of the robot

5 - 24
 Wiring

5.2.2 Connecting the robot control

Attach the robot cables in the following order.

1. Connect the encoder cable (1BC) X11 connection X-1 to the robot controller.
2. Connect the power cable (2BC) X21 connection X-2 to the robot controller.
Make sure that you hear the locking clips snap into place (clicking sound).

X 11

X -1 X 21

X -2

Fig. 5-5: Connection robot control

5 - 25
Wiring

5.2.3 Connecting the programming pendant

Connect the programming pendant cable to the connection (X81) on the door of the robot
controller (see diagram "Connecting the programming pendant").

X81
Motoman DX100
Part No.
WARNING
Power Supply
AC 400/415/440 V
Peak
Average
kVA
kVA
High Voltage
Serial No.
Date/Signature
Do not open the door
Type
Robot Type
ERDR-
with power ON.
Robot Order No.
Robot Serial No.

YASKAWA Electric corporation

2-1 Kurosaki Shiroishi Yahatanishi-Ku Kitakyushu-City Fukuoka 806-0004 Japan

Kammerfeldstr. 1, D-85391 Allershausen

NJ3053-1

CHECK ALL THE DOOR LOCKS

PROPERLY.
NJ3005-1

PROGRAMMING PENDANT
X81

Fig. 5-6: Connection programming pendant

1 Alignment marks

5 - 26
 Technical data

6 Technical data
Type: A10
Types of Mounting: Celling mounted
Degree of freedom: 6
Carrying capacity: 10 kg
Repeatability:1 ± 0.08 mm
Power consumption: 2.0 kVA
Weight: 280 kg
Working area main axis:
S-axis (turning) -180° ~ +180°
2
L-axis (lower arm) -105° ~ +155°
U-axis (upper arm)² -170° ~ +220°
Working area wrist axis:
R-axis (wrist roll)² -150° ~ +150°
B-axis (wrist yaw/pitch) -90° ~ +135°
T-axis (wrist twist) -210° ~ +210°
Protection class (IP):
Main axes 54
Wrist axis 67
Maximum speed:
S-axis 3.44 rad/s, 197°/s
L-axis 3.32 rad/s, 190°/s
U-axis 3.67 rad/s, 210°/s
R-axis 7.16 rad/s, 410°/s
B-axis 7.16 rad/s, 410°/s
T-axis 10.06 rad/s, 610°/s
3
Admissible moment (Nm):
R-axis 22 Nm
B-axis 22 Nm
T-axis 9.8 Nm
Permissible moment of inertia (kgm²):
R-axis 0.65 kgm²
B-axis 0.65 kgm²
T-axis 0.17 kgm²
4
Sound pressure level (dB): 77 dB
1. Tested according to ISO 9283

2. The range of motion of L, U and R axes is limited depending on their position.

3. See the following diagram "Moment of arm rating in section 7" for further information on the permissible
moment of inertia.

4. It is measured at maximum load and speed of the robot. The measurement is performed at height of 1.2 m
and 1.5 m above the floor and at distance of 400 mm to the working area.

6 - 27
Technical data

6.1 Parts and work axis label

U+ R+ 1
B+ T+

B- T-
U- R-

L- L+

4
S+

S-

Fig. 6-1: Part names and working axes

1 Upper arm (U-arm) 4 Rotating head of S-axis

2 Wrist Flange 5 Robot base
3 Lower arm (L-arm)

6.2 Robot base dimension

375

335

316
60
1
335
375
292

60

Fig. 6-2: Robot base dimensions

1 4 mounting holes Ø 18 2 Hole Ø 12 H7

All dimensions in mm

6 - 28
 Technical data

6.3 Dimensions and defined working area

1284

1710
2010

1287
561

559

792
0
1284

568
495 A
229 266

0
199

505
3649

157 850

760
139 1

95
3

200
100 1082 150

2365

R20
10
2
61
R5

Fig. 6-3: Part names and working axes

1 P point 3 The working area in which the robot can work with
its wrist units (B-axis) pointing downwards.
2 Working area, defined All dimensions in mm
with point P

6 - 29
Technical data

6.4 Adjustable working area

Depending on the type of use, the S-axis working area can be changed.
If any modification is necessary, please contact the local YASKAWA branch office.

Item Specifications
S-axis working range ± 180° (standard)
± 150°
± 120°
± 105°
± 90°
± 60°
± 30°

6.5 Stopping Angle and Time at the Emergency Stop

NOTICE
 The overrun distance is the angle that the robot travels from the point of time when the
stop signal is triggered until the robot comes to a complete stop.
 The overrun time is the time that elapses from the point of time when the stop signal is
triggered until the robot comes to a complete stop.
 The axis movement with the longest stopping point is the decisive axis movement for
calculating the safety distance .
 The values are shown for S, L and U axes.
 The values shown for stop category 0 are reference values determined through testing
and simulation. They are average values and fulfil the requirements according to DIN
EN ISO 10218-1. The actual overrun distances and overrun times may differ due to
internal and external influence on the braking torque. Therefore, if necessary, it is
recommended to determine the overrun distances and overrun times under real, local
conditions when the robot is used.
 The brake wear may vary depending on the operating mode, robot use and number of
times stop category 0 is triggered. Check the overrun distance at least once a year.

6 - 30
 Technical data

100%

66%
33%

Fig. 6-4: Stop position of the robot axes

Definitions Description
Category 0 Load 100% pink
Category 0 Load 66% green
Category 0 Load 33% gray
Category 1 blue
Overrun distance degrees° [deg]
Overrun time second [sec]
Robot speed degrees°/second [deg/s]

6 - 31
Technical data

6.5.1 Stop category 0

6.5.1.1 Stop position S-axis

100%
㻜㻚㻡
㻟㻡

㻟㻜
㻜㻚㻠
㻞㻡
㻜㻚㻟
㻞㻜

[sec]
[deg]

㻝㻡
㻜㻚㻞
㻝㻜

㻡 㻜㻚㻝

㻜
㻜 㻡㻜 㻝㻜㻜 㻝㻡㻜 㻞㻜㻜 㻞㻡㻜 㻜
㻜 㻡㻜 㻝㻜㻜 㻝㻡㻜 㻞㻜㻜 㻞㻡㻜

[deg/s] [deg/s]
Fig. 6-5: Stop position 100%

66%
㻟㻡 㻜㻚㻡

㻟㻜
㻜㻚㻠
㻞㻡

㻞㻜 㻜㻚㻟
[sec]
[deg]

㻝㻡
㻜㻚㻞

㻝㻜
㻜㻚㻝
㻡

㻜 㻜
㻜 㻡㻜 㻝㻜㻜 㻝㻡㻜 㻞㻜㻜 㻞㻡㻜 㻜 㻡㻜 㻝㻜㻜 㻝㻡㻜 㻞㻜㻜 㻞㻡㻜
[deg/s] [deg/s]

Fig. 6-6: Stop position 66%

33%
㻟㻡 㻜㻚㻡

㻟㻜
㻜㻚㻠
㻞㻡

㻜㻚㻟
㻞㻜
[sec]
[deg]

㻝㻡
㻜㻚㻞

㻝㻜
㻜㻚㻝
㻡

㻜 㻜
㻜 㻡㻜 㻝㻜㻜 㻝㻡㻜 㻞㻜㻜 㻞㻡㻜 㻜 㻡㻜 㻝㻜㻜 㻝㻡㻜 㻞㻜㻜 㻞㻡㻜
[deg/s] [deg/s]

Fig. 6-7: Stop position 33%

6 - 32
 Technical data

6.5.1.2 Stop position L-axis

100%
㻟㻡 㻜㻚㻡

㻟㻜
㻜㻚㻠
㻞㻡

㻜㻚㻟
㻞㻜

[sec]
[deg]

㻝㻡
㻜㻚㻞

㻝㻜
㻜㻚㻝
㻡

㻜 㻜
㻜 㻡㻜 㻝㻜㻜 㻝㻡㻜 㻞㻜㻜 㻞㻡㻜 㻜 㻡㻜 㻝㻜㻜 㻝㻡㻜 㻞㻜㻜

[deg/s] [deg/s]
Fig. 6-8: Stop position 100%

66%
㻟㻡 㻜㻚㻡

㻟㻜
㻜㻚㻠
㻞㻡

㻜㻚㻟
㻞㻜
[sec]
[deg]

㻝㻡 㻜㻚㻞

㻝㻜
㻜㻚㻝
㻡

㻜 㻜
㻜 㻡㻜 㻝㻜㻜 㻝㻡㻜 㻞㻜㻜 㻞㻡㻜 㻜 㻡㻜 㻝㻜㻜 㻝㻡㻜 㻞㻜㻜 㻞㻡㻜

[deg/s] [deg/s]

Fig. 6-9: Stop position 66%

33%
㻟㻡 㻜㻚㻡

㻟㻜
㻜㻚㻠
㻞㻡

㻜㻚㻟
㻞㻜
[sec]
[deg]

㻝㻡
㻜㻚㻞

㻝㻜
㻜㻚㻝
㻡

㻜 㻜
㻜 㻡㻜 㻝㻜㻜 㻝㻡㻜 㻞㻜㻜 㻞㻡㻜 㻜 㻡㻜 㻝㻜㻜 㻝㻡㻜 㻞㻜㻜 㻞㻡㻜

[deg/s] [deg/s]

Fig. 6-10: Stop position 33%

6 - 33
Technical data

6.5.1.3 Stop position U-axis

100%
㻟㻡 㻜㻚㻡

㻟㻜
㻜㻚㻠
㻞㻡

㻞㻜 㻜㻚㻟

[sec]
[deg]

㻝㻡
㻜㻚㻞
㻝㻜
㻜㻚㻝
㻡

㻜 㻜
㻜 㻡㻜 㻝㻜㻜 㻝㻡㻜 㻞㻜㻜 㻞㻡㻜 㻜 㻡㻜 㻝㻜㻜 㻝㻡㻜 㻞㻜㻜 㻞㻡㻜
[deg/s] [deg/s]
Fig. 6-11: Stop position 100%

66%
㻟㻡 㻜㻚㻡

㻟㻜
㻜㻚㻠
㻞㻡

㻜㻚㻟
㻞㻜
[sec]
[deg]

㻝㻡 㻜㻚㻞

㻝㻜
㻜㻚㻝
㻡

㻜 㻜
㻜 㻡㻜 㻝㻜㻜 㻝㻡㻜 㻞㻜㻜 㻞㻡㻜 㻜 㻡㻜 㻝㻜㻜 㻝㻡㻜 㻞㻜㻜 㻞㻡㻜

[deg/s] [deg/s]

Fig. 6-12: Stop position 66%

33%
㻟㻡 㻜㻚㻡

㻟㻜
㻜㻚㻠
㻞㻡
㻜㻚㻟
㻞㻜
[sec]
[deg]

㻝㻡 㻜㻚㻞

㻝㻜
㻜㻚㻝
㻡

㻜 㻜
㻜 㻡㻜 㻝㻜㻜 㻝㻡㻜 㻞㻜㻜 㻞㻡㻜 㻜 㻡㻜 㻝㻜㻜 㻝㻡㻜 㻞㻜㻜 㻞㻡㻜
[deg/s] [deg/s]

Fig. 6-13: Stop position 33%

6 - 34
 Technical data

6.5.2 Stop category 1

The stopping angle and time at the emergency stop in category 1 are not subjected to the
robot position and the load.
Stop of category1 doesn't depend on the robot position and the load.

6.5.2.4 Stop position S-axis

㻣㻜 㻜㻚㻤

㻢㻜 㻜㻚㻣

㻜㻚㻢
㻡㻜
㻜㻚㻡
㻠㻜
㻜㻚㻠

[sec]
[deg]

㻟㻜
㻜㻚㻟
㻞㻜
㻜㻚㻞
㻝㻜 㻜㻚㻝

㻜 㻜
㻜 㻡㻜 㻝㻜㻜 㻝㻡㻜 㻞㻜㻜 㻞㻡㻜 㻜 㻡㻜 㻝㻜㻜 㻝㻡㻜 㻞㻜㻜 㻞㻡㻜

[deg/s] [deg/s]
Fig. 6-14: Stop position

6.5.2.5 Stop position L-axis

㻣㻜 㻜㻚㻤

㻢㻜 㻜㻚㻣

㻜㻚㻢
㻡㻜
㻜㻚㻡
㻠㻜
[sec]
[deg]

㻜㻚㻠
㻟㻜
㻜㻚㻟
㻞㻜
㻜㻚㻞

㻝㻜 㻜㻚㻝

㻜 㻜
㻜 㻡㻜 㻝㻜㻜 㻝㻡㻜 㻞㻜㻜 㻞㻡㻜 㻜 㻡㻜 㻝㻜㻜 㻝㻡㻜 㻞㻜㻜 㻞㻡㻜

[deg/s] [deg/s]

Fig. 6-15: Stop position

6 - 35
Technical data

6.5.2.6 Stop position U-axis

㻣㻜 㻜㻚㻤

㻢㻜 㻜㻚㻣

㻜㻚㻢
㻡㻜
㻜㻚㻡
㻠㻜

[sec]
[deg]

㻜㻚㻠
㻟㻜
㻜㻚㻟
㻞㻜
㻜㻚㻞
㻝㻜 㻜㻚㻝

㻜 㻜
㻜 㻡㻜 㻝㻜㻜 㻝㻡㻜 㻞㻜㻜 㻞㻡㻜 㻜 㻡㻜 㻝㻜㻜 㻝㻡㻜 㻞㻜㻜 㻞㻡㻜
[deg/s] [deg/s]

Fig. 6-16: Stop position

6 - 36
 Allowable load for wrist axis and wrist flange

7 Allowable load for wrist axis and wrist flange

7.1 Wrist flange
The dimensions of the wrist flange are shown in the following figure "Wrist flange". To
ensure that the zero position marks can be seen at all times, the tool may only be flange-
mounted with the inner diameter. The internal depth of the threaded joint may not exceed
5 mm .

NOTICE
Before mounting a tool, remove anticorrosive coating on the flange. Thinner or light fuel oil
are the most suitable for this purpose.

1
2

6 5 4

7 5 4

Fig. 7-1: Wrist flange

1 8 tapped holes M4 x 8 5 Ø 62 h7
2 Hole Ø 4 H7x 6 6 Ø 50
3 P.C.D 56 7 Mount tools in this range.
4 Ø 100 8 Depth: 5
All dimensions in mm

7.2 Maximum load of the S-axis

For peripheral devices of specific applications, additional mounting options are provided on
the robot.

7.3 Optimal robot performance

To achieve optimal robot performance, the maximum load of the S-axis must never exceed
the permissible bearing capacity of the robot.

7 - 37
Allowable load for wrist axis and wrist flange

7.4 Allowable Wrist Load

The maximum allowable wrist load is 10 kg. Should however force instead of load be
exercised on the wrist axis, the power has to be at the axes within the moments (see the
following figure and table).
For further information or assistance, please contact your YASKAWA branch.

Allowed moment and maximum moment of inertia

Axis Allowed moment (Nm) Permissible moment of inertia (kgm²)

R-axis 22 Nm 0.65 kgm²

B-axis 22 Nm 0.65 kgm²

T-axis 9.8 Nm 0.17 kgm²

Keep the distance of the load/mass from the centre of gravity within the values specified,
see the following figure "Moment of arm rating".

LB 300
1
238
100 W=3kg
200
LT[mm]

166
LT

W=6kg
2 100
W=10kg

3 220 329 465

100 200 300 400 500

LB[mm]

Fig. 7-2: Moment of arm rating

1 P point 3 B-axis rotation center line

2 R-, T-axes rotation center line All dimensions in mm

7.5 Maximum capacity load

The maximum permissible load for U-axis, including wrist, is 19 kg.
For example, if the load mounted on the joint is 10 kg, the load on the upper arm must not
exceed 9 kg.
The maximum load for S-axis is 20 kg. Install the peripheral devices on the S-axis in such
a way that the moment of inertia (GD2/4) of the rotation centre of the S-axis does not exceed
1.25 kgm² kg.

7 - 38
 Allowable load for wrist axis and wrist flange

130
15 48 15

70
165
2
View B

6
28.5 50
3 A
300 60

917 165

168 70 5

130
26

70
30 229

100
13

2
15 6
8 45 92 7 45

Fig. 7-3: Installing peripheral equipment mounts

1 4 threaded holes M8 x 16 5 4 threaded holes M6 x 12

2 2 threaded holes M6 x 12 6 4 threaded holes M6 x 14
3 Mount the peripherals in this range. 7 2 threaded holes M10 x 12
4 Mount the accessories, so that the 8 2 threaded holes M10 x 18
centre of gravity of the accessories is
in the U arm within this range.
All dimensions in mm

7 - 39
Internal cables and compressed air lines

8 Internal cables and compressed air lines

Internal cables (3BC: 14 wires 8 x 0.20 mm², 2 x 0.75mm² and 4 x 1.25 mm²) and air hoses
are used in order to use peripheral devices (e.g. gripper). They are mounted on the upper
arm as shown in the following diagram "Connector for internal cables and compressed air
lines".
The pins 1 to 16 are assigned as shown in the following figure. Wiring must be performed
by the user.
The following requirements must be met:
• The total current value for the internal wiring harness must be 40 A .
• The current-carrying capacity per single conductor (cross-section 0.20 mm², 0.75 mm²
and 1.25 mm²) must not exceed 3 A or less .
• The air pressure for the air hose must not exceed 600 kPA (the inner diameter of the air
hose is Ø 6.5 und Ø 8 mm).

8 - 40
 Internal cables and compressed air lines

• For the power cable when arc welding the nominal current may not exceed 500A. In
permanent operation the current may not exceed 80% of the nominal current
(permissible current at permanent operation = 80% x (500A/operating current)²).

2
1

2BC
6
1BC

3BC

9 8

Fig. 8-1: Connectors for internal user I/O wiring harness and air line

1 Air outlet with cap A 6 Air inlet with cap A

2 Air outlet with cap B 7 Power cable for arc welding (recom-
mended connection: R100-10, cover
(TS200CHM) is included in the deliv-
ery).
3 Connector plug for the internal cable 8 View A
feedthrough: JL05-2A20-29SC (sock-
et connector with a cap) JL05-6A20-
29P.
4 Power cable for arc welding 9 Connector plug for the internal cable
(TS200CHM) feedthrough: JL05-2A20-29PC (sock-
et connector with a cap) JL05-6A20-
29S.
5 Air inlet with cap B

List of connector types

Description Type of connector

Connector for the internal user I/O wiring JL05-2A20-29PC (optional: JL05-6A20-
harness on the base 29S)

Connector for the internal user I/O wiring JL05-2A20-29SC (optional: JL056A20-
harness on the U-arm 29P)

Welding power cable

8 - 41
Internal cables and compressed air lines

The welding power cable is only integrated as standard in the robot MA2010-A00. Fig. 8-2:
"Robot type Welding power cable").

1 1

39

A A
2
3 4

Fig. 8-2: Robot type Welding power cable

1 Internal wiring harness 3 Section A-A MA2010-A00

2 Welding power cable 4 Section -A MA2010 A10

1 2
1 1
2 2
3
4
3
3
5 7 4
5
6 6
7 1 7 4 1

5 8
9 4
2
5
3
6
5 8
9 4
2
5
3
6
10 7 8 10 7 8
11 (0.75mm22) 9 10 11 (0.75mm2) 9 10
12 (0.75mm ) 11 12 12 (0.75mm2) 11 12
13 (1.25mm2) 13 14 13 (1.25mm2) 13 14
14 (1.25mm2) 14 (1.25mm2)
15 (1.25mm2) 15 16 15 (1.25mm2) 15 16
16 (1.25mm2) 16 (1.25mm2)

6 6

Fig. 8-3: Details of the plug

 = assigned
 = unassigned

1 Connector plug for the internal cable 5 Pins used

feedthrough on the connector base
2 Connector plug for the internal cable 6 Internal user I/O wiring harness: 8
feedthrough on U-arm wires 0.2 mm², 2 wires 0.75 mm², 4
wires 1.25 mm²
3 +24 V (1A) for shock sensor 7 7 and 8 are open
4 Shock sensor signal input
The pins used on the connectors (3BC: 14 wires 8 x 0.20 mm², 2 x 0.75mm² and 4 x 1.25
mm²) are connected to the stand and arm with individual wires.
In the standard specification, pins 7 and 8 are connected as follows:
• To the 3BC connection for the collision sensor on the U arm.
• To the 3BC connection for the collision sensor on the robot controller.
Pins 7 and 8 of the respective 3BC connections on the connector plate and U arm are
connected to each other.

8 - 42
 Mains cable Internal cable

Notice
1. The connecting terminal A B for the indication of the end switch has been changed as follows:
2. The connection C applies only if the cable is for the main power supply of the automatic welding machine.

LC1 LC1
LD1 LD1 LD1 OVERRUN LIMIT SWITCH S AXIS B1
LD1 LC2 connected to
LD2 OVERRUN LIMIT SWITCH L AXIS B2
LC3 connected to
LD3 L AND U AXIS COLLISION LIMIT SWITCH L.S. B3
connected to
0BT 1 0BAT11 17 0BAT1 LA1 LA1
K R P BAT 2 BAT11 18 BAT1 LB1 LB1 LB1
0BT 3 0BAT12 19 0BAT2 OVERRUN LIMIT SWITCH S AXIS A1
K R P BAT 4 BAT12 20 BAT2 LB1 LA2 connected to
21 0BAT3 LB2
22 BAT3 OVERRUN LIMIT SWITCH L AXIS A2
23 LA3 connected to
24 LB3 A3
0BT 5 0BAT21 25 0BAT4 L AND U AXIS COLLISION LIMIT SWITCH L.S.
K R P BAT 6 BAT21 26 BAT4 S, L, and U axes with overrun limit switch details connected to
0BT 7 0BAT22 27
K R P BAT 8 BAT22 28 LC1 LC1
29 LD1 LD1
30 OVERRUN LIMIT SWITCH S AXIS B1
1 31 LD1 LC2 connected to
2 32 LD2 LD2
3 1 PG0V1 LD2 LC3
4 2 PG5V1
5 3 PG0V2 LD1 LD3
6 4 PG5V2 LB1 LA2 LA1
7 5 PG0V3 LA1
8 6 PG5V3 P LB2 A2 LB1 LB1 OVERRUN LIMIT SWITCH S AXIS A1
7 PG0V4 LB1 LA2
8 PG5V4 LB2 LB2 connected to
Controller 1BC(10X4) 9 PG0V5 LD1 LC2
10 PG5V5 P LD2 B2 LB2 LA3
CN1-5 CN1-5 +24V 1 11 PG0V6 LB1 LB3
CN1-4 P CN1-4 0V 3 12 PG5V6
13 S-Axis limit switch specification
CN1-10 CN1-10 +24V 2 14
CN1-9 P CN1-9 0V 4 15
16 No. 22CN No. 18CN
CN1-1 CN1-1 SPG+1 22CN-1 DATA+1 18CN-1 DATA+1
CN1-2 P CN1-2 SPG-1 P -2 DATA-1 P -2 DATA-1 S-AXIS
-6 BAT -6 BAT
P -5 OBT P -5 OBT PG
-4 +5V -4 +5V
P -9 0V P -9 0V
CN1-3 CN1-3 FG1 -7 FG1 -10 FG1

No. 23CN No. 19CN

CN1-6 CN1-6 SPG+2 23CN-1 DATA+2 19CN-1 DATA+2
CN1-7 P CN1-7 SPG-2 P -2 DATA-2 P -2 DATA-2 L-AXIS
-6 BAT -6 BAT
diagram A" and "Connection diagram B".

P -5 OBT P -5 OBT PG
-4 +5V -4 +5V
P -9 0V P -9 0V
CN1-8 CN1-8 FG2 -7 FG2 -10 FG2

CN4-1 CN4-1 +24V

CN4-6 P CN4-6 LB1
CN4-2 CN4-2 SS2
CN4-7 P CN4-7 AL1
No. 16CN
CN2-1 CN2-1 SPG+3 16CN-1 DATA+3
CN2-2 P CN2-2 SPG-3 P -2 DATA-3
-6 BAT
P -5 OBT PG
CN2-3 CN2-3 FG3 -4 +5V U-AXIS
P -9 0V
-10 FG3

No. 9CN
CN2-6 CN2-6 SPG+4 9CN-1 DATA+4
CN2-7 P CN2-7 SPG-4 P -2 DATA-4
1BC(10X4) -3 BAT
P -4 OBT PG R-AXIS
CN2-8 CN2-8 FG4 10CN-1 +5V
P -2 0V
-3 FG4
CN2-10 CN2-10 +24V
No. 10CN OBT
P BAT
No. 13CN No. 1CN

Fig. 8-4: Internal connection diagram (a)

CN3-1 CN3-1 SPG+5 -1 DATA+5 1CN-1 DATA+5
CN3-2 P CN3-2 SPG-5 P -7 DATA-5 P -2 DATA-5
-2 BAT -3 BAT
CN3-3 CN3-3 FG5 -8 OBT P -4 OBT PG B-AXIS
-3 +5V 2CN-1 +5V
CN2-4 CN2-4 P -9 0V P -2 0V
CN2-5 P CN2-5 SPG+7 -3 FG5
SPG-7
No. 2CN OBT
CN2-9 CN2-9 FG7 BAT
No. 3CN
CN3-6 CN3-6 SPG+6 -4 DATA+6 3CN-1 DATA+6
CN3-7 P CN3-7 SPG-6 P -10 DATA-6 P -2 DATA-6
-3 BAT
-4 OBT PG T-AXIS
CN3-8 CN3-8 FG6 -5 +5V 4CN-1 +5V
P -11 0V P -2 0V
-6 FG6 -3 FG6
CN4-3 CN4-3 BC2 No. 4CN OBT
CN4-8 P CN4-8 AL2 BAT

CN4-10 CN4-10 0V
P FOR LAMP (OPTIONAL)
CN3-4 CN3-4
CN3-5 P CN3-5 0V
+5V

CN3-9 LA1 LB1 LB2 LB2 LA3

CN3-10 P
CN3-9 0V
CN3-10 +5V
A1 LB1 P LB3 A3
CN4-4 CN4-4 +24V LC1 LD1 LD2 LD2 LC3
CN4-5 P CN4-5 LD1 LD1 P LD3 B3
CN4-9 CN4-9 FG8

8
B1
For the wiring, see the following figure, "Connecting diagram for internal connections."

E E

- 43
The internal connections of the robot are shown in the following diagrams "Connection
Internal cables and compressed air lines
8
- 44
E E E

Stand Housing
3BC(20-29) 3BC(20-29)
E E E E E
3BC-1 1 1 1 1 1 1 3BC-1
-2 2 2 2 P 2 2 P 2 -2
-3 3 3 3 3 3 3 -3
-4 4 4 4 P 4 4 P 4 -4
-5 5 5 5 5 -5
-6 6 6 6 P 6 -6
-7 7 7 SS1 SS1 SS1 SS1 7 -7
-8 8 8 SS2 SS2P SS2 SS2 P 8 -8
-9 9 9 -9 For reserve cable
-10 10 P 10 -10
-11 11 11 -11
-12 12 12 -12
-13 13 13 -13
-14 14 14 -14
-15 15 15 -15
-16 16 16 -16

2BC(6X6)
E
E
Internal cables and compressed air lines

No. 20CN
CN1-1 CN1-1 ME1 3CN-3 MU1
CN1-2 CN1-2 ME2 -2 MV1 S-AXIS
CN1-3 ME2 -1 MW1 SM
CN1-3
CN1-4 CN1-4 MU1 -PE ME1
CN1-5 CN1-5 MV1 -4 BA1
CN1-6 CN1-6 MW1 -5 BB1 YB

No. 21CN
CN2-1 CN2-1 MU2 4CN1-A MU2
CN2-2 CN2-2 MV2 -B MV2 L-AXIS
CN2-3 MW2 -C MW2 SM
CN2-3
CN2-4 CN2-4 MU2 -D ME2
CN2-5 CN2-5 MV2 -1 BA2
CN2-6 CN2-6 MW2 -2 BB2 YB
No. 24CN

No. 17CN
CN3-1 CN3-1 MU3 17CN-3 MU3
CN3-2 CN3-2 MV3 -2 MV3 U-AXIS
CN3-3 MW3 -1 MW3 SM
CN3-3
CN3-4 CN3-4 MU4 -PE ME3
CN3-5 CN3-5 MV4 -4 BA3
CN3-6 CN3-6 MW4 -5 BB3 YB
No. 11CN
CN4-1 CN4-1 MU5 11CN-1 MU4
2BC(6X6) CN4-2 CN4-2 MV5 -2 MV4
CN4-3 CN4-3 MW5 -3 MW4 SM R-AXIS
CN4-4 CN4-4 MU6 -4 ME4
CN4-5 CN4-5 MV6 -1 BA4
CN4-6 CN4-6 MW6 -2 BB4 YB

Fig. 8-5: Internal connection diagram (b)

No. 14CN No. 12CN No. 5CN
CN5-1 CN5-1 ME3 14CN-1MU5 5CN-1 MU5
CN5-2 CN5-2 ME4 -2 MV5 -2 MV5
CN5-3 ME5 -3 MW5 -3 MW5 SM B-AXIS
CN5-3
CN5-4 CN5-4 ME6 -4 ME5 -4 ME5
CN5-5 CN5-5 BA1 -1 BA5
CN5-6 CN5-6 BB1 -2 BB5 YB
No. 6CN
No. 7CN
CN6-1 CN6-1 BA2 -5 MU6 7CN-1 MU6
CN6-2 CN6-2 BA3 -6 MV6 -2 MV6
CN6-3 BA4 -7 MW6 -3 MW6 SM T-AXIS
CN6-3
CN6-4 CN6-4 BB4 -8 ME6 -4 ME6
CN6-5 CN6-5 BA5 -1 BA6
CN6-6 CN6-6 BA6 15CN-1BA5 -2 BB6 YB
-2 BB5
-3 BA6 No. 8CN
-4 BB6
Note 2) No. 15CN
PE

C
 Maintenance and inspection

9 Maintenance and inspection

DANGER!
Danger to life due to electric shock
Maintenance and inspections must be performed by specified personnel.
The instructions given below must be followed before taking maintenance and inspection
measures:
 Turn OFF the main power supply.
 Put up the warning sign prescribed, e.g. "Do not turn the power on!".
 Install a switch-on guard as prescribed.

If you have any questions regarding disassembly or repair, please contact the local
YASKAWA branch office.

NOTICE
Home position data is lost
Before removing the connector of the encoder cable to perform maintenance or inspection,
 Connect the spare battery pack.

9 - 45
Maintenance and inspection

9.1 Inspection schedule

Proper inspections are essential not only to assure that the mechanism will be able to
function for a long period. But also to prevent malfunctions and assure safe operation.
Inspection are classified into several time levels as shown by the following table "Inspection
intervals".
In the table of "Inspection intervals", the inspections are divided according to three levels of
requirement:
• Works, carried out by trained staff.
• Work carried out by staff trained by YASKAWA.
• Works, carried out by YASKAWA staff.
Inspections are only carried out by trained staff.

NOTICE
 The inspection intervals depend on the SERVO power time (see point 1 in Fig. 9-1:
"SERVO power time").
 The table "Inspection intervals" applies to normal cases.
 Deviations are to be determined by the TCS service department of YEU-R.

START HOLD
REMOTE TEACH
PLAY

JOB EDIT DISPLAY UTILITY

JOB CONTENT
-TEST01 S:0000
CONTROL GROUP:R1 TOOL:
0000 NOP
0001 SET B000 1
0002 SET B001 0
0003 MOVJ VJ=80.00
0004 MOVJ VJ=80.00
0005 DOUT OT#(10) ON
0006 TIMER T=3.00
0007 MOVJ VJ=80.00
0008 MOVJ VJ=100.00
0009 MOVJ VJ=100.00
0010 MOVJ VJ=100.00
0011 MOVJ VJ=100.00
MOVJ VJ=0.78

Main Menu Short Cut Turn on servo power

LAYOUT TOOL SEL GO BACK

DIRECT
COORD OPEN
Multi PAGE AREA
ENTRY
SERVO
SELECT
MAIN SIMPLE ON CANCEL
MENU MENU READY ASSIST

SERVO ON
X- X+ X- X+
S- S+ R- R+
HIGH
SPEED
Y- Y+ Y- Y+
L- L+ B- B+
FAST
Z- Z+ MANUAL SPEED
Z- Z+
U- U+ T- T+
SLOW
E- E+ 8- 8+

INTER 7 8 9 TEST
SHIFT
SHIFT
LOCK START

ROBOT INFORM 4 5 6 BWD FWD

LIST

EX.AXIS
WELD 1 2 3 DELETE INSERT
ON/OFF

MOTION 0 . -
AUX MODIFY ENTER
TYPE

DATA EDIT DISPLAY UTILITY

SYS MONITORING TIME

CONTROL POWER TIME (1998/07/06 10:00 )

2385:42'02
1 SERVO POWER TIME (1998/07/06 10:30 )
36000:00'00
PLAYBACK TIME (1998/10/22 11:12 )
2210:00'20
MOVING TIME (1998/10/22 15:30 )
1875:15'30
OPERATING TIME (1998/10/22 16:12 )
0:0'0

Main Menu ShortCut

Fig. 9-1: SERVO power time

9 - 46
 Inspection intervals

Item number1 Schedule Checking method Operation Inspection

Charge:

YASKAWA trained staff

Every 12000 hours
Every 24000 hours
Every 36000 hours
Every 1000 hours
Every 6000 hours

YASKAWA staff
trained staff
Daily
1 Alignment marks  Visual inspection Check alignment mark accordance and damage   
at the home position.

2 External cable  Visual inspection Check cable for damage.   

3 Working area and robot  Visual inspection Dirty working area has to be cleaned. Please   
control the robot for damage and external
cracks.

4 Motor for S-, L-, U-axes  Visual inspection Check for grease leakage.   

5 Baseplate mounting bolts  Using correspond- Tighten loose screws (replace if necessary).   
ing tool

Maintenance and inspection

6 Cover mounting screws  Using correspond- Tighten loose screws (replace if necessary).   
ing tool

7 Power input module  Manual Check for loose connectors   

8 Toothed belt for B- and T-axes  Manual Check for tension and wear  
9
- 47
 Inspection intervals
9 - 48

Maintenance and inspection

Item number1 Schedule Checking method Operation Inspection
Charge:

YASKAWA trained staff

Every 12000 hours
Every 24000 hours
Every 36000 hours
Every 1000 hours
Every 6000 hours

YASKAWA staff
trained staff
Daily
9 Wiring harness in the robot  Visual, multimeter Check for conduction between the main con-  
(wires of the S-, L-, U-, R-, B- necter of base and intermediate connector with
and T-axis) manually shaking the wire. Check the protection
spring2.

 Replacement3 

10 Wiring harness in the robot  Visual, multimeter Check the wires between the terminals for wear.  
(wires of the B- and T-axis)
 Replacement 

11 Protective tube  Visual inspection Inspect the protective tube for holes, cracks and   
adhesion of welding spatters (replace if neces-
sary).

 Refer to manual "OPTIONS FOR PROTECTIVE   

TUBING (VELCRO TYPE) REPLACING PRO-
CEURES".

12 Battery pack in robot  If a battery alarm appears or after the robot has  
been operated for 36,000 hours, the battery
must be replaced.
 Inspection intervals

Item number1 Schedule Checking method Operation Inspection

Charge:

YASKAWA trained staff

Every 12000 hours
Every 24000 hours
Every 36000 hours
Every 1000 hours
Every 6000 hours

YASKAWA staff
trained staff
Daily
13 S-axis gear   Grease gun Check for faults (replace if necessary). The  
grease4 must be refilled every 6000 hours or re-
placed every 12000 hours (see chapter 9.3.1
"Grease replenishment/exchange for S-axis re-
duction gear unit" on page 59).

14 L- and U-axes gear   Grease gun Check for faults (replace if necessary). The  
grease must be refilled every 6000 hours or re-
placed every 12000 hours (see chapter 9.3.2
"Grease replenishment/exchange for L-axis re-
duction gear unit" on page 60).

15 R-axis gear  Grease gun Check for faults, replace if necessary. The  
grease has to be refilled every 6000 hours (see

Maintenance and inspection

chapter 9.3.4 "Grease replenishment/exchange
for R-axis gear" on page 62).

16 B-axis gear  Grease gun Check for faults, replace if necessary. The  
grease has to be refilled every 6000 hours (see
chapter 9.3.5 "Grease replenishment/exchange
for B- and T-axes gear" on page 63).
9
- 49
 Inspection intervals
9 - 50

Maintenance and inspection

Item number1 Schedule Checking method Operation Inspection
Charge:

YASKAWA trained staff

Every 12000 hours
Every 24000 hours
Every 36000 hours
Every 1000 hours
Every 6000 hours

YASKAWA staff
trained staff
Daily
17 T-axes gear  Grease gun Check for faults, replace if necessary. The  
grease has to be refilled every 6000 hours (see
chapter 9.3.5.10 "Refilling grease at T-axis gear"
on page 64).
 Inspection intervals

Item number1 Schedule Checking method Operation Inspection

Charge:

YASKAWA trained staff

Every 12000 hours
Every 24000 hours
Every 36000 hours
Every 1000 hours
Every 6000 hours

YASKAWA staff
trained staff
Daily
18 Overhaul  
1. The item numbers correspond to the following diagram "Inspection intervals"

2. When checking for conduction with multimeter, connect the battery to "BAT" and "OBT" of connectors on the motor side for each axis. Now remove the connectors of the encoders of the
respective motor. Failure to observe this sequence can lead to loss of home positions (see section 9.2.3.1 "Wrist unit" on page 58

3. The internal wiring harness in the robot (for the S, L, U, R, B and T axes) must be replaced at the 24,000 hours inspection.

4. The grease and/or lubricants used can be found in the following table "Inspection parts and grease used".

Tab. 9-1: Inspection intervals

Maintenance and inspection

9
- 51
Maintenance and inspection

4
17

14

14

13
8
8
15
4
5

11
11

12

Fig. 9-2: Inspection intervals

The numbers in the above figure are equal to the numbers in the table of "Inspection
intervals".

9 - 52
 Maintenance and inspection

Inspection parts and grease used

No. Grease Used Material Inspected Parts

no.

12, 13 Molywhite grease RE No. 0 100274 S-, L-, U axes gear

14, 15 Harmonic grease 4B No. 2 127612 R- and B-axes gear

16 Grease Shell Gadus S2 V220 146745 T-axes gear

2

Tab. 9-2: Grease used

Safety datasheets on grease types can be requested from YEU-R.

9.2 Note on battery unit

9.2.1 Changing battery unit

$%

$%

$%
;$
OO0O

8#

1
2
4
3

Fig. 9-3: Battery unit location

1 Battery holder 3 Connector plate

2 Battery pack 4 Mounting screws of cover plate
The battery units are installed as shown in picture "The location of the battery unit".
If battery alarm occuring in the robot controller, battery pack has to be changed in the
following form.

9 - 53
Maintenance and inspection

1. Turn the robot controller to the main power supply (see Fig. 9-4: "Main power switch in
"switch-off" position").

WARNING
High Voltage
Do not open the door
with power ON.

Fig. 9-4: Main power switch in "switch-off" position

1 Main power switch in "switch-off" position

2. Remove the fixing screws from the cover plate.
3. Carefully pull out the battery pack from the base.

NOTICE
The absolute encoder data will be lost
Removing the battery pack, make sure you not to remove the plug from circuit board.

4. Connect the new battery pack to the unoccupied connector on the board.

6 1

Fig. 9-5: Battery pack connections

1 Old battery pack before replacement 4 Plug

2 New battery pack 5 Circuit board
3 See exchange, step 6 6 See exchange, step 7
5. Remove the old battery pack from the battery holder.
6. Mount the new battery pack to the battery holder.

NOTICE
The absolute encoder data will be lost
Never remove old battery pack before having installed new battery pack.

9 - 54
 Maintenance and inspection

7. Please remove old battery pack plug from circuit board.

NOTICE
Make sure that no wires are pinched when you install the battery pack and the cover plate
again.

8. Please apply Teroson Plast sealing compound (material no. 143813) to thread part of
screws.
Exchanging the battery unit iscompleted after reinstalling the cover plate on the plug plate.

9 - 55
Maintenance and inspection

9.2.2 Battery pack connector (including warning note)

3
2

OBT b a OBT*
BAT a b BAT

5 4

Fig. 9-6: Battery pack connector diagram for S-, L- and U-axes

1 Motor 4 Battery pack

2 Motor power connector 5 Plug for backup
3 Encoder connector
Before removing the encoder connector (with CAUTION label), connect the battery to the
motor as shown in the following figure.

9 - 56
 Maintenance and inspection

1
9

8 7
b OBT4
OBT a a BAT4
BAT b

removing connector.
to save the data before
Connect battery to encoder

CAUTION
5 3

6
OBT a b OBT4
4 BAT b a BAT4

Fig. 9-7: Battery pack connector diagram for R-, B- and T-axes

1 Encoder 6 Warning label

2 Motor cable 7 Power connector
3 Battery pack 8 Wiring harness of the robot
4 a: Plug - socket 9 Motor
b: Plug - pin
5 Encoder connector

9 - 57
Maintenance and inspection

9.2.3 Note on maintenance

9.2.3.1 Wrist unit

The motor and encoder units are provided with the wrist unit. To prevent fumes penetrating
into wrist unit, matched parts are sealed. If you have removed the wrist cover, the seal must
be replaced with Teroson Plast sealing compound (material no. 143813) (see section 10
"Recommended spare parts list" on page 77).

1 2

2
1

Fig. 9-8: Sealing wrist unit

1 Cover jointing face 2 Cover

9.3 Instructions on grease replenishment

Make sure to follow the instructions. If the following instructions are not followed, it might
cause damage to motor or gear.

NOTICE
 Make sure that the plug has been removed from the grease outlet. If the plug is not
removed, grease will enter the motor or the oil seal of the gear will be damaged. This
might cause damage to the motor or gear.
 Lubrication or grease replacement is only allowed at operating temperature.
 Do not install a joint, hose, etc. to the grease outlet. If this instruction is not followed, the
motor will be damaged.
 Avoid air getting into the gear.
 Insert grease with a grease gun.
 If an automatic lubricating pump is used, the grease supply pressure must be 0.3 kPa.
 Set the grease injection rate to a value not higher than 8 g/s.
 The limit values may not be exceeded also if a conventional grease gun is used.
 In ceiling-mounted robots the grease outlet and the grease inlet are located the other
way around (related to the figures in the operating and maintenance instructions).

9 - 58
 Maintenance and inspection

9.3.1 Grease replenishment/exchange for S-axis reduction gear unit

3 2

Fig. 9-9: S-axis gear

1 Grease exhaust port (plug) 3 Grease inlet port (plug)

2 S-axis gear

9.3.1.2 Refill grease

See figure "S-axis gear diagram".

NOTICE
Follow the instructions in the chapter 9.3 "Instructions on grease replenishment" on page
58.

1. Remove plug from grease exhaust port and grease inlet port.
2. Install lubricating nipple to grease inlet port.
3. Squeeze grease by grease gun in grease inlet port.
– Amount of grease: 400 cm³ / ca. 350 g
4. Move S-axis for a few minutes to discharge excess grease.
5. Wipe away excess grease with a cloth. Remove the grease zerk from the grease inlet
port, and reinstall the plug. Before mounting the plug, apply Teroson Plast sealing
compound (material no. 143813) to thread part.

9.3.1.3 Replace grease

See figure "S-axis gear diagram".
1. Remove plug from grease exhaust port and grease inlet port.
2. Install lubricating nipple to grease inlet port.
3. Squeeze grease by grease gun in grease inlet port.
– Amount of grease: 1950 cm³ / ca. 1700 g
Grease exchange has completed if new grease appears from grease exhaust port.
New grease seperates from old grease by lighter color.
4. Move S-axis for a few minutes to discharge excess grease.
5. Wipe away excess grease with a cloth. Remove the grease zerk from the grease inlet
port, and reinstall the plug. Before mounting the plug, apply Teroson Plast sealing
compound (material no. 143813) to thread part.

9 - 59
Maintenance and inspection

9.3.2 Grease replenishment/exchange for L-axis reduction gear unit

2 1

Fig. 9-10: L-axis gear

1 Grease leakage detection hole 3 Grease inlet port

2 L-arm

9.3.2.4 Refill grease

See figure "L-axis gear diagram".

NOTICE
Follow the instructions in the chapter 9.3 "Instructions on grease replenishment" on page
58.

1. Remove plug from grease exhaust port and grease inlet port.
2. Install the lubricating nipple.
3. Squeeze grease by grease gun in grease inlet port.
– Amount of grease: 170 cm³ / approx. 150 g
4. Move L-axis for a few minutes to discharge excess grease.
5. Wipe away excess grease with a cloth. Remove the grease zerk from the grease inlet
port, and reinstall the plug. Before installing the plugs, apply Teroson Plast sealing
compound (material no. 143813) to thread part.

9.3.2.5 Replace grease

See figure "L-axis gear diagram".
1. Remove plug from grease exhaust port and grease inlet port.
2. Install lubricating nipple to grease inlet port.
3. Squeeze grease by grease gun in grease inlet port.
– Amount of grease: 860 cm³ / approx. 750 g
Grease exchange has completed if new grease appears from grease exhaust port.
New grease seperates from old grease by lighter color.
4. Move L-axis for a few minutes to discharge excess grease.
5. Wipe away excess grease with a cloth. Remove the grease zerk from the grease inlet
port, and reinstall the plug. Before installing the plugs, apply Teroson Plast sealing
compound (material no. 143813) to thread part.

9 - 60
 Maintenance and inspection

9.3.3 Grease replenishment/exchange for U-axis reduction gear unit

Fig. 9-11: U-axis gear

1 U-arm 3 U-axis gear

2 Grease leakage detection hole 4 Grease inlet port

9.3.3.6 Refill grease

See figure "U-axis gear diagram".

NOTICE
Follow the instructions in the chapter 9.3 "Instructions on grease replenishment" on page
58.

1. Set U-arm horizontal to ground

2. Remove plug from grease exhaust port and grease inlet port.
3. Install lubricating nipple to grease inlet port.
4. Squeeze grease by grease gun in grease inlet port.
– Amount of grease: 90 cm³ / approx. 80 g
5. Move U-axis for a few minutes to discharge excess grease.
6. Wipe away excess grease with a cloth. Remove the grease zerk from the grease inlet
port, and reinstall the plug. Before installing the plugs, apply Teroson Plast sealing
compound (material no. 143813) to thread part.

9.3.3.7 Replace grease

See figure "U-axis gear diagram".
1. Remove plug from grease exhaust port and grease inlet port.
2. Install lubricating nipple to grease inlet port.
3. Squeeze grease by grease gun in grease inlet port.
– Amount of grease: 460 cm³ / approx. 400 g
Grease exchange has completed if new grease appears from grease exhaust port.
New grease seperates from old grease by lighter color.
4. Move S-axis for a few minutes to discharge excess grease.
5. Wipe away excess grease with a cloth. Remove the grease zerk from the grease inlet
port, and reinstall the plug. Before installing the plugs, apply Teroson Plast sealing
compound (material no. 143813) to thread part.

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Maintenance and inspection

9.3.4 Grease replenishment/exchange for R-axis gear

1
3

Fig. 9-12: R-axis gear

1 R-axis gear 3 Grease exhaust port (plug)

2 Grease inlet port (lubricating nipple)

9.3.4.8 Refill grease

See figure "R-axis gear diagram".

NOTICE
Follow the instructions in the chapter 9.3 "Instructions on grease replenishment" on page
58.

1. Remove plug from grease exhaust port and grease inlet port.
2. Install lubricating nipple to grease inlet port.
3. Squeeze grease by grease gun in grease inlet port
– Amount of grease: 12 cm³ / approx. 10 g
4. Move R-axis for a few minutes to discharge excess grease.
5. Wipe away excess grease with a cloth. Remove the grease zerk from the grease inlet
port, and reinstall the plug. Before mounting the plug, apply Teroson Plast sealing
compound (material no. 143813) to thread part.

9 - 62
 Maintenance and inspection

9.3.5 Grease replenishment/exchange for B- and T-axes gear

9.3.5.9 Refilling grease at B-axis gear

1
4

Fig. 9-13: B-axis gear

1 Grease inlet port 3 Grease exhaust port

2 B-axis gear 4 Cover
1. Remove plug from grease exhaust port and grease inlet port.
2. Install lubricating nipple to grease inlet port.
3. Squeeze grease by grease gun in grease inlet port.
– Amount of grease: 6 cm³ / approx. 5 g
4. Wipe away excess grease with a cloth. Remove the grease zerk from the grease inlet
port, and reinstall the plug. Before mounting the plug, apply Teroson Plast sealing
compound (material no. 143813) to thread part.

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Maintenance and inspection

9.3.5.10 Refilling grease at T-axis gear

1
Fig. 9-14: T-axis gear

1 Grease inlet 2 3 Grease inlet 1

2 Grease exhaust port
See figure "T-axis gear diagram".
1. Remove plug from grease exhaust port and grease inlet port.
2. Install lubricating nipple to grease inlet port.
3. Squeeze grease by grease gun in grease inlet port.
– Amount of grease: 11 cm³ / approx. 10 g
4. Move T-axis gear for a few minutes to discharge excess grease.
5. Wipe away excess grease with a cloth. Remove the grease zerk from the grease inlet
port, and reinstall the plug. Before mounting the plug, apply Teroson Plast sealing
compound (material no. 143813) to thread part.

9 - 64
 Maintenance and inspection

9.3.6 Replenishment/Exchange for R-axis cross roller bearings

Fig. 9-15: R-axes tapered roller bearing

1 Grease leakage detection hole 3 Grease inlet port

2 R-axis gear
See figure "R-axis cross roller bearing diagram".
1. Remove plug from grease exhaust port and grease inlet port.
2. Install lubricating nipple to grease inlet port.
3. Squeeze grease by grease gun in grease inlet port.
– Amount of grease: 45 cm³ / 40 g
4. Move R-axis gear for a few minutes to discharge excess grease.
5. Wipe away excess grease with a cloth. Remove the grease zerk from the grease inlet
port, and reinstall the plug. Before mounting the plug, apply Teroson Plast sealing
compound (material no. 143813) to thread part.

9.4 Home position calibration

Follow the safety instructions described in section 1.7 "Safety" on page 8 .

9 - 65
Maintenance and inspection

NOTICE
 Teaching or playback are not possible before the completion of the home position
calibration.
 Teach and save a second testing position immediately after installing the robot system.
This second testing position can be determined, e.g., by using tips (screw-in tip on the
torch, fixed counterpart on the cell wall) and stored in the robot controller.
 After a collision or in the event of track deviations it is recommended not to re-teach
individual jobs, but to approach and reset the basic position and/or the second home
position.
 After each collision or emergency stop situation the robot must be moved to its basic
position in setup mode and its home position must be checked.
 In a system with two or more Robots, the home position of all the Robots must be
calibrated before starting teaching or playback.
 For more information, see also system setup in the manual or contact your YASKAWA
branch.

When setting the home position, the position of the absolute encoder must match it.
Although this operation is performed prior to shipment at the factory, the following cases
require this operation to be performed again.
• Change in the combination of the robot and robot controller.
• Replacement of the motor or absolute encoder.
• Clearing stored memory (by replacement of the main CPU board, weak battery pack,
etc.).
• Home position deviation caused by hitting the robot.
Home position calibration
To calibrate the home position mark on each axis, use the axis keys, so that the robot can
take their position as home position.
There are two operations for home position calibration:
• All the axes can be moved at the same time.
– If the combination of robot and main board (CPU) has been changed, reset the
home position. The home position set by moving all axes simultaneously.
• Axes can be moved individually.
– If you have replaced the motor or the absolute encoder, reset the home position for
the individual axes.
If the absolute data of its posture for the home position is already known, set them again
after completing home position registration.

NOTICE
The window for calibrating the home position is only displayed if safety mode is selected as
the management mode.

9 - 66
 Maintenance and inspection

9.4.1 Register all axes

1. Select {ROBOT} from the main menu.

The sub-menu choices appear.

2. Select {HOME POSITION}.

The <HOME POSITIONING> window appears.

9 - 67
Maintenance and inspection

3. Select {DISPLAY}
The pull-down menu appears.

The same operation as in step 3 can also be performed by selecting the {PAGE} button.
In this case a selection box appears.

4. Select the sub-assembly to calibrate (e.g. R1:ROBOT).

Select the control group for {HOME POSITIONING}.
The control group can also be selected by pressing page key .
5. Select {EDIT} in the main menu.
The pull-down menu appears.

9 - 68
 Maintenance and inspection

6. Select {SELECT ALL AXES}.

A confirmation dialog box is displayed.

7. Select {YES}.
Displayed position data of all axes are registered as home position.
When {NO} is selected, the registration will be canceled.

9.4.2 Register individual axes

1. Select {ROBOT} from the main menu.

The sub-menu choices appear.
2. Select {HOME POSITION}.
3. Select the sub-assembly to calibrate (e.g. R1:ROBOT).
Carry out steps 3 and 4 as described in section 9.4.1 "Register all axes" on page 67 to
select the desired control group.
4. Move cursor to the axis that you want to register, and select it.

A confirmation dialog box appears.

5. Select {YES}.
The displayed position data of the selected axis is registered as home position.
When {NO} is selected, the registration will be canceled.

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Maintenance and inspection

9.4.3 Changing absolute data

After you have set the home position, change the absolute data of the axis as follows:
1. Select {ROBOT} from the main menu.
The sub-menu choices appear.
2. Select {HOME POSITION}.
3. select the sub-assembly/components to be calibrated.
Carry out steps 3 and 4 as described in section 9.4.1 "Register all axes" on page 67 to
select the desired control group.
4. Select the absolute data to be registered.

5. Enter the absolute data using the numeric keys.

6. Select {ENTER}.
The absolute encoder data is changed.

9.4.4 Clearing absolute data

Once you have set the home position, delete the absolute data of the axis as follows:
1. Select {ROBOT} from the main menu.
The sub-menu choices appear.
2. Select {HOME POSITION}.
Carry out steps 3 and 4 as described in section 9.4.1 "Register all axes" on page 67 to
select the desired control group.
3. Select {DATA} from the main menu.
The pull-down menu appears.

9 - 70
 Maintenance and inspection

4. Select {CLEAR ALL DATA}.

A confirmation dialog box appears.

5. Select {YES}.
All absolute data will be deleted.

When {NO} is selected, the registration will be canceled.

9.5 Setting the second home position (check point)

9.5.1 Purpose of position check operation

If the absolute number of rotations determined at power supply ON does not match the data
stored in the absolute encoder the last time the power supply was turned OFF, an error
message is issued.
There are two possible causes of this alarm:
• Error in the pulse generator system
• The robot was moved after the power supply was turned OFF
If the alarm "OUTSIDE THE RANGE (ABSOLUTE DATA)" appears, automatic mode is not
possible. The home position must be checked.

9 - 71
Maintenance and inspection

NOK

OK

1 If the "OUT OF RANGE (ABSO DA- 6 Compare second home position

TA)" alarm occurs: (check point)* pulses with current po-
sition pulses.
2 alarm reset 7 Alarm occurs again
3 SERVO-ON power ON 8 Correct the faulty axis, replace the
pulse generator system, set the home
position
4 Procedure after alarm 9 * Position checking point
5 Position confirmation operation 10 Automatic mode possible

9 - 72
 Maintenance and inspection

Position check
After the "OUT OF RANGE (ABSO DATA)" alarm occurs, move to the second home position
using the axis keys and perform the position confirmation. Automatic mode, test runs and
FWD movement cannot be performed without checking the position with "CONFIRM
POSITION".
Pulse difference check
The pulse number at the second home position is compared with that at the current position.
If the deviation is within the allowable range, automatic operation can be performed.
If not, the alarm occurs again.

NOTICE
 The allowable range pulse is the number of pulses per rotation of the motor (PPR data).
 The initial value of the second home position is the home position (where all axes are
at pulse 0). The second home position can be changed. For further information, refer to
9.5.2 "Procedure for the second home position setting" on page73.

Alarm messages
If the alarm occurs again, there may be an error in the pulse generator system. Check the
pulse generator system. After adjusting the faulty axis, calibrate the home position of the
axis, then check the position again.

NOTICE
Home position calibration of all axes at the same time enables automatic mode without to
checking position.
However, as a rule, always perform "CONFIRM POSITION". Under the above special
conditions, the robot moves as follows:
 After the start, the robot moves at low speed (1/10 of the maximum speed) to the step
indicated by the cursor. If the robot stops and restarts during this motion, speed is
retained until wanted step at cursor is reached.
 Regardless of cycle setting, the robot stops after reaching cursor indicated step.
Starting the Robot again then moves it at the programmed speed and cycle of the job.

9.5.2 Procedure for the second home position setting

Apart from the “home position” of the robot, the second home position can be set up as a
check point for absolute data. Use the following steps to set the specified point.

NOTICE
If 2 or more Robots or stations are controlled by one controller, the second home position
must be set for each robot or station.

9 - 73
Maintenance and inspection

1. Select {ROBOT} from the main menu.

- The sub-menu choices appear.

2. Select {SECOND HOME POS}.

The {SECOND HOME POS} window appears. Message is spoken „Available to move
to and modify specified point“.

3. Press the „page key“ or select {PAGE} to display the selection window for the
control group.
Occuring 2 or more group axes, select those one to you intend to specify second home
position.

4. Press the axis keys.

- Move the Robot to the new second home position.
5. Press {MODIFY} then {ENTER}.
- The second home position is changed.

9 - 74
 Maintenance and inspection

9.5.3 Procedure after alarm

Follow the safety instructions described in section 1.7 "Safety" on page 8 .

WARNING!
Death or injury because of danger of crushing
Irregularities in the PG system may lead to an alarm and the robot may perform unexpected
movements.

If the "OUT OF RANGE (ABSO DATA)" alarm occurs,

• Reset the alarm.
• the SERVO power ON.
Then confirm the second home position. After the confirmation, if the PG system is found
to be the cause of the alarm, perform the necessary operation, such as replacing the PG
system, etc.
The robot current position data when turning main power supply ON and OFF can be
confirmed in {POWER ON/OFF POS} window.
1. Select {ROBOT} from the main menu.
The sub-menu choices appear.
2. Select {SECOND HOME POS} from the main menu.
The SECOND HOME POS window appears.

3. Press the „page key“ or select {PAGE} to display the selection window for the
control group.
Occuring two or more group axes, select those one to you intend to specify second
home position.

9 - 75
Maintenance and inspection

4. Press {FWD}.
TCP moves to the second home position. The robot moving speed is set as selected
manual speed.
5. Select {DATA} in the menu.
6. Select {CONFIRM POSITION}.
A message "Home position checked" appears.
Pulse data of the second home position and current pulse data should be compared.
Automatic mode can be done if compared error is in allowed range.
If the error is beyond the allowed range, the alarm occurs again.

9 - 76
 Recommended spare parts list

10 Recommended spare parts list

It is recommended to keep in stock parts and components in the following table as spare
parts. Product performance cannot be guaranteed when using spare parts from any
company other than YASKAWA.
The spare parts are ranked as follows:
• Category A:
– Expendable and frequently replaced parts.
• Category B:
– Parts for which replacement may be necessary as a result of frequent operation.
• Category C:
– Motor

NOTICE
Please contact your YASKAWA branch office if you need spare or replacement parts.

List of recommended spare parts for stocking

Qty per unit

Material no.
Description
Category

Type

Qty
A Grease Molywhite RE No. 0 100274 16 kg -

A Grease Harmonic grease SK1A 127610 2.5 kg -

A Grease Grease Shell Gadus S2 E146745 16 kg -

V220 2

A Sealing compound Teroson Plast 143813 200 ml -

A Battery pack Robot 128708 1 1

A Battery pack Control 155543 1 1

A Protective tube MTK-50FR 1.5 m 1

B Toothed belt B-axis 60S3.M642 164742 1 1

B Toothed belt T-axis 80S3.M819 164744 1 1

B S-axis gear Y005C-MA02010A00S E144081 1 1

HW0387753-B

B Pinion S-axis HW0312491-1 1 1

B L-axis gear Y005C-MA02010A00L 1 1

HW0387753-G

B Pinion L-axis HW1304336-1 1 1

B U-axis gear Y005C-MA02010A00U 1 1

HW0386621-C

B Pinion U-axis HW1304321-1 1 1

10 - 77
Recommended spare parts list

List of recommended spare parts for stocking

Qty per unit

Material no.
Description
Category

Type

Qty
B R-axis gear Y005C-MA02010A00R 164748 1 1
HW1382521-A

B B-axis gear Y005C-MA02010A00B 1 1

B Pinion T-axis Y005C-MA02010A00T 1 1

B Pinion R-axis Y005C-MA02010A00RU 1 1

B Wrist unit Y005C-MA02010A00BT 1 1

B Wiring harness in the ro- HW1171441-A 1 1

bot

B Internal wiring harness for HW1271107-A 1 1

B- and T-axes

C S-axis motor HW0388665-A E144076 1 1

SGMRV-09ANA-YR1*

C L-axis motor HW0388666-A 1 1

SGMRV-13ANA-YR1*

C U-axis motor HW0388663-A 1 2

SGMRV-05ANA-YR1*

C R-axis motor HW0389295-A 1 1

SGMAV-02ANA-YR1*

C B- and T-axes motor HW0389294-A E144070 1 2

SGMAV-01ANA-YR1*

C Circuit board SGDR-EFBA02A 1 1

10 - 78
 Parts lists

11 Parts lists
11.1 S-axis unit

1026 1027 1002

1014 1003
1004
1027

1044
1008
1030

1012
1005
1011
1006

1038
1039
1037 1035 1007
1032
1036 1033 1043

1041
1034 1042
1037
1036 1039

1040
1038

1001

1015
1021
1016
1046
1024 1045
1022
1046
1045
1029
1046
1010
1019 1031

1020 1009
1023
1028

1013

1025

1017
1018

Fig. 11-1: S-axis drive

11 - 79
Parts lists

No. DWG no. Designation Pcs

1001 HW1100684-1 Stand 1
1002 M8 x 30 Screw 3
1003 M4 X 8 Screw 4
1004 2H-4 Washer 4
1005 M8 x 50 Screw 3
1006 2H-8 Washer 3
1007 HW1304342-1 Housing 1
1008 HW0313491-1 Pinion 1
1009 HW0387753-B Gear box 1
1010 M10 x 40 Screw 16
1011 M6 x 60 Screw 1
1012 2H-6 Washer 1
1013 HW1100683-1 Housing 1
1014 SGMRV-09ANA-YR1* Motor 1
1015 M12 x 45 Screw 8
1016 2H-12 Washer 8
1017 TSH8-03 Link 1
1018 NB-0860 Hose 1
1019 MSB8-15 Screw 1
1020 HW0400645-3 Plug 1
1021 TSH8-03 Support 1
1022 HW1304380-1 Cover 1
1023 M6 x 15 Screw 7
1024 M6 x 15 Screw 2
1025 M5 x 10 Screw 6
1026 HW1304381-A Cover 1
1027 M6 x 15 Screw 11
1028 EZ5036A0 Sealing plug 1
1029 HW1304382-1 Cover 1
1030 HW1304379-1 Cover 1
1031 PMF8-03 Link 1
1032 HW1405431-1 Support 1
1033 TA1-S10 Terminal 1
1034 M5 x 8 Screw 1
1035 T50R Cable tie 1
1036 M5 x 12 Screw 4
1037 CD-31 Clamp 2
1038 M5 x 8 Screw 4

11 - 80
 Parts lists

No. DWG no. Designation Pcs

1039 2H-5 Washer 4
1040 HW1405589-1 Support 1
1041 TA1-S10 Terminal 1
1042 M5 x 8 Screw 1
1043 T50R Cable tie 1
1044 C-30-SG-30A Cover 1
1045 KQ2L08-00 Link 2
1046 NB-0860 Hose 3
Tab. 11-1: S-axis drive

11 - 81
Parts lists

11.2 L-axis unit

2016
2024
2022

2025

2018

2023

2017
2013
2020
2002 2019 2015
2004
2003

2014
2012

2001

2011 2008
2007

2021 2006
2005
2010
1001 2009

Fig. 11-2: L-axis drive

No. DWG no. Designation Pcs

2001 HW1100696-1 L-arm 1
2002 HW1304336-1 Pinion 1
2003 M6 x 90 Screw 1
2004 2H-6 Washer 1
2005 M12 x 40 Screw 12
2006 2H-12 Washer 12
2007 M10 x 35 Screw 6
2008 2H-10 Washer 6
2009 M12 x 35 Screw 2
2010 HW1405429-1 Washer 2
2011 HW0387753-G Gear box 1
2012 M10 x 40 Screw 16
2013 HW0401506-1 Washer 1

11 - 82
 Parts lists

No. DWG no. Designation Pcs

2014 HW1304555-1 Housing 1
2015 M8 x 30 Screw 4
2016 SGMRV-13ANA-YR1* Motor 1
2017 Y426012.5 Oil seal 1
2018 M8 x 25 Screw 4
2019 PT1/8 Set screw 2
2020 PT3/8 Set screw 1
2021 NPTF3/8 Set screw 1
2022 HW1405456-1 Cover 1
2023 M6 x 15 Screw 4
2024 HW1405226-1 Support 1
2025 M5 x 10 Screw 2
1001 HW1100684-1 Housing 1
Tab. 11-2: L-axis drive

11 - 83
Parts lists

11.3 U-axis drive

3021
3023
3022
3025
3018 3024
3019
3026 3001
3027 3028
3020
3029

3004
3017 3011
3015 3007
3014 3006 3002
3012
3013

3003
3002

2001

3009
3016
3005

3008

Fig. 11-3: U-axis drive

11 - 84
 Parts lists

No. DWG no. Designation Pcs

3001 HW1100686-1 Housing 1
3002 M12 x 25 Screw 2
3003 2H-12 Washer 2
3004 HW1304321-1 Pinion 1
3005 NPTF3/8 Set screw 1
3006 M5 x 90 Screw 1
3007 2H-5 Washer 1
3008 HW0386621-C Gear box 1
3009 M6 x 35 Screw 16
3011 M5 x 16 Screw 3
3012 M8 x 40 Screw 18
3013 2H-8 Washer 18
3014 SGMRV-05ANA-YR1* Motor 1
3015 M8 x 30 Screw 4
3016 PT3/8 Set screw 1
3017 M4 X 12 Screw 3
3018 HW1405434-1 Cover 1
3019 CP-30-OB-8 Plug 1
3020 HW1405433-1 Cover 1
3021 M4 X 12 Screw 3
3022 KQE12-03 Union 1
3023 PT3/8 Set screw 1
3024 KQE10-03 Union 1
3025 PT3/8 Set screw 1
3026 M3 x 16 Screw 2
3027 M3 Nut 2
3028 HW1405648-1 Housing 1
3029 M4 X 12 Screw 5
2001 HW1100696-1 L-arm 1
Tab. 11-3: U-axis drive

11 - 85
Parts lists

11.4 R-axis unit

4056 5063
4057
4054
4055

4058 4061

4063 4062
4059
4060
4011

4012
4010
4013
4008 4031
4029 4032
4030
4009 4028 3001

4034
4042
4040 4037
4038
4035
4036 4033
4035 4038
4006 4039
4002
4052 4041
4047
4016
4023 4007
4048
4024

4026

4004 4003 4049

4005 4051
4019
4018
4015 4017 4043
4020 4046
4001 4044
4025 4027
4014
4053 4045

4021 4050

4022

Fig. 11-4: R-axis drive

11 - 86
 Parts lists

No. DWG no. Designation Pcs

4001 HW1200340-1 Housing 1
4002 M5 x 45 Screw 8
4003 HW1304319-1 Pinion 1
4004 HW1303257-2 Shaft 1
4005 M3 x 12 Screw 5
4006 HW1382521-A Gear box 1
4007 TC52647 Oil seal 1
4008 M6 x 40 Screw 7
4009 HW1304069-1 Shaft 1
4010 TC1151306 Oil seal 1
4011 M6 x 20 Screw 6
4012 M6 x 20 Screw 7
4013 HW1304196-1 Shaft 1
4014 SGMAV-02ANA-YR1* Motor 1
4015 TC20305 (FKM) Oil seal 1
4016 M3 x 12 Screw 6
4017 HW1405390-1 Housing 1
4018 HW1304320-1 Pinion 1
4019 M4 X 14 Screw 1
4020 2H-4 Washer 1
4021 M3 x 12 Screw 4
4022 M4 X 12 Screw 4
4023 M4 X 12 Screw 4
4024 PT1/8 Set screw 3
4025 PT1/8 Set screw 1
4026 HW1404157-* Sim 1
4027 HW1405571-* Sim 1
4028 TA1-S8 Terminal 1
4029 M4 X 6 Screw 1
4030 M4 Washer 1
4031 T30R Cable tie 1
4032 HW1405181-1 Support 1
4033 PZ1212 Clamp 1
4034 PZ1208 Clamp 1
4035 M4 x6 Screw 4
4036 M4 X 12 Screw 2
4037 HW1405459-1 Cover 1
4038 M4 X 6 Screw 4
4039 PZ1208 Clamp 1
4040 HW1405430-1 Support 1
4041 M4 X 12 Screw 2

11 - 87
Parts lists

No. DWG no. Designation Pcs

4042 PZ1212 Clamp 1
4043 TA1-S8 Terminal 1
4044 M4X6 (STAINLESS) Screw 1
4045 T50R Cable tie 1
4046 HW1404041-1 Production support 1
4047 M4 X 12 Screw 2
4048 HW1404786-1 Gasket 1
4049 HW1303904-1 Cover 1
4050 M4 X 12 Screw 7
4051 HW9481319-D Cable feedthrough 1
4052 M4 X 12 Screw 1
4053 M4 X 12 Screw 2
4054 HW1200341-1 Spacer 1
4055 HW1405367-1 Cover 1
4056 M4 X 10 Screw 10
4057 MSTH6-20 Pin 1
4058 HW1304345-1 Shaft 1
4059 M6X25 Screw 6
4060 HW1405461-1 Support 2
4061 M4X12 Screw 4
4062 M6X25 Screw 6
4063 HW1405368-1 Cover 1
3001 HW1100686-1 Housing 1
5063 HW1100618-1 U-arm 1
Tab. 11-4: R-axis drive

11 - 88
 Parts lists

11.5 Wrist unit

5043
5045
5008
5007 5041
5006 5001
5047 5040
5035 5005 5046

5042

5055 5044
5039 5009
5038 5028
5036
5037
5001

5026 5002
5003
5021
5005 5005
5025
5022 5019
5018
5020
5005
5027
5029 5031
5009 5016 5030 5024
5005
5033
5017 5028
5032
5066
5015
5011
5034
5013 5023
5014 5062
5012
5065 5063

5010 5054
5058 5051
5050 5005
5058 5048

5059 5064
5052
5060
5049 5005
5010
5061
5065 5053
5014
5066 5015

4054 5056

5057

5009

Fig. 11-5: Wrist unit

11 - 89
Parts lists

No. DWG no. Designation Pcs

5001 M6 x 6 Screw 5
5002 HW0404371-1 Screw 1
5003 HW1404058-1 Cover 1
5005 M3 x 10 Screw 39
5006 HW1404060-1 Packing 1
5007 HW1404069-1 Cover 1
5008 M4X10 (STAINLESS) Screw 2
5009 M4 X 12 Screw 23
5010 M4 X 10 Screw 4
5011 HW1404053-1 Flywheel 1
5012 HW1404038-A Pulley 1
5013 M4 X 16 Screw 1
5014 2H-4 Washer 2
5015 M4 X 16 Screw 4
5016 HW1303244-1 Cover 1
5017 80S3M819 Toothed belt 1
5018 WR20 Terminal 1
5019 HW1303260-1 Shaft 1
5020 HW1404049-1 Cover 1
5021 M8 x 40 Screw 1
5022 2H-8 Washer 1
5023 HW1481728-A Bearing 1
5024 6809DDU Bearing 1
5025 HW1404059-6 Spring 1
5026 HW1303248-1 Pinion 1
5027 6804 Bearing 1
5028 M3 x 28 Screw 18
5029 M8 x 20 Screw 1
5030 2H-8 Washer 1
5031 HW1404039-A Pulley 1
5032 HW1303249-1 Pinion 1
5033 HW1404048-1 Cover 1
5034 HW1404054-1 Shaft 1
5035 TC50606 Oil seal 1
5036 AR28 Terminal 1
5037 WR15 Terminal 1
5038 NA4902 Bearing 1
5039 HW1303250-1 Pinion 1
5040 HW1371294-A Assembly gear 1
5041 RA9008C0 Bearing 1
5042 TC1001105 Oil seal 1

11 - 90
 Parts lists

No. DWG no. Designation Pcs

5043 TC64746 Oil seal 1
5044 HW1303261-1 Flange 1
5045 HW1404055-1 Holder 1
5046 HW1303262-1 Flange 1
5047 HW1100619-1 Housing 1
5048 HW1303259-1 Shaft 1
5049 M3 x 20 Screw 12
5050 IRTW26 Circlip 1
5051 6803LLU Bearing 1
5052 HW1404037-A Pulley 1
5053 M3 x 16 Screw 4
5054 HW1404047-1 Housing 1
5055 HW1382522-A Gear box 1
5056 60S3M642 Toothed belt 1
5057 HW1303243-1 Cover 1
5058 SGMAV-01ANA-YR1* Motor 2
5059 HW1404046-1 Housing 1
5060 HW1404036-A Pulley 1
5061 M4 X 12 Screw 1
5062 HW1404052-1 Housing 1
5063 HW1100618-1 U-arm 1
5064 6902 Bearing 1
5065 HW1404516-1 Cover 2
5066 M4 X 8 Screw 4
4054 HW1200341-1 Spacer 1
Tab. 11-5: Wrist unit

11 - 91
Parts lists

11.6 Gear unit

6004 6001

6007
6002 6005

6003
6006

Fig. 11-6: Gear unit

No. DWG no. Designation Pcs

6001 HW1303251-1 Gear box 1
6002 HW1303252-1 Gear box 1
6003 HW1404051-1 Sleeve 2
6004 HW1404050-1 Pin 6
6005 WB5-30 Clamping sleeve 3
6006 M3 x 12 Screw 2
6007 M3 x 10 Screw 2
Tab. 11-6: Parts list gear unit

11 - 92
Parts lists

11 - 93
YASKAWA contacts

YASKAWA YASKAWA Europe GmbH YASKAWA academy and YASKAWA Europe GmbH
Headquarters Robotics Division sales office Frankfurt Robotics Division
Yaskawastraße 1 Hauptstraße 185
D-85391 Allershausen D-65760 Eschborn
Tel. +49 (0) 8166/90-0 Tel. +49 (0) 6196/77725-0
Fax +49 (0) 8166/90-103 Fax +49 (0) 6196/77725-39

YASKAWA Group Distributors

A YASKAWA Austria BG Kammarton Bulgaria Ltd.
Schwechat/Wien +43(0)1-707-9324-15 Sofia +359-02-926-6060
CZ YASKAWA Czech s.r.o. CH Messer Eutectic Castolin Switzerland S.A.
Rudná u Prahy +420-257-941-718 Dällikon +41-44-847-17-17
E YASKAWA Ibérica, S.L. DK Robotcenter Danmark
Gavà/Barcelona +34-93-6303478 Løsning +45 7022 2477
F YASKAWA France SARL EE RKR Seadmed OÜ
Saint-Aignan-de-Grand-Lieu Tallinn/Estonia +372-68-35-235
+33-2-40131919 GR Gizelis Robotics
FIN YASKAWA Finland Oy Nea Kifissia +30-2106251455
Turku +358-(0)-403000600 H Flexman Robotics Kft
GB YASKAWA UK Ltd. Budapest +36-30-9510065
Banbury +44-1295-272755 LT Profibus UAB
I YASKAWA Italia s.r.l. Panevezys +370-45-518575
Torino +39-011-9005833 N Skala Robotech AS
IL YASKAWA Europe Technology Ltd. Lierstranda +47-32240600
Rosh Ha’ayin +972-3-9004114 PL Integrator RHC Sp. z o.o.
NL YASKAWA Benelux B.V. Torun +48-56-6519710
EB Son +31-40-2895500 PT ROBOPLAN Lda
RUS YASKAWA Nordic AB Aveiro +351-234 943 900
Moskva +46-480-417-800 RO Sam Robotics srl
SE YASKAWA Nordic AB Timisoara +40-720-279-866
Torsås +46-480-417-800 RO MPL Automation S.R.L.
SI YASKAWA Slovenia Satu Mare +40 (0) 261 750 741
Ribnica +386-1-8372-410
TR YASKAWA Turkey Elektrik Ticaret Ltd. Sti.
İstanbul +90-216-5273450
ZA YASKAWA Southern Africa (PTY) Ltd
Johannesburg +27-11-6083182

www.yaskawa.eu.com
[email protected]

Technical data may be subject to change without previous notice.