Motoman® NX100 Controller

SSF2000
Manipulator Manual

Part Number: 153683-1CD

Revision: 0

Motoman, Incorporated
805 Liberty Lane
West Carrollton, Ohio 45449 USA
937.847.6200 (Voice)
937.847.6277 (Fax)
937.847.3200 (24-Hour Support)
www.motoman.com
info@motoman.com
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received with your Motoman robotic solution.
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The information contained within this document is the proprietary property of Motoman, Inc., and may not be
copied, reproduced or transmitted to other parties without the expressed written authorization of Motoman,
Inc.

©2007 by MOTOMAN
All Rights Reserved

Because we are constantly improving our products, we reserve the right to change specifications without
notice. MOTOMAN is a registered trademark of YASKAWA Electric Manufacturing.
 SSF2000
153683-1

Chapter 1

Introduction

1.1 About This Document

This manual provides information for the SSF2000 manipulator and contains the following sections:
CHAPTER 1 - INTRODUCTION
Provides general information about the structure of this manual, a list of reference documents, and
customer service information.
CHAPTER 2 - SAFETY
This section provides information regarding the safe use and operation of Motoman products.
CHAPTER 3 - SSF2000 INSTRUCTIONS
Provides detailed information for the SSF2000 manipulator.

1.2 Reference to Other Documentation

For additional information refer to the following:
• NX100 Controller Manual (P/N 149201-1)
• Concurrent I/O Manual (P/N 149230-1)
• Operator’s Manual for your application
• Vendor manuals for system components not manufactured by Motoman

1.3 Customer Service Information

If you are in need of technical assistance, contact the Motoman service staff at (937) 847-3200. Please have
the following information ready before you call:
• Robot Type (SSF2000)
• Application Type (welding, handling, etc.)
• Robot Serial Number (located on back side of robot arm)
• Robot Sales Order Number (located on back of controller)

Final page 1
Manipulator Manual
Chapter 1 Introduction

Notes

page 2 Final
 SSF2000
153683-1

Chapter 2

Safety

2.1 Introduction

It is the purchaser’s responsibility to ensure that all local, county, state,

and national codes, regulations, rules, or laws relating to safety and safe
operating conditions for each installation are met and followed.

We suggest that you obtain and review a copy of the ANSI/RIA National Safety Standard for
Industrial Robots and Robot Systems. This information can be obtained from the Robotic Industries
Association by requesting ANSI/RIA R15.06-1999. The address is as follows:
Robotic Industries Association
900 Victors Way
P.O. Box 3724
Ann Arbor, Michigan 48106
TEL: (734) 994-6088
FAX: (734) 994-3338
INTERNET: www.roboticsonline.com

Ultimately, the best safeguard is trained personnel. The user is responsible for providing personnel
who are adequately trained to operate, program, and maintain the robot cell. The robot must not be
operated by personnel who have not been trained!

We recommend that all personnel who intend to operate, program, repair, or use the robot system be
trained in an approved Motoman training course and become familiar with the proper operation of the
system.

Final page 3
Manipulator Manual
Chapter 2 Safety

This safety section addresses the following:

• Standard Conventions (Section 2.2)
• General Safeguarding Tips (Section 2.3)
• Mechanical Safety Devices (Section 2.4)
• Installation Safety (Section 2.5)
• Programming, Operation, and Maintenance Safety (Section 2.6)

2.2 Standard Conventions

This manual includes the following alerts – in descending order of severity – that are essential to the
safety of personnel and equipment. As you read this manual, pay close attention to these alerts to
insure safety when installing, operating, programming, and maintaining this equipment.

DANGER!
Information appearing in a DANGER concerns the protection of personnel from the immediate
and imminent hazards that, if not avoided, will result in immediate, serious personal injury or
loss of life in addition to equipment damage.

WARNING!
Information appearing in a WARNING concerns the protection of personnel and equipment from
potential hazards that can result in personal injury or loss of life in addition to equipment
damage.

CAUTION!
Information appearing in a CAUTION concerns the protection of personnel and equipment,
software, and data from hazards that can result in minor personal injury or equipment damage.

Note: Information appearing in a Note provides additional information which is helpful in understanding the item being
explained.

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 SSF2000
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2.3 General Safeguarding Tips

All operators, programmers, plant and tooling engineers, maintenance personnel, supervisors, and
anyone working near the robot must become familiar with the operation of this equipment. All
personnel involved with the operation of the equipment must understand potential dangers of
operation. General safeguarding tips are as follows:
• Improper operation can result in personal injury and/or damage to the equipment. Only
trained personnel familiar with the operation of this robot, the operator's manuals, the system
equipment, and options and accessories should be permitted to operate this robot system.
• Do not enter the robot cell while it is in automatic operation. Programmers must have the
teach pendant when they enter the robot cell.
• Improper connections can damage the robot. All connections must be made within the
standard voltage and current ratings of the robot I/O (Inputs and Outputs).
• The robot must be placed in Emergency Stop (E-STOP) mode whenever it is not in use.
• In accordance with ANSI/RIA R15.06-1999, section 4.2.5, Sources of Energy, use
lockout/tagout procedures during equipment maintenance. Refer also to Section 1910.147
(29CFR, Part 1910), Occupational Safety and Health Standards for General Industry
(OSHA).

2.4 Mechanical Safety Devices

The safe operation of the robot, positioner, auxiliary equipment, and system is ultimately the user's
responsibility. The conditions under which the equipment will be operated safely should be reviewed
by the user. The user must be aware of the various national codes, ANSI/RIA R15.06-1999 safety
standards, and other local codes that may pertain to the installation and use of industrial equipment.
Additional safety measures for personnel and equipment may be required depending on system
installation, operation, and/or location. The following safety equipment is provided as standard:
• Safety fences and barriers
• Light curtains and/or safety mats
• Door interlocks
• Emergency stop palm buttons located on operator station, robot controller, and
programming pendant

Check all safety equipment frequently for proper operation. Repair or replace any non-functioning
safety equipment immediately.

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Manipulator Manual
Chapter 2 Safety

2.5 Installation Safety

Safe installation is essential for protection of people and equipment. The following suggestions are
intended to supplement, but not replace, existing federal, local, and state laws and regulations.
Additional safety measures for personnel and equipment may be required depending on system
installation, operation, and/or location. Installation tips are as follows:
• Be sure that only qualified personnel familiar with national codes, local codes, and
ANSI/RIA R15.06-1999 safety standards are permitted to install the equipment.
• Identify the work envelope of each robot with floor markings, signs, and barriers.
• Position all controllers outside the robot work envelope.
• Whenever possible, install safety fences to protect against unauthorized entry into the work
envelope.
• Eliminate areas where personnel might get trapped between a moving robot and other
equipment (pinch points).
• Provide sufficient room inside the workcell to permit safe teaching and maintenance
procedures.

2.6 Programming, Operation, and Maintenance Safety

All operators, programmers, plant and tooling engineers, maintenance personnel, supervisors, and
anyone working near the robot must become familiar with the operation of this equipment. Improper
operation can result in personal injury and/or damage to the equipment. Only trained personnel
familiar with the operation, manuals, electrical design, and equipment interconnections of this robot
should be permitted to program, operate, and maintain the system. All personnel involved with the
operation of the equipment must understand potential dangers of operation.
• Inspect the robot and work envelope to be sure no potentially hazardous conditions exist. Be
sure the area is clean and free of water, oil, debris, etc.
• Be sure that all safeguards are in place. Check all safety equipment for proper operation.
Repair or replace any non-functioning safety equipment immediately.
• Do not enter the robot cell while it is in automatic operation. Be sure that only the person
holding the programming pendant enters the workcell.
• Check the E-STOP button on the programming pendant for proper operation before
programming. The robot must be placed in Emergency Stop (E-STOP) mode whenever it is
not in use.
• Back up all programs and jobs onto suitable media before program changes are made. To
avoid loss of information, programs, or jobs, a backup must always be made before any
service procedures are done and before any changes are made to options, accessories, or
equipment.

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 SSF2000
153683-1

• Any modifications to PART 1, System Section, of the robot controller concurrent I/O
program can cause severe personal injury or death, as well as damage to the robot! Do not
make any modifications to PART 1, System Section. Making any changes without the written
permission of Motoman will VOID YOUR WARRANTY!
• Some operations require standard passwords and some require special passwords. Special
passwords are for Motoman use only. YOUR WARRANTY WILL BE VOID if you use
these special passwords.
• The robot controller allows modifications of PART 2, User Section, of the concurrent I/O
program and modifications to controller parameters for maximum robot performance. Great
care must be taken when making these modifications. All modifications made to the
controller will change the way the robot operates and can cause severe personal injury or
death, as well as damage the robot and other parts of the system. Double-check all
modifications under every mode of robot operation to ensure that you have not created
hazards or dangerous situations.
• Check and test any new or modified program at low speed for at least one full cycle.
• This equipment has multiple sources of electrical supply. Electrical interconnections are
made between the controller and other equipment. Disconnect and lockout/tagout all
electrical circuits before making any modifications or connections.
• Do not perform any maintenance procedures before reading and understanding the proper
procedures in the appropriate manual.
• Use proper replacement parts.
• Improper connections can damage the robot. All connections must be made within the
standard voltage and current ratings of the robot I/O (Inputs and Outputs).

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Manipulator Manual
Chapter 2 Safety

Notes

page 8 Final
 YASKAWA

MOTOMAN-SSF2000
INSTRUCTIONS
TYPE: YR-SSF6-A00 (STANDARD SPECIFICATION)
YR-SSF6-A01 (WITH LIMIT SWITCHES FOR S-, L-, U-AXES)

Upon receipt of the product and prior to initial operation, read these instructions thoroughly, and retain
for future reference.

MOTOMAN INSTRUCTIONS
MOTOMAN-SSF2000 INSTRUCTIONS
NX100 INSTRUCTIONS
NX100 OPERATOR’S MANUAL
NX100 MAINTENANCE MANUAL
The NX100 operator’s manuals above correspond to specific usage.
Be sure to use the appropriate manual.

YASKAWA MANUAL NO.

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MANDATORY
• This instruction manual is intended to explain operating instructions
and maintenance procedures primarily for the MOTOMAN-SSF2000.

• General items related to safety are listed in the Section 1: Safety of the
NX100 instructions. To ensure correct and safe operation, carefully
read the NX100 instructions before reading this manual.

CAUTION
• Some drawings in this manual are shown with the protective covers or
shields removed for clarity. Be sure all covers and shields are replaced
before operating this product.

• The drawings and photos in this manual are representative examples

and differences may exist between them and the delivered product.

• YASKAWA may modify this model without notice when necessary due to
product improvements, modifications, or changes in specifications.
If such modification is made, the manual number will also be revised.

• If your copy of the manual is damaged or lost, contact a YASKAWA rep-

resentative to order a new copy. The representatives are listed on the
back cover. Be sure to tell the representative the manual number listed
on the front cover.

• YASKAWA is not responsible for incidents arising from unauthorized

modification of its products. Unauthorized modification voids your prod-
uct’s warranty.

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Notes for Safe Operation

Read this manual carefully before installation, operation, maintenance, or inspection of the
NX100.
In this manual, the Notes for Safe Operation are classified as “WARNING”, “CAUTION”,
“MANDATORY”, or “PROHIBITED”.

Indicates a potentially hazardous situation which, if not avoided,

WARNING could result in death or serious injury to personnel.

Indicates a potentially hazardous situation which, if not avoided,

CAUTION could result in minor or moderate injury to personnel and dam-
age to equipment. It may also be used to alert against unsafe
practices.

Always be sure to follow explicitly the items listed under this

MANDATORY heading.

PROHIBITED Must never be performed.

Even items described as “CAUTION” may result in a serious accident in some situations.
At any rate, be sure to follow these important items.

NOTE To ensure safe and efficient operation at all times, be sure to follow all instructions, even if
not designated as “CAUTION” and “WARNING”.

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WARNING
• Before operating the manipulator, check that servo power is turned off
when the emergency stop buttons on the front door of the NX100 and
programing pendant are pressed.
When the servo power is turned off, the SERVO ON LED on the program-
ing pendant is turned off.

Injury or damage to machinery may result if the emergency stop circuit cannot stop the
manipulator during an emergency. The manipulator should not be used if the emergency
stop buttons do not function.

Emergency Stop Button

• Once the emergency stop button is released, clear the cell of all items
which could interfere with the operation of the manipulator.
Then turn the servo power ON.

Injury may result from unintentional or unexpected manipulator motion.

TURN

Release of Emergency Stop

• Observe the following precautions when performing teaching operations

within the working envelope of the manipulator :
- View the manipulator from the front whenever possible.
- Always follow the predetermined operating procedure.
- Ensure that you have a safe place to retreat in case of emergency.

Improper or unintended manipulator operation may result in injury.

• Confirm that no persons are present in the manipulator’s work envelope

and that you are in a safe location before:
- Turning on the NX100 power
- Moving the manipulator with the programing pendant
- Running check operations
- Performing automatic operations

Injury may result if anyone enters the working envelope of the manipulator during opera-
tion. Always press an emergency stop button immediately if there are problems.
The emergency stop button is located on the right of the front door of the NX100 and pro-
graming pendant.

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CAUTION
• Perform the following inspection procedures prior to conducting manip-
ulator teaching. If problems are found, repair them immediately,
and be sure that all other necessary processing has been performed.
-Check for problems in manipulator movement.
-Check for damage to insulation and sheathing of external wires.

• Always return the programing pendant to the hook on the NX100 cabi-
net after use.

The programing pendant can be damaged if it is left in the manipulator’s work area, on the
floor, or near fixtures.

• Read and understand the Explanation of the Warning Labels in the

NX100 instructions before operating the manipulator.

Definition of Terms Used Often in This Manual

The MOTOMAN manipulator is the YASKAWA industrial robot product.
The manipulator usually consists of the controller, the programing pendant, and manipulator
cables.
In this manual, the equipment is designated as follows:

Equipment Manual Designation

NX100 Controller NX100

NX100 Programing Pendant Programing Pendant

Cable between the manipulator and controller Manipulator Cable

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Explanation of Warning Labels

The following warning labels are attached to the manipulator.
Always follow the warnings on the labels.
Also, an identification label with important information is placed on the body of the manipula-
tor. Prior to operating the manipulator, confirm the contents.

WARNING label A

WARNING label B

Nameplate

Nameplate: WARNING label A:

MOTOMAN WARNING
TYPE
Moving parts
PAYLOAD MASS
kg kg may cause
ORDER NO. DATE injury
SERIAL NO.

YASKAWA ELECTRIC CORPORATION

JAPAN
WARNING label B:

WARNING
Do not enter
robot
work area.

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1 Product Confirmation
1.1 Contents Confirmation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.2 Order Number Confirmation . . . . . . . . . . . . . . . . . . . . . . . 1-2

2 Transporting
2.1 Transporting Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.1.1 Using a Crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2
2.1.2 Using a Forklift. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3
2.2 Shipping Bolts and Brackets . . . . . . . . . . . . . . . . . . . . . . . 2-3

3 Installation
3.1 Installation of the Safeguarding . . . . . . . . . . . . . . . . . . . . 3-2
3.2 Mounting Procedures for Manipulator Base . . . . . . . . 3-2
3.2.1 Mounting Example. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3
3.3 Types of Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3.3.1 S-axis Operating Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4
3.3.2 Fixing the Manipulator Base . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4
3.3.3 Precautions to Prevent the Manipulator from Falling. . . . . . . . .3-4
3.4 Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

4 Wiring
4.1 Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4.2 Cable Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.2.1 Connection to the Manipulator. . . . . . . . . . . . . . . . . . . . . . . . . .4-3
4.2.2 Connection to the NX100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3

5 Basic Specifications
5.1 Basic Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.2 Part Names and Working Axes . . . . . . . . . . . . . . . . . . . . 5-2
5.3 Baseplate Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
5.4 Dimensions and P-Point Maximum Envelope . . . . . . 5-3
5.5 Alterable Operating Range . . . . . . . . . . . . . . . . . . . . . . . . 5-4

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6 Allowable Load for Wrist Axis and Wrist Flange

6.1 Allowable Wrist Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.2 Wrist Flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

7 System Application
7.1 Peripheral Equipment Mounts . . . . . . . . . . . . . . . . . . . . . . 7-1
7.1.1 Allowable Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
7.1.2 Installation Position. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
7.2 Internal User I/O Wiring Harness and Air Lines . . . . . 7-3

8 Motoman Construction
8.1 Location of Limit Switches . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
8.2 Internal Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2

9 Maintenance and Inspection

9.1 Inspection Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
9.2 Notes on Maintenance Procedures . . . . . . . . . . . . . . . . . 9-6
9.2.1 Battery Pack Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6
9.3 Notes on Grease Replenishment/Exchange
Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8
9.3.1 Grease Replenishment/Exchange for S-axis Speed Reducer . 9-8
„ Grease Replenishment (Refer to " Fig. 28 S-axis Speed
Reducer Diagram ".) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9
„ Grease Exchange (Refer to " Fig. 28 S-axis Speed Reducer
Diagram ".) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9
9.3.2 Grease Replenishment/Exchange for L-axis Speed Reducer 9-10
„ Grease Replenishment (Refer to " Fig. 29 L-axis Speed
Reducer Diagram ".) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10
„ Grease Exchange (Refer to " Fig. 29 L-axis Speed Reducer
Diagram ".) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-11
9.3.3 Grease Replenishment/Exchange for U-axis Speed Reducer 9-12
„ Grease Replenishment (Refer to " Fig. 30 U-axis Speed
Reducer Diagram ".) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12
„ Grease Exchange (Refer to " Fig. 30 U-axis Speed Reducer
Diagram ".) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-13
9.3.4 Grease Replenishment for R-axis Speed Reducer. . . . . . . . . 9-14
9.3.5 Grease Replenishment for B- and T-axes Speed Reducers . 9-15
9.3.6 Grease Replenishment for T-axis Gear . . . . . . . . . . . . . . . . . 9-16

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9.3.7 Grease Replenishment for R-axis Cross Roller

Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-17
9.3.8 Notes for Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-18
„ Wrist Axes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-18
„ Battery Pack Connector (with CAUTION label) . . . . . . . . . .9-18

10 Recommended Spare Parts

11 Parts List
11.1 S-axis Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1
11.2 L-Axis Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-3
11.3 U-Axis Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-5
11.4 R-Axis Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-7
11.5 Wrist Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-9

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1.1 Contents Confirmation

1 Product Confirmation

CAUTION
• Confirm that the manipulator and the NX100 have the same order num-
ber. Special care must be taken when more than one manipulator is to
be installed.

If the numbers do not match, manipulators may not perform as expected and cause injury
or damage.

1.1 Contents Confirmation

Confirm the contents of the delivery when the product arrives.

Standard delivery includes the following four items (Information for the content of optional
goods is given separately):

• Manipulator
• NX100
• Programing Pendant
• Manipulator Cable (Between Manipulator and NX100)

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1.2 Order Number Confirmation

1.2 Order Number Confirmation

Check that the order number of the manipulator corresponds to the NX100. The order number
is located on a label as shown below.

Label (Enlarged view)

THE MANIPULATOR AND THE CONTROLLER

SHOULD HAVE SAME ORDER NUMBER. Check that the manipulator
and the NX100 have the
ORDER. No. same order number.

NX100
TYPE ERCR-
******
POWER SUPPLY
200V 50Hz
220V 50/60Hz 3PHASE kVA

SERIAL No.
DATE

MADE IN JAPAN NJ2484-1

THE MANIPULATOR AND THE CONTROLLER

SHOULD HAVE SAME ORDER NUMBER.

ORDER NO.
NJ1529

WARNING
Do not open the door

ON
ED
IPP
TR
OFF
ET
RES

MULTI
COORD. SERVO
DISPLAY
SWITCH POWER
SELECT
MAIN SHORTCUT ASSIST
MENU MENU

X- X+ x x
S- S+ R- R+

Y- Y+ y y
L- L+ B- B+

- + z z
R- R+ T- T+

SHIFT INTER
LOCK
7 WEAVING
8WELD
9 TEST RUN SHIFT
START START FEED

ROBOT 4 5 6
RETRUCT BACK NEXT
AUXILIARY WEAVING WELD
SWITCH COMPLETE COMPLETE

EX-AXIS 1 2 3CURRENT DELETE INSERT

SWITCH AUXILIARY TIMER VOLTAGE

CABCEK 0 . -CURRENT ENTER

INTER. REF.
POINT VOLTAGE MODIFY

(a) NX100 (Front View) (b) Manipulator (Top View)

Fig. 1 Location of Order Number Labels

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2 Transporting

CAUTION
• Sling applications and crane or forklift operations must be performed by
authorized personnel only.

Failure to observe this caution may result in injury or damage.

• Avoid excessive vibration or shock during transporting.

Failure to observe this caution may adversely affect the performance as the system con-
sists of precision components.

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2.1 Transporting Method

2.1 Transporting Method

• The weight of the manipulator is approximately 135 kg including the shipping bolts and
NOTE brackets. Use a wire rope strong enough to withstand the weight.
• Mount the shipping bolts and brackets for transporting the manipulator.
• Avoid putting external force on the arm or motor unit when transporting by a crane, fork-
lift, or other equipment. Failure to observe this instruction may result in injury.

2.1.1 Using a Crane

As a rule, when removing the manipulator from the package and moving it, a crane should be
used. The manipulator should be lifted using wire rope.
Be sure the manipulator is fixed with the shipping bolts and brackets before transporting, and
lift it in the posture as shown in " Fig. 2 Transporting Position ".

Shipping bracket

View A

Hexagon socket head

cap screw M10
(2 screws)

Shipping bracket

Fig. 2 Transporting Position

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2.2 Shipping Bolts and Brackets

2.1.2 Using a Forklift

When using a forklift, the manipulator should be fixed on a pallet with bolts as shown in " Fig.
3 Using a Forklift ". Insert claws under the pallet and lift it. The pallet must be strong enough
to support the manipulator. Transporting of the manipulator must be performed slowly in order
to avoid overturning or slippage.

Bolts M16 (4 bolts)

Pallet

Forklift claw entry

Fig. 3 Using a Forklift

2.2 Shipping Bolts and Brackets

The manipulator is provided with a shipping bracket and 2 screws. (See " Fig. 2 Transporting
Position ".)
Shipping bracket

Front View Side View

Hexagon socket head
cap screw M10 (2 screws)

Fig. 4 Shipping Bolts and Brackets

• The shipping bracket and screws are painted yellow.

• The shipping bracket is fixed with the hexagon socket head cap screw M10 (2 screws).

Before turning on the power, make sure that the shipping bolts and brackets are removed.
NOTE The shipping bolts and brackets then must be stored for future use, in the event that the
manipulator must be moved again.

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3 Installation

WARNING
• Install the safeguarding.

Failure to observe this warning may result in injury or damage.

• Install the manipulator in a location where the manipulator’s tool or the

workpiece held by the manipulator will not reach the wall, safeguarding,
or NX100 when the arm is fully extended.

Failure to observe this warning may result in injury or damage.

• Do not start the manipulator or even turn on the power before it is firmly
anchored.

The manipulator may overturn and cause injury or damage.

• When mounting the manipulator on the ceiling or wall, the base section
must have sufficient strength and rigidity to support the weight of the
manipulator. Also, it is necessary to consider countermeasures to pre-
vent the manipulator from falling.

Failure to observe these warnings may result in injury or damage.

CAUTION
• Do not install or operate a manipulator that is damaged or lacks parts.

Failure to observe this caution may cause injury or damage.

• Before turning on the power, check to be sure that the shipping bolts
and brackets explained in " Fig. 4 Shipping Bolts and Brackets " are
removed.

Failure to observe this caution may result in damage to the driving parts.

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3.1 Installation of the Safeguarding

3.1 Installation of the Safeguarding

To insure safety, be sure to install safeguarding. They prevent unforeseen accidents with
personnel and damage to equipment. The following is quoted for your information and
guidance.

Responsibility for Safeguarding (ISO10218)

The user of a manipulator or robot system shall ensure that safeguarding is provided and
used in accordance with Sections 6, 7, and 8 of this standard. The means and degree of
safeguarding, including any redundancies, shall correspond directly to the type and level of
hazard presented by the robot system consistent with the robot application. Safeguarding may
include but not be limited to safeguarding devices, barriers, interlock barriers, perimeter
guarding, awareness barriers, and awareness signals.

3.2 Mounting Procedures for Manipulator Base

The manipulator should be firmly mounted on a baseplate or foundation strong enough to

support the manipulator and withstand repulsion forces during acceleration and deceleration.
Construct a solid foundation with the appropriate thickness to withstand maximum repulsion
forces of the manipulator as shown in "Table. 1 Maximum Repulsion Forces of the Manipulator
at Emergency Stop" and "Table. 2 Maximum Torque of Acceleration and Deceleration".
The flatness for installation must be kept at 0.5 mm or less: insufficient flatness of installation
surface may deform the manipulator shape and affect its functional abilities. Mount the
manipulator base as shown in " 3.2.1 Mounting Example " in principle.

Table. 1 Maximum Repulsion Forces of the Manipulator at Emergency Stop

Horizontal rotating maximum torque 2000 N • m

(S-axis moving direction) (204 kgf• m)

Vertical rotating maximum torque 3500 N • m

(LU-axis moving direction) (357 kgf• m)

Table. 2 Endurance Torque in Operation

Endurance torque in horizontal operation 450 N • m

(S-axis moving direction) (46 kgf • m)

Endurance torque in vertical operation 1300 N • m

(LU-axis moving direction) (132 kgf • m)

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3.2 Mounting Procedures for Manipulator Base

3.2.1 Mounting Example

Fix the baseplate onto the floor. The baseplate should be rugged and durable to prevent
shifting of the manipulator or the mounting fixture. The thickness of the baseplate is 40 mm or
more, and an M16 size or larger anchor bolt is recommended.
Fix the manipulator base onto the baseplate with the hexagon socket head cap screws M16
(mm). The plate is tapped for four M16 (length: 50 mm) screws. Tighten the screws and
anchor bolts securely so that they will not work loose during operation.
See " Fig. 5 Mounting the Manipulator Baseplate " for the method.

Hexagon socket head cap screw

M16 (4 screws)
Spring washer
Washer
40 or more 20

Manipulator base

Baseplate

Manipulator base
Anchor bolt M16 or more
Baseplate

Units: mm

300

260
Baseplate
240 132±0.1
+0.018
16 dia. 0
(2 holes)
Tapped hole 18 dia.
(4 holes)
102±0.1

60
153±0.1
300

260

216

60
130±0.1

132±0.1

+0.018
12 dia. 0

102±0.1

100±0.1 153±0.1 Units: mm

Fig. 5 Mounting the Manipulator Baseplate

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3.3 Types of Mounting

3.3 Types of Mounting

The manipulator can be mounted in three different ways: floor-mounted (standard), wall-
mounted, and ceiling-mounted types are available. For wall- and ceiling-mounted types, the
following points are different from the floor-mounted types.

• S-axis Operating Range

• Fixing the Manipulator Base
• Precautions to Prevent the Manipulator from Falling

3.3.1 S-axis Operating Range

For the wall-mounted type, the S-axis movable range must be ±30°. (Adjusted prior to the
shipment.)

3.3.2 Fixing the Manipulator Base

For the wall- or ceiling-mounted types, be sure to use four hexagon socket head cap screws
M16 when fixing the manipulator base. Use a torque of 206 N• m when tightening the bolts.

3.3.3 Precautions to Prevent the Manipulator from Falling

For the wall- or ceiling-mounted types, take appropriate measures to avoid the falling of the
manipulator in case of emergency. Refer to " Fig. 6 Precaution against Falling " for details.

Support

Manipulator base Hexagon socket head cap screw M16

(4 screws)
(Tensile strength: 1200 N/mm2 or above)

Fig. 6 Precaution against Falling

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3.4 Location

In case of using the wall-/ceiling-mounted type, inform YASKAWA of the matter when plac-
NOTE ing an order. Be sure to contact YASKAWA representative (listed on the back cover of this
instruction manual) to perform a wall/ceiling installation on site.

3.4 Location

When installing the manipulator, it is necessary to satisfy the undermentioned environmental

conditions:

• Ambient Temperature: 0° to +45°C

• Humidity: 20 to 80%RH (non-condensing)
• Free from dust, soot, or water
• Free from corrosive gas or liquid, or explosive gas
• Free from excessive vibration (less than 4.9 m/s2 [0.5G])
• Free from large electrical noise (plasma)
• The flatness for installation is 0.5 mm or less

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4 Wiring

WARNING
• Ground resistance must be 100 Ω or less.

Failure to observe this warning may result in fire or electric shock.

• Before wiring, make sure to turn the primary power supply off, and put
up a warning sign. (ex. DO NOT TURN THE POWER ON.)

Failure to observe this warning may result in fire or electric shock.

CAUTION
• Wiring must be performed by authorized or certified personnel.

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

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4.1 Grounding

4.1 Grounding

Follow the local regulations and electrical installation standards for grounding. A wire of 5.5
mm2 or more is recommended.
For grounding, connect the ground wire directly to the manipulator as in " Fig. 7 Grounding
Method ".

• Do not use this line in common with other ground wires or grounding electrodes for other
NOTE electric power, motor power, welding devices, etc.
• Where metal ducts, metallic conduits, or distributing racks are used for cable laying,
ground in accordance with the local electrical installation standards.
A

5.5 mm2 or more

Bolts M8 (for grounding) View A

Delivered with the manipulator

Fig. 7 Grounding Method

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4.2 Cable Connection

4.2 Cable Connection

Two manipulator cables are provided; an encoder cable (1BC) and a power cable (2BC).
(Refer to " Fig. 8 Manipulator Cable Connections ".) Connect these cables to the manipulator
base connectors and to the NX100. Refer to " Fig. 9 (a) Details of the Manipulator Cable
Connectors (Manipulator Side) " and " Fig. 9 (b) Manipulator Cable Connections to the NX100
".

4.2.1 Connection to the Manipulator

Before connecting the manipulator cables to the manipulator, verify the numbers: 1BC and
2BC on both the cables and the manipulator base connectors. Connect 2BC first, and then
1BC. After inserting the cables, set the lever low until it clicks.

4.2.2 Connection to the NX100

Before connecting the manipulator cables to the NX100, verify the numbers: 1BC and 2BC on
both the cables and the NX100 connectors. Connect 2BC first, and then 1BC. After inserting
the cables, set the lever low until it clicks.

NX100 side Manipulator side

1BC
X11

X11 1BC
1BC

Encoder cable

NX100 side Manipulator side

2BC
X21

2BC
X21
2BC

Power cable

Fig. 8 Manipulator Cable Connections

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4.2 Cable Connection

2BC

1BC

3BC

2BC

1BC

3BC

Connector details
Manipulator side

Fig. 9 (a) Details of the Manipulator Cable Connectors (Manipulator Side)

X11
X21

Fig. 9 (b) Manipulator Cable Connections to the NX100

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5.1 Basic Specifications

5 Basic Specifications

5.1 Basic Specifications

Table. 3 Basic Specifications*1
Configuration Vertically Articulated

Degree of Freedom 6

Payload 6 kg

Repetability*2 ±0.08 mm

S-axis (turning) ±170°

L-axis (lower arm) +155°, -90°

Range of U-axis (upper arm) +250°, -175°

Motion R-axis (wrist roll) ±180°

B-axis (wrist pitch/yaw) +225°, -45°

T-axis (wrist twist) ±360°

S-axis 3.67 rad/s, 210°/s

L-axis 3.32 rad/s, 190°/s

Maximum U-axis 3.67 rad/s, 210°/s

Speed R-axis 6.98 rad/s, 400°/s

B-axis 6.98 rad/s, 400°/s

T-axis 10.47 rad/s, 600°/s

R-axis 11.8 N•m (1.2 kgf•m)

Allowable
B-axis 9.8 N•m (1.0 kgf•m)
Moment*3
T-axis 5.9 N•m (0.6 kgf•m)

R-axis 0.24 kg•m2

Allowable
Inertia B-axis 0.17 kg•m2
(GD2/4)
T-axis 0.06 kg•m2

Approx. Mass 130 kg

Temperature 0° to 45°C

Humidity 20 to 80% RH at constant temperature

Ambient Vibration Acceleration Less than 4.9 m/s2 (0.5 G)
Conditions
• Free from corrosive gas or liquid, or explosive gas.
Others • Free from water, oil, or dust.
• Free from excessive electrical noise (plasma).
Power Capacity 1.5 kVA

*1 SI units are used in this table. However, gravitational unit is used in ( ).

*2 Conformed to ISO9283
*3 Refer to " 6.1 Allowable Wrist Load " for details on the permissible moment of inertia.

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5.2 Part Names and Working Axes

5.2 Part Names and Working Axes

U+ R+ B+ T+

Wrist flange

U- R- B- T-

U-arm
L-arm Wrist

L- L+

Rotary head

S+

S- Manipulator base

Fig. 10 Part Names and Working Axes

5.3 Baseplate Dimensions

300

260
240 132±0.1
102±0.1

Tapped holes
153±0.1

18 dia. (4 holes)
60
300

260
216

+0.018
60

16 dia. 0
(2 holes)
+0.018
12 dia. 0
132±0.1
130±0.1
20

102±0.1

100±0.1 153±0.1
A

View A Units: mm

Fig. 11 Baseplate Dimensions

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5.4 Dimensions and P-Point Maximum Envelope

5.4 Dimensions and P-Point Maximum Envelope

170°

8 144
87 R137
R3

130
380
R285

210 170
170°
134

View A
1078

1378
328

387
270
612

192
0

1678
P-point maximum
envelope
150 640 95
75
155

P-point
°
83
1250

°
90
570

681
A
155°
20°

294
160°
450

0
10

204
277

725 Units: mm
494
459

Fig. 12 Dimensions and P-Point Maximum Envelope

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5.5 Alterable Operating Range

5.5 Alterable Operating Range

The operating range of the S-axis can be altered as in " Fig. 4 S-axis Operating Range " in
accordance with the operating conditions. If alteration is necessary, contact your Yaskawa
representative in advance.

Table. 4 S-axis Operating Range

Item Specifications

±170°(standard)
±150°
±135°
±120°
S-axis ±105°
Operating ±90°
Range ±75°
±60°
±45°
±30°
±15°

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6.1 Allowable Wrist Load

6 Allowable Load for Wrist Axis and Wrist

Flange

6.1 Allowable Wrist Load

The allowable wrist load is 6 kg. If force is applied to the wrist instead of the load, force on
R-, B-, and T-axes should be within the value shown in " Table. 5 Moment and Total Inertia ".
Contact your Yaskawa representative for further information or assistance.

Table. 5 Moment and Total Inertia

Axis Moment N•m (kgf•m)*1 GD2/4 Total Inertia kg•m2

R-axis 11.8 (1.2) 0.24

B-axis 9.8 (1.0) 0.17
T-axis 5.9 (0.6) 0.06

*1 ( ): Gravitational unit

When the volume load is small, refer to the moment arm rating shown in " Fig. 13 Moment
Arm Rating ".
The allowable total inertia is calculated when the moment is at the maximum. Contact your
Yaskawa representative when only inertia moment, or load moment is small and inertia
moment is large. Also, when the load mass is combined with an outside force, contact your
Yaskawa representative in advance.

LB
Load gravity
95
position
200
LT

141
LT (mm)

W = 3 kg
R-, T-axes rotation 100
center line

W = 6 kg
B-axis rotation center line

0 100 167 200 238 300

LB (mm)

Fig. 13 Moment Arm Rating

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6.1 Allowable Wrist Load

15

Moment (Nxm) 11.8

10

0
0.24 0.483
0 0.2 0.4 0.6
GD2/4 (kgxm2)

Fig. 14 The Diagram Moment/Inertia for R-axis

10
9.8

7.5
Moment (Nxm)

2.5

0
0.17 0.37
0 0.1 0.2 0.3 0.4
GD2/4 (kgxm2)

Fig. 15 The Diagram Moment/Inertia for B-axis

6
5.9
Moment (Nxm)

0
0.06 0.14
0 0.05 0.1 0.15

GD2/4 (kgxm2)

Fig. 16 The Diagram Moment/Inertia for T-axis

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6.2 Wrist Flange

6.2 Wrist Flange

The wrist flange dimensions are shown in " Fig. 17 Wrist Flange ". In order to see the align-
ment marks, it is recommended that the attachment be mounted inside the fitting. Fitting
depth of inside and outside fittings must be 5 mm or less.

Tapped holes M6
(depth:9 mm) (pitch:1.0) (4 holes)

45°

P.C
.D4
0

+0.015
6 dia. 0
(depth: 6 mm)

6
+0.021

50 dia. -0.039
0
025 dia.

Units: mm

Fig. 17 Wrist Flange

NOTE Wash off anti-corrosive paint (solid color) on the wrist flange surface with thinner or light oil
before mounting the tools.

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7.1 Peripheral Equipment Mounts

7 System Application

7.1 Peripheral Equipment Mounts

The peripheral equipment mounts are provided on the U-axis (upper arm) and S-axis (rotary
head) as shown in " Fig. 18 Installing Peripheral Equipment " for easier installation of the
users’ system applications. The following conditions should be observed to attach or install
peripheral equipment.

7.1.1 Allowable Load

• The allowable load on the U-axis is a maximum of 15 kg, including the wrist load.
For instance, when the mass installed in the wrist point is 6 kg, the mass which can be
installed on the upper arm becomes 9 kg.
• The allowable load on the S-axis is a maximum of 20 kg. Install the peripheral equipment
on the S-axis so that the moment of inertia (GD2/4) from the S-axis rotation center
becomes 1.25 kg m2 or less.

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7.1 Peripheral Equipment Mounts

7.1.2 Installation Position

There is a limitation also on the installation position.
" Fig. 19 Allowable Load on U-axis " shows the distance between the U-axis rotation center
and the load gravity.
A
View A
W2
70
Z-direction restriction

Z-direction Upper arm

W1
350 or less

230

70
X-direction

U-axis Tapped holes M6

rotation center (length: 12) (4 holes)

155 90 105
155

Rotary head
50

Tapped hole M10 (4 holes)

(pitch: 1.5) (depth: 20)

Units: mm

Fig. 18 Installing Peripheral Equipment

X Direction Restriction
20

W1 = 0 kg
15
Weight W2 (kg)

10

W1 = 3 kg
W1 = 6 kg
5

0
-200 -100 0 100 200 300 400
Distance between U-Axis Rotation Center and Load Gravity (mm)

Fig. 19 Allowable Load on U-axis

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7.2 Internal User I/O Wiring Harness and Air Lines

7.2 Internal User I/O Wiring Harness and Air Lines

Internal user I/O wiring harness (0.2 mm2 x 8, 1.25 mm2 x 6) and an air lines are incorporated
in the manipulator for the drive of peripheral device mounted on the upper arm as shown in "
Fig. 20 Internal User I/O Wiring Harness and Air Lines ".
The connector pins 1 to 16 are assigned as shown in " Fig. 21 Detailed Drawing of Connector
Pin Numbers ". Wiring must be performed by users, following the conditions below:

• The allowable current for internal user I/O wiring harness: 3A or less for each wire.
(The total current value for pins 1 to 16 must be 40 A or less.)
• The maximum pressure for the air line: 490 kPa (5 kgf/cm2) or less.
(The airline inside diameter: 6.5 mm)

Air inlet
Tapped hole PT3/8
with pipe plug

2BC

1BC

3BC

Connector for internal user I/O wiring

harness on U-axis: JL05-2A20-29SC
(socket connector with a cap).
Connector for internal user I/O wiring Prepare pin connector JL05-6A20-29P.
harness on S-axis: JL05-2A20-29PC
(pin connector with a cap).
Exhaust port
Prepare socket connector JL05-6A20-29S.
Tapped holes PT3/8
View A with pipe plug

Fig. 20 Internal User I/O Wiring Harness and Air Lines

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7.2 Internal User I/O Wiring Harness and Air Lines

Connector for Internal User I/O Wiring Harness Connector for Internal User I/O Wiring Harness
on the Connector Base on the U-arm
1 1
2 2
3 3
4 4
5 5
6 6
7 (Open) 1 7 (+24V (1A): for shock sensor) 1
Pins used 8 (Open) 2 3 Pins used 8 (Shock sensor signal input) 2 3
9 5 9 4 5
4 6 6
10 7 8 10 7 8
11 (1.25 mm2) 9 10 11 (1.25 mm2) 9 10
12 (1.25 mm2) 11 12 12 (1.25 mm2) 11 12
13 (1.25 mm2) 13 14 13 (1.25 mm2) 13 14
14 2
14 2
15 (1.25 mm ) 15 16 15 (1.25 mm ) 15 16
16 (1.25 mm2) 16 (1.25 mm2)

Internal user I/O wiring harness : 0.2 mm2, 8 lead wires Internal user I/O wiring harness : 0.2 mm2, 8 lead wires
: 1.25 mm2, 6 lead wires : 1.25 mm2, 6 lead wires

Fig. 21 Detailed Drawing of Connector Pin Numbers

• For the standard specification, the pins No.7 and No.8 of 3BC connector on the U-Arm
NOTE are respectively connected with the shock sensor power supply and shock sensor signal
input port of the NX100 controller.
• The pins No.7 and No.8 of respective 3BC connectors on the connector base side and
the U-Arm side are not connected with each other.
• For the wiring, refer to " Fig. 24 (a) Internal Connection Diagram ".

The same pin number (1-16) of two connectors is connected in the lead line of single 0.2 mm2
or 1.25 mm2.

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8.1 Location of Limit Switches

8 Motoman Construction

8.1 Location of Limit Switches

The limit switches are optional and are located as shown in " Fig. 22 Location of Limit
Switches ". The overrun limit switches for the the S-axis and L-axis, and LU-axes interference
limit switch are applied to the robot type: YR-SSF6-A01.

L-and U-axes interference L.S.

(optional)

L-axis overrun L.S.

(optional)

S-axis overrun L.S.

(optional)

Fig. 22 Location of Limit Switches

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8.2 Internal Connections

8.2 Internal Connections

High reliability connectors which can be easily put on and removed are used with each
connector part. For the numbers, types, and locations of connectors, refer to " Fig. 23
Location and Numbers of Connectors " and " Table. 6 List of Connector Types " .
Diagrams for internal connections of the manipulator are shown in " Fig. 24 (a) Internal Con-
nection Diagram " and " Fig. 24 (b) Internal Connection Diagram " .

3BC (for internal user

I/O wiring harness)

3BC (for internal user I/O

wiring harness)

Fig. 23 Location and Numbers of Connectors

Table. 6 List of Connector Types

Name Type of Connector

Base Connector
JL05-2A20-29PC
for Internal User I/O
(JL05-6A20-29S: Optional)
Wiring Harness

U-arm Connector
JL05-2A20-29SC
for Internal User I/O
(JL05-6A20-29P: Optional)
Wiring Harness

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8.2 Internal Connections

POWER CABLE INTERNAL CABLE IN S-AXIS INTERNAL CABLE IN L-AXIS INTERNAL CABLE IN BT-AXIS

0BT 1 0BAT11 17 0BAT1

K R P BAT 2 BAT11 18 BAT1
0BT 3 0BAT12 19 0BAT2
K R P BAT 4 BAT12 20 BAT2
21 0BAT3
22 BAT3
23
24
0BT 5 0BAT21 25 0BAT4
K R P BAT 6 BAT21 26 BAT4
0BT 7 0BAT22 27
K R P BAT 8 BAT22 28

1
29
30
31
<NOTES>
2 32
3
4
1
2
PG0V1
PG5V1
1. - For the limit switch specification, the connection of the section A is changed as follows:
5 3 PG0V2
6 4 PG5V2
7 5 PG0V3 S-AXIS OVERRUN LIMIT SWITCH
8 6 PG5V3 LA1 LA1
LB1
7 PG0V4 LB1 LA2 LA2 LA2
8 PG5V4 LB2 L-AXIS OVERRUN LIMIT SWITCH
NX100
CN1-5
1BC(10X4)

CN1-5 +24V 1
9
10
11
PG0V5
PG5V5
PG0V6
P LA3
LB3 LB3
A
L AND U-AXES INTERFERENCE
CN1-4 P CN1-4 0V 3 12 PG5V6 LIMIT SWITCH
13
CN1-10 CN1-10 +24V 2 14
CN1-9 P CN1-9 0V 4 15 SLU-AXES WITH OVERRUN L.S. SPECIFICATION
16 No.20CN
CN1-1 CN1-1 SPG+1 20CN-1 DATA+1
CN1-2 P CN1-2 SPG-1 P -2 DATA-1

P
-6
-5
BAT
OBT PG S-AXIS 2. - For standard specification, the pins No.7 and No.8 of 3BC connector
P
-4
-9
+5V
0V
on the U-arm are respectively connected with the shock sensor power supply
CN1-3 CN1-3 FG1 -7 FG1
OBT
and shock sensor signal input port of the NX100 controller.
BAT
No.21CN
CN1-6 CN1-6 SPG+2 21CN-1 DATA+2 Pin No. Connected Port in NX100
CN1-7 P CN1-7 SPG-2 P -2 DATA-2
-6 BAT 7 Shock sensor power supply; +24V (1A)
P -5 OBT PG L-AXIS
-4 +5V 8 Shock sensor signal input
P -9 0V
CN1-8 CN1-8 FG2 -7 FG2
OBT
BAT

CN2-1 CN2-1 SPG+3

No.22CN
22CN-1 DATA+3 3. - In case of connecting the pins No.7 and No.8 of respecteve 3BC connectors on the U-arm
CN2-2 P CN2-2 SPG-3 P -2 DATA-3
-6 BAT and connector base, the connection in the section B should be changed as shown in
P -5 OBT PG
-4 +5V U-AXIS section C below.
P -9 0V
CN2-3 CN2-3 FG3 -7 FG3 (Contact your Yaskawa representative in case of modifying the wiring before use.)
OBT
BAT
No.23CN
CN2-6 CN2-6 SPG+4 23CN-1 DATA+4
CN2-7 P CN2-7 SPG-4 P -2 DATA-4
1BC(10X4) P
-3
-4
BAT
OBT PG R-AXIS
24CN-1 +5V
P -2 0V
CN2-8 CN2-8 FG4 -3 FG4
OBT
BAT
No.7CN No.14CN
CN3-1 CN3-1 SPG+5 7CN-1 DATA+5 14CN-1 DATA+5
CN3-2 P CN3-2 SPG-5 P -7 DATA-5 P -2 DATA-5
-2 BAT -3 BAT
P -8 OBT P -4 OBT PG B-AXIS
-3 +5V 15CN-1 +5V
P -9 0V P -2 0V
CN3-3 CN3-3 -3 FG5
FG5
OBT
BAT
No.16CN
CN3-6 CN3-6 SPG+6 -4 DATA+6 16CN-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
-5 +5V 17CN-1 +5V
P -11 0V P -2 0V
CN3-8 CN3-8 -6 FG6 -3 FG6
FG6
OBT
BAT
C
CN4-1 CN4-1 +24V LA1 LA2
CN4-6 P CN4-6 LB1 P LB3 LA2

CN4-2 CN4-2 SS2 A POWER CABLE INTERNAL CABLE

CN4-7 P CN4-7
CONNECTOR BASE U-ARM

CN4-3 CN4-3 BC2

CN4-8 P CN4-8
NX100 1BC(4X10)

P FOR LAMP(OPTION)
CN2-4 CN2-4 CN4-1 CN4-1 +24V(1A) SS1
0V
CN2-5 P CN2-5 +5V CRIMPED
CN4-2 CN4-2 SS2 SS2 CONTACT-PIN
E E
CN2-9 CN2-9 0V E
Casing
CN2-10 P CN2-10 +5V Base 3BC(20-29)
3BC(20-29)
E E E E E
UNUSED
3BC-1 1 1 1 1 1 1 3BC-1
CN3-4 CN3-4 0V -2 2 2 2 P 2 2 P 2 -2
CN3-5 P CN3-5 +5V -3 3 3 3 3 3 3 -3
-4 4 4 4 P 4 4 P 4 -4
-5 5 5 5 5 -5
S-AXIS OVERRUN L.S -6 6 6 6 P 6 -6
CN3-9 CN3-9 LA1 LA1
CN3-10 P CN3-10
0V LB1 -7 7 7 SS1 SS1 SS1 7 -7
+5V LB1 LB1 LA2 LA2 -8 8 8 SS2 P SS2 SS2 P 8 -8
LB2 L-AXIS OVERRUN L.S A -9 9 9 -9
-10 10 P 10 -10
P LA3 -11 11 11 -11
LB3 LB3 L AND U-AXIS INTERFERENCE L.S -12 12 12 -12
CN4-4 CN4-4 SPG+7
CN4-5 P CN4-5 -13 13 13 -13
SPG-7 -14 14 14 -14
CN4-9 CN4-9 FG7
SLU-AXES WITH OVERRUN L.S. SPECIFICATION -15
-16
15
16
15
16
-15
-16
E
E

WIRING OF 3BC CABLE AFTER CHANGING CONNECTIONS OF B

Fig. 24 (a) Internal Connection Diagram

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8.2 Internal Connections

E E E

Base Casing
B
E E E

3BC(20-29) 3BC(20-29)
E E
3BC-1 1 1 1 1 1 1 2BC-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 FOR SPARE CABLE
-8 8 8 SS2 SS2 P SS2 SS2 P 8 -8
-9 9 9 -9
-10 10 P 10 -10 SHOCK SENSOR
-11 11 11 -11 (OPTIONAL)
-12 12 12 -12
-13 13 13 -13
-14 14 14 -14
-15 15 15 -15
-16 16 16 -16

2BC(6X6)
E
E
No.3CN
CN1-1 CN1-1 BA1 3CN-1 MU1
CN1-2 CN1-2 BA2 -2 MV1
SM S-AXIS
CN1-3 CN1-3 BB1 -3 MW1
CN1-4 CN1-4 ME1 -4 ME1
CN1-5 CN1-5 ME2 -5 BA1
CN1-6 CN1-6 -6 BB1 YB

No.4CN
CN2-1 CN2-1 MU1 4CN-1 MU2
CN2-2 CN2-2 MV1 -2 MV2
SM L-AXIS
CN2-3 CN2-3 MW1 -3 MW2
CN2-4 CN2-4 MU2 -4 ME2
CN2-5 CN2-5 MV2 -5 BA2
CN2-6 CN2-6 MW2 -6 BB2 YB

No.26CN
CN3-1 CN3-1 26CN-1 MU3
CN3-2 CN3-2 -2 MV3
CN3-3 CN3-3 -3 MW3
SM U-AXIS
CN3-4 CN3-4 MU3 -4 ME3
CN3-5 CN3-5 MV3 -5 BA3
CN3-6 CN3-6 MW3 -6 BB3 YB
2BC(6X6)
No.25CN
CN4-1 CN4-1 MU4 25CN-1 MU4
CN4-2 CN4-2 MV4 -2 MV4
SM R-AXIS
CN4-3 CN4-3 MW4 -3 MW4
CN4-4 CN4-4 MU5 -4 ME4
CN4-5 CN4-5 MV5 -1 BA4
CN4-6 CN4-6 MW5 -2 BB4 YB
No.35CN No.18CN
No.10CN
CN5-1 CN5-1 MU6 10CN-1 MU5 18CN-1 MU5
CN5-2 CN5-2 MV6 -2 MV5 -2 MV5
SM
CN5-3 CN5-3 MW6 -3 MW5 -3 MW5 B-AXIS
CN5-4 CN5-4 ME3 -4 ME5 -4 ME5
CN5-5 CN5-5 ME4 -1 BA5
CN5-6 CN5-6 ME5 -2 BB5 YB
No.36CN
No.19CN
CN6-1 CN6-1 ME6 -5 MU6 19CN-1 MU6
CN6-2 CN6-2 BA3 -6 MV6 -2 MV6
SM
CN6-3 CN6-3 BB4 -7 MW6 -3 MW6 T-AXIS
CN6-4 CN6-4 BA4 -8 ME6 -4 ME6
CN6-5 CN6-5 BA5 -1 BA6
CN6-6 CN6-6 BA6 -2 BB6 YB
No.12CN No.37CN
12CN-1 BA5
-2 BB5
-3 BA6
PE
-4 BB6

Fig. 24 (b) Internal Connection Diagram

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9.1 Inspection Schedule

9 Maintenance and Inspection

WARNING
• Before maintenance or inspection, be sure to turn the main power sup-
ply off, and put up a warning sign. (ex. DO NOT TURN THE POWER ON.)

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

CAUTION
• Maintenance and inspection must be performed by specified personnel.

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

• For disassembly or repair, contact your Yaskawa representative.

• The battery pack must be connected before removing detection connec-

tor when maintenance and inspection.

Failure to observe this caution may result in the loss of home position data.

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
intervals are displayed in six levels. Conduct periodical inspections according to the
inspection schedule in " Table. 7 Inspection Items ".
In " Table. 7 Inspection Items ", the inspection items are classified into three types of
operation: operations which can be performed by personnel authorized by the user,
operations which can be performed by personnel being trained, and operations which can be
performed by service company personnel. Only specified personnel are to do inspection work.

• The inspection interval must be based on the servo power supply on time.
NOTE • These inspections were developed for applications where the manipulator is used for arc
welding work. For any different or special applications, the inspection process should be
developed on an case-by-case basis.
For axes which are used very frequently (in handling applications, etc.), it is recom-
mended that inspections be conducted at shorter Intervals. Contact your Yaskawa repre-
sentative.

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9.1 Inspection Schedule

Table. 7 Inspection Items

Schedule Inspection Charge

Items*4 1000 6000 12000 Method Operation

24000 36000 Specified Service
Daily H H H Licensee
H H Person Company
Cycle Cycle Cycle

Check tram mark

Alignment accordance and
1 Visual
mark damage at the home
position.

Check for damage

and deterioration of
2 External lead Visual leads.

Clean the work area

Working area if dust or spatter is
3 and Visual present. Check for
manipulator damage and outside
cracks.

Check for grease

S,L,U-axes
4 motor Visual leakage.*5

Baseplate Tighten loose bolts.

Spanner Replace if necessary.
5 mounting Wrench
bolts

Tighten loose bolts.

Cover mount- Screw- Replace if necessary.
6 ing screws driver,
Wrench

Check for loose con-

Base connec- nectors.
7 Manual
tors

Check for belt

BT-axes tim- tension and wear.
8 Manual
ing belt

Check for conduc-

tion between the
main connecter of
Visual base and intermedi-
Wire harness
Multimeter ate connector with
9
in manipulator manually shaking the
(SLURBT- wire. Check for wear
axes leads)) of protective spring*1

Replace*2

Check for conduc-

Visual tion between termi-
Wire harness
Multimeter nals and wear of
In manipulator
10 (BT-axes protective spring.*1

leads)
Replace*2

Replace the battery

Battery pack pack when the bat-
11 tery alarm occurs or
in manipulator the manipulator
drove for 36000H.

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9.1 Inspection Schedule

Table. 7 Inspection Items

Schedule Inspection Charge

Items*4 1000 6000 12000 Method Operation

24000 36000 Specified Service
Daily H H H Licensee
H H Person Company
Cycle Cycle Cycle

Check for malfunc-

tion. (Replace if nec-
essary.)

S-axis speed Supply grease*3

Grease
12 (6000H cycle). See
reducer Gun
Par. 9.3.1.
Replace grease*3.
(12000H cycle)
See Par. 9.3.1.

Check for malfunc-

tion. (Replace if nec-
essary.)
LU-axes Supply grease*3
Grease
13 speed reduc- Gun
(6000H cycle). See
ers Par. 9.3.2 and 9.3.3.
Replace grease*3
(12000H cycle). See
Par. 9.3.2 and 9.3.3.

Check for malfunc-

tion. (Replace if nec-
RBT-axes essary.) Supply
Grease
14 speed reduc- Gun grease*3 (6000H
ers cycle).
See Par. 9.3.4 and
9.3.5.

Check for malfunc-

tion. (Replace if nec-
essary.) Supply
Grease grease*3 (6000H
15 T-axis gear
Gun cycle).See Par.
" 9.3.6 Grease
Replenishment for T-
axis Gear ".

Check for malfunc-

tion. (Replace if nec-
essary.) Supply
R-axis cross Grease grease*3 (6000H
16 cycle). See Par.
roller bearing Gun
" 9.3.7 Grease
Replenishment for R-
axis Cross Roller
Bearing ".

17 Overhaul

*1 When checking for conduction with multimeter, connect the battery to “BAT” and “OBT” of connectors on the
motor side for each axis, and then remove connectors on detector side for each axis from the motor. Other-
wise, the home position may be lost. (Refer to " 9.3.8 Notes for Maintenance ".)
*2 Wire harness in manipulator to be replaced at 24000H inspection.
*3 For the grease, refer to " Table. 8 Inspection Parts and Grease Used ".
*4 Inspection No. correspond to the numbers in " Fig. 25 Inspection Parts and Inspection Numbers (Manipula-
tor in Home Position: Except for B-axis) ".
*5 The occurrence of a grease leakage indicates the possibility that grease has seeped into the motor. This can
cause a motor breakdown. Contact your Yaskawa representative.

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9.1 Inspection Schedule

Table. 8 Inspection Parts and Grease Used

No. Grease Used Inspected Parts

VIGO Grease RE No.0 S-, L-, and U-axis speed reducers

12 , 13

Harmonic Grease SK-1A R-, B-, and T-axis speed reducers,

14 , 15 T-axis gear

Alvania EP Grease 2 R-axis cross roller bearings

16

The numbers in the above table correspond to the numbers in " Table. 7 Inspection Items ".

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4
Note: The home position of the manipulator takes the B-axis folded to a 90 degree
downward position to the manipulators illustrated in "Fig. 25 Inspection Parts and
Inspection Numbers".
The manipulator illustrated in "Fig. 25" is not in a complete home position since
the B-axis is extended horizontally to the ground.
8 B-axis

14 B-axis
T-axis 15
14 R-axis 16

13

9-5
4

13

11 4
9
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Fig. 25 Inspection Parts and Inspection Numbers (Manipulator in Home Position: Except for B-axis)
9.1 Inspection Schedule

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9.2 Notes on Maintenance Procedures

9.2 Notes on Maintenance Procedures

9.2.1 Battery Pack Replacement

Battery packs are located as illustrated in " Fig. 26 Battery Location ".
If the battery alarm occurs in the NX100, replace the battery in accordance with the following
procedure:

Battery pack

Support
Plate fastening bolt Connector base

Fig. 26 Battery Location

See procedure 5 Battery pack before replacement

Connector

Board
See procedure 4
New battery pack

Fig. 27 Battery Connection

1. Turn off the NX100 main power supply.

2. Uninstall the plate from the base connector and pull the battery pack out to replace with
a new battery pack.
3. Remove the battery pack from the battery holder.
4. Connect the new battery pack to the unoccupied connectors on the board.
5. Remove the old battery pack from the board.

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9.2 Notes on Maintenance Procedures

NOTE Remove the old battery pack after connecting the new one so that the encoder absolute
data does not disappear.

6. Mount the new battery pack on the battery holder.

7. Reinstall the plate.

NOTE Do not pinch the cable when the plate is installed.

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9.3 Notes on Grease Replenishment/Exchange Procedures

9.3 Notes on Grease Replenishment/Exchange Proce-

dures

Make sure to follow the instructions listed below at grease replenishment/exchange. Failure
to observe the following instructions may result in damage to a motor and a speed reducer.

• If grease is added with a plug on, the grease will go inside the motor or an oil seal of the
NOTE speed reducer will come off, resulting in damage to the motor and speed reducer. Make
sure to remove the plug before the grease injection.
• Do not install a joint, a hose, etc. to a grease exhaust port. Failure to observe this instruc-
tion may result in damage to the motor due to coming off of an oil seal.
• Make sure to use a grease pump to inject grease. Set air supply pressure to the grease
pump at 0.3 MPa or less, and the grease injection rate at 8 g/s or less.
• Make sure to fill a hose on the grease inlet with grease to keep air from entering into the
speed reducer.

9.3.1 Grease Replenishment/Exchange for S-axis Speed

Reducer

Grease exhaust port

Hexagon socket
head plug PT1/8

Grease inlet
S-axis speed reducer
Hexagon socket head plug PT1/8

Fig. 28 S-axis Speed Reducer Diagram

NOTE For ceiling mounted manipulators, the grease exhaust port and the grease inlet are
inverted.

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9.3 Notes on Grease Replenishment/Exchange Procedures

Grease Replenishment (Refer to " Fig. 28 S-axis Speed Reducer

Diagram ".)
Replenish the grease in accordance with the following procedure:
1. Remove the plugs from the grease exhaust port and grease inlet.

• If grease is added with the plugs on, the grease will go inside the motor and may cause a
NOTE damage. Make sure to remove the plugs before the grease injection.
• Do not install a joint, a hose, etc. to a grease exhaust port. Failure to observe this instruc-
tion may result in damage to the motor due to coming off of an oil seal.

2. Install the grease zerk PT1/8 to the grease inlet. (The grease zerk is delivered with the
manipulator.)
3. Inject the grease into the inlet using a grease gun.

Grease type: VIGO Grease RE No.0

Amount of grease: 65 cc
(130 cc for 1st supply)
Grease pump air supply pressure: 0.3 MPa or less
Grease injection rate: 8 g/s or less

4. Move the S-axis for a few minutes to discharge the excess grease.
5. Remove the grease zerk, then reinstall the plugs to the exhaust and inlet.
Tighten the plugs to a tightening torque of 4.9 N m (0.5 kgf m).
Apply Three Bond 1206C to screwed parts when installing the plugs.

Grease Exchange (Refer to " Fig. 28 S-axis Speed Reducer Dia-

gram ".)
1. Remove the plug from the grease exhaust port.

• If grease is added with the plug on, the grease will go inside the motor and may cause a
NOTE damage. Make sure to remove the plug before the grease injection.
• Do not install a joint, a hose, etc. to a grease exhaust port. Failure to observe this instruc-
tion may result in damage to the motor due to coming off of an oil seal.

2. Install the grease zerk PT1/8 to the grease inlet. (The grease zerk is delivered with the
manipulator.)
3. Inject the grease into the grease inlet using a grease gun.

Grease type: VIGO Grease RE No.0

Amount of grease: 410 cc
Grease pump air supply pressure: 0.3 MPa or less
Grease injection rate: 8 g/s or less

4. The grease replacement is complete when new grease appears in the exhaust port.
The new grease can be distinguished from the old grease by its color.
5. Move the S-axis for a few minutes to discharge the excess grease.

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9.3 Notes on Grease Replenishment/Exchange Procedures

6. Wipe the waste grease with a cloth. Remove the grease zerk from the grease inlet,
then reinstall the plugs to the inlet and exhaust ports.
Tighten the plugs to a tightening torque of 4.9 N m (0.5 kgf m).
Apply Three Bond 1206C to screwed parts when installing the plugs.

9.3.2 Grease Replenishment/Exchange for L-axis Speed

Reducer

L-arm Grease exhaust port

Hexagon socket head plug PT1/8

L-axis
Grease inlet speed reducer
Hexagon socket head cap screw M6

Fig. 29 L-axis Speed Reducer Diagram

NOTE For ceiling mounted manipulators, the grease exhaust port and the grease inlet are
inverted.

Grease Replenishment (Refer to " Fig. 29 L-axis Speed Reducer

Diagram ".)
1. Make the L-arm vertical to ground.
2. Remove the plug from the grease exhaust port.
3. Remove the bolt from the grease inlet.

• If grease is added with the exhaust plug on, the grease will go inside the motor and may
NOTE cause a damage. Make sure to remove the plug before the grease injection.
• Do not install a joint, a hose, etc. to a grease exhaust port. Failure to observe this instruc-
tion may result in damage to the motor due to coming off of an oil seal.

4. Install the grease zerk A-MT6 x 1 to the grease inlet. (The grease zerk is delivered
with the manipulator.)

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9.3 Notes on Grease Replenishment/Exchange Procedures

5. Inject grease into the grease inlet using a grease gun.

Grease type: VIGO Grease RE No.0

Amount of grease: 55 cc
(110 cc for 1st supply)
Grease pump air supply pressure: 0.3 MPa or less
Grease injection rate: 8 g/s or less

6. Move the L-axis for a few minutes to discharge the excess grease.
7. Remove the grease zerk from the grease inlet and reinstall the bolt.
Tighten the bolt to a tightening torque of 10 N m (1.0 kgf m).
Apply Three Bond 1206C to screwed parts when installing the bolts.
8. Wipe the waste grease with a cloth and reinstall the plug to the exhaust port.
Tighten the plug to a tightening torque of 4.9 N m (0.5 kgf m).
Apply Three Bond 1206C to screwed parts when installing the plug.

Grease Exchange (Refer to " Fig. 29 L-axis Speed Reducer Dia-

gram ".)
1. Make the L-arm vertical to ground.
2. Remove the plug from the grease exhaust port.
3. Remove the bolt from the grease inlet.

• If grease is added with the exhaust plug on, the grease will go inside the motor and may
NOTE cause a damage. Make sure to remove the plug before the grease injection.
• Do not install a joint, a hose, etc. to a grease exhaust port. Failure to observe this instruc-
tion may result in damage to the motor due to coming off of an oil seal.

4. Install the grease zerk A-MT6 x 1 to the grease inlet. (The grease zerk is delivered
with the manipulator.)
5. Inject grease into the grease inlet using a grease gun.

Grease type: VIGO Grease RE No.0

Amount of grease: approx. 360 cc
Grease pump air supply pressure: 0.3 MPa or less
Grease injection rate: 8 g/s or less

6. The grease replacement is complete when new grease appears in the exhaust port.
The new grease can be distinguished from the old grease by its color.
7. Move the L-axis for a few minutes to discharge the excess grease.
8. Remove the grease zerk from the grease inlet and reinstall the bolt to the grease inlet.
Tighten the bolt to a tightening torque of 10 N m (1.0 kgf m).
Apply Three Bond 1206C to screwed parts when installing the bolts.
9. Wipe the waste grease with a cloth and reinstall the plug to the exhaust port.
Tighten the plug to a tightening torque of 4.9 N m (0.5 kgf m).
Apply Three Bond 1206C to screwed parts when installing the plug.

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9.3 Notes on Grease Replenishment/Exchange Procedures

9.3.3 Grease Replenishment/Exchange for U-axis Speed

Reducer
U-arm

Grease exhaust port

Hexagon socket head
cap screw M6

Grease inlet
Hexagon socket head
plug PT1/8
U-axis speed reducer

Fig. 30 U-axis Speed Reducer Diagram

NOTE For ceiling mounted manipulators, the grease exhaust port and the grease inlet are
inverted.

Grease Replenishment (Refer to " Fig. 30 U-axis Speed Reducer

Diagram ".)
1. Make the U-arm horizontal to ground.
2. Remove the bolt from the grease exhaust port.
3. Remove the plug from the grease inlet.

• If grease is added with the bolt on, the grease will go inside the motor and may cause a
NOTE damage. Make sure to remove the bolt before the grease injection.
• Do not install a joint, a hose, etc. to a grease exhaust port. Failure to observe this instruc-
tion may result in damage to the motor due to coming off of an oil seal.

4. Install the grease zerk PT1/8 to the grease inlet. (The grease zerk is delivered with the
manipulator.)
5. Inject grease into the grease inlet using a grease gun.

Grease type: VIGO Grease RE No.0

Amount of grease: 30 cc
(60 cc for 1st supply)
Grease pump air supply pressure: 0.3 MPa or less
Grease injection rate: 8 g/s or less

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9.3 Notes on Grease Replenishment/Exchange Procedures

6. Move the U-axis for a few minutes to discharge the excess grease.
7. Remove the grease zerk from the grease inlet and reinstall the plug.
Tighten the plug to a tightening torque of 4.9 N m (0.5 kgf m).
Apply Three Bond 1206C to screwed parts when installing the plug.
8. Wipe the waste grease with a cloth and reinstall the bolt to the exhaust port.
Tighten the bolt to a tightening torque of 10 N m (1.0 kgf m).
Apply Three Bond 1206C to screwed parts when installing the bolt.

Grease Exchange (Refer to " Fig. 30 U-axis Speed Reducer Dia-

gram ".)
1. Make the U-arm horizontal to ground.
2. Remove the bolt from the grease exhaust port.
3. Remove the plug from the grease inlet.

• If grease is added with the bolt on, the grease will go inside the motor and may cause a
NOTE damage. Make sure to remove the bolt before the grease injection.
• Do not install a joint, a hose, etc. to a grease exhaust port. Failure to observe this instruc-
tion may result in damage to the motor due to coming off of an oil seal.

4. Install the grease zerk PT1/8 to the grease inlet. (The grease zerk is delivered with the
manipulator.)
5. Inject grease into the grease inlet using a grease gun.

Grease type: VIGO Grease RE No.0

Amount of grease: approx. 200 cc
Grease pump air supply pressure: 0.3 MPa or less
Grease injection rate: 8 g/s or less

6. The grease replacement is complete when new grease appears in the exhaust port.
The new grease can be distinguished from the old grease by its color.
7. Move the U-axes for a few minutes to discharge the excess grease.
8. Remove the grease zerk from the grease inlet and reinstall the plug.
Tighten the plug to a tightening torque of 4.9 N m (0.5 kgf m).
Apply Three Bond 1206C to screwed parts when installing the plug.
9. Wipe the waste grease with a cloth and reinstall the bolt to the exhaust port.
Tighten the bolt to a tightening torque of 10 N m (1.0 kgf m).
Apply Three Bond 1206C to screwed parts when installing the bolt.

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9.3 Notes on Grease Replenishment/Exchange Procedures

9.3.4 Grease Replenishment for R-axis Speed Reducer

Grease inlet
Exhaust port
Pipe plug Grease zerk A-MT6X1
(Plug LP-M5)

Fig. 31 R-axis Speed Reducer Diagram

1. Remove a plug from the exhaust port.

2. Remove the pipe plug.
3. Inject grease into the grease inlet using a grease gun. (Refer to " Fig. 31 R-axis Speed
Reducer Diagram ".)

Grease type: Harmonic grease SK-1A

Amount of grease: 8 cc
(16 cc for first supply)

NOTE The exhaust port is used for air flow. Do not inject excessive grease into the grease inlet.

4. Reinstall the pipe plug.

5. Reinstall the plug on the exhaust port.

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9.3 Notes on Grease Replenishment/Exchange Procedures

9.3.5 Grease Replenishment for B- and T-axes Speed

Reducers
Exhaust port (T-axis)
Hexagon socket head
cap screw M6

T-axis
speed reducer

Exhaust port (B-axis)

Plug LP-M5
B-axis speed reducer Grease inlet (T-axis)
Hexagon socket head
cap screw M6
Grease inlet (B-axis)
Hexagon socket head
cap screw M6

Fig. 32 B- and T-axes Speed Reducers Diagram

1. Remove the plug of B-axis or the bolt of T-axis from the exhaust ports.

NOTE Remove the U-arm cover side of the B-axis speed reducer.

2. Remove the bolts from the grease inlets and install the grease zerk A-MT6 x 1. (The
grease zerk is delivered with the manipulator.)
3. Inject grease into the grease inlets using a grease gun. (Refer to " Fig. 32 B- and T-
axes Speed Reducers Diagram ".)

Grease type: Harmonic grease SK-1A

Amount of grease:
For B-axis: 10 cc (20 cc for 1st supply)
For T-axis: 5 cc (10 cc for 1st supply)

NOTE The exhaust ports are used for air flow. Do not inject excessive grease into the grease
inlets.

4. Remove the grease zerk form the grease inlets and reinstall the bolts.
Tighten the bolts to a tightening torque of 6 N m (0.6 kgf m).
Apply Three Bond 1206C to screwed parts when installing the bolts.
5. Reinstall the plug of B-axis or the bolt of T-axis to the exhaust ports.
Tighten the bolt to a tightening torque of 6 N m (0.6 kgf m).
Apply Three Bond 1206C to screwed parts when installing the plug or bolt.

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9.3 Notes on Grease Replenishment/Exchange Procedures

NOTE Mount the U-arm cover side of the B-axis speed reducer. (Refer to " 9.3.8 Notes for Main-
tenance ".)

9.3.6 Grease Replenishment for T-axis Gear

Exhaust port
Plug LP-M5

Grease inlet
Hexagon socket head cap screw M6

Fig. 33 T-axis Gear Diagram

1. Remove the plug from the grease exhaust port.

2. Remove the bolt from the grease inlet, then install the grease zerk A-MT6 x 1. (The
grease zerk is delivered with the manipulator.)
3. Inject grease into the grease inlet using a grease gun. (Refer to " Fig. 33 T-axis Gear
Diagram ".)

Grease type: Harmonic grease SK-1A

Amount of grease: 5 cc
(10 cc for 1st supply)

NOTE The exhaust port is used for air flow. Do not inject excessive grease into the gear grease
inlet.

4. Remove the grease zerk from the grease inlet and reinstall the bolt.
Tighten the bolt to a tightening torque of 6 N m (0.6 kgf m).
Apply Three Bond 1206C to screwed parts when installing the bolt.
5. Reinstall the plug to the exhaust port.
Apply Three Bond 1206C to screwed parts when installing the plug.

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HW0483931
9.3 Notes on Grease Replenishment/Exchange Procedures

9.3.7 Grease Replenishment for R-axis Cross Roller

Bearing

R-axis cross roller bearing

Exhaust port
(Plug LP-M5)

Grease inlet
Hexagon socket head
cap screw M6 (6 screws)

Fig. 34 R-axis Cross Roller Bearing Diagram

1. Remove the plug from the exhaust port.

2. Remove the bolts of the grease inlet, then install the grease zerk A-MT6 x 1. (The
grease zerk is delivered with the manipulator.)
3. Inject grease into the grease inlet using a grease gun. (Refer to " Fig. 34 R-axis Cross
Roller Bearing Diagram ".)

Grease type: Alvania EP grease 2

Amount of grease: 3 cc
(6 cc for 1st supply)

NOTE The exhaust port is used for air flow. Do not inject excessive grease into the gear grease
inlet.

4. Remove the grease zerk from the grease inlet and reinstall the bolts.
Tighten the bolts to a tightening torque of 6 N m (0.6 kgf m).
Apply Three Bond 1206C to screwed parts when installing the bolts.
5. Reinstall the plug to the exhaust port.
Apply Three Bond 1206C to screwed parts when installing the plug.

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 HW0483931

9.3 Notes on Grease Replenishment/Exchange Procedures

9.3.8 Notes for Maintenance

Wrist Axes
The motor and encoder units are provided with the wrist unit. To prevent fumes from
penetrating into the wrist unit, the matched parts are sealed with sealing bond. Therefore, if
the wrist cover is disassembled, be sure to reapply the sealing bond when reassemble the
cover. (Three Bond 1206C, refer to " Table. 9 Spare Parts for YR-SSF6-A00, -A01 ".)
Cover
Cover jointing face

Cover jointing face

Cover

Fig. 35 Sealing Part of Wrist Unit

Battery Pack Connector (with CAUTION label)

Connect the battery pack with reference to the following figure before removing the encoder
connector (with CAUTION label).

Motor

Power connector

Encoder connector

OBT b a OBT*
BAT a b BAT*

Battery pack: HW9470932

Connector for battery backup

Fig. 36 (a) Battery Pack Connector Diagram for SLU-axes

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HW0483931
9.3 Notes on Grease Replenishment/Exchange Procedures

Encoder

Motor

Motor cable etc.

Internal wire Power connector

Connect
OBT4
OBT BAT4
BAT
removing connector.
to save the data before
Connect battery to encoder

CAUTION

Encoder connector Battery pack

CAUTION label

OBT a b OBT4
BAT b a BAT4

CAUTION label (Enlarged view) a: Crimped contact-pin (socket)

b: Crimped contact-pin (pin)

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

Fig. 36 (b) Battery Pack Connector Diagram for RBT-axes

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 HW0483931

10 Recommended Spare Parts

It is recommended that the following parts and components be kept in stock as spare parts for
the MOTOMAN-SSF2000. The spare parts list for the MOTOMAN-SSF2000 is shown below.
Product performance can not be guaranteed when using spare parts from any company other
than Yaskawa. The spare parts are ranked as follows:

• Rank A: Expendable and frequently replaced parts

• Rank B: Parts for which replacement may be necessary as a result of frequent operation
• Rank C: Drive unit

NOTE For replacing parts in Rank B or Rank C, contact your Yaskawa representative.

Table. 9 Spare Parts for YR-SSF6-A00, -A01

Qty
Parts
Rank Name Type Manufacturer Qty per Remarks
No.
Unit

Grease VIGO Grease RE Yaskawa Electric

A 1 16 kg -
No.0 Corporation

Grease Harmonic Grease Harmonic Drive

A 2 2.5 kg -
SK-1A Systems Inc.

Grease Alvania EP Showa Shell

A 3 16 kg -
Grease 2 Sekiyu K.K.

Liquid Gasket Three Bond 1206C Three Bond Co.,

A 4 - -
Ltd.

Battery Pack HW0470360-A Yaskawa Electric

A 5 1 1
Corporation

Battery Pack HW9470932-A Yaskawa Electric

A 6 1 1
Corporation

B-axis Timing Belt 60S4.5M558 Mitsuboshi Belt-

B 7 1 1
ing Limited

T-axis Timing Belt 60S4.5M387 Mitsuboshi Belt-

B 8 1 1
ing Limited

S-axis HW0386621-B Yaskawa Electric

B 9 1 1
Speed Reducer Corporation

S-axis Input Gear HW0310786-1 Yaskawa Electric

B 10 1 1
Corporation

L-axis HW9280732-B Yaskawa Electric

B 11 1 1
Speed Reducer Corporation

L-axis Input Gear HW0303276-1 Yaskawa Electric

B 12 1 1
Corporation

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HW0483931

Table. 9 Spare Parts for YR-SSF6-A00, -A01

Qty
Parts
Rank Name Type Manufacturer Qty per Remarks
No.
Unit

U-axis HW9280738-B Yaskawa Electric

B 13 1 1
Speed Reducer Corporation

U-axis Input Gear HW0303277-1 Yaskawa Electric

B 14 1 1
Corporation

R-axis HW0382277-A Yaskawa Electric

B 15 1 1
Speed Reducer Corporation

B-axis HW0381646-A Yaskawa Electric

B 16 1 1
Speed Reducer Corporation

T-axis HW0382917-A Yaskawa Electric

B 17 1 1
Speed Reducer Corporation

R-axis Cross Roller HW0381872-A Yaskawa Electric

B 18 1 1
Bearing Corporation

Wire Harness in HW0171196-A Yaskawa Electric

B 19 1 1
Manipulator Corporation

B- and T-axes HW0270875-A Yaskawa Electric

B 20 Wire Harness in Corporation 1 1
Manipulator

S-and U-axes SGMRS-06A2B- Yaskawa Electric

C 21 1 2
AC Servomotor YR1* Corporation

L-axis SGMRS-12A2B- Yaskawa Electric

C 22 1 1
AC Servomotor YR1* Corporation

R- B-, and T-axes SGMPH-01A2A- Yaskawa Electric

C 23 1 3
AC Servomotor YR1* Corporation

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 HW0483931

11.1 S-axis Unit

11 Parts List

11.1 S-axis Unit

1002
1001 1008 1025
1007
1024

1006
1003 1026

1004

1005

1032
1033 1009
1031 1032
1029 1033

1028 1029

1027
1030 1015
1016
1011 1017
1013 1010
1014

1018 1012

1023 1019
1022

1020
1021

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HW0483931
11.1 S-axis Unit

No. DWG No. Name Pcs

1001 SGMRS-06A2B-YR1* Motor 1
1002 M8X30 GT-SA Bolt 3
1003 HW0310786-1 Gear 1
1004 2H-4 Spring washer 1
1005 M4X85 Socket screw 1
1006 HW0310754-1 M-Base 1
1007 M8X30 GT-SA Bolt 7
1008 M8X30 GT-SA Bolt 18
1009 HW0101815-1 S-head 1
1010 HW0386621-B Speed reducer 1
1011 M6X35 GT-SA Bolt 16
1012 HW0101813-1 Base 1
1013 HW0200492-1 Cover 1
1014 M5X16 GT-SA Bolt 3
1015 HW9405278-1 Dog 1
1016 M10X35 Socket screw 1
1017 2H-10 Spring washer 1
1018 M10X20 GT-SA Bolt 1
1019 EZ5036A0 Cap 1
(YR-SSF6-A00)
HW9481319-A Cap 1
(YR-SSF6-A01)
1020 TSH6-01M Air joint 1
1021 NB-0640B Tube 1
1022 HW030350-A Limit switch 1
(YR-SSF6-A01)
1023 M5X12 GT-SA Bolt 2
(YR-SSF6-A01)
1024 POC6-01 Union 1
1025 NB-0640B Tube 1
1026 PT1/8 Pulg 1
1027 HW0404549-1 Support 1
1028 HW0403842-1 Support 1
1029 M6X15 GT-SA Bolt 4
1030 CD-19 Saddle 1
1031 CD-31 Saddle 1
1032 M6X8 Socket screw 4
1033 2H-6 Spring washer 4

11-2

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 HW0483931

11.2 L-Axis Unit

11.2 L-Axis Unit

2002

2001

2003
2005
2004
2008

2021

2006
2013
2007

2012

2015
2014
2011

2019 2010
2018 2009
2017
1009
2016 2020
2021

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HW0483931
11.2 L-Axis Unit

No. DWG No. Name Pcs

2001 SGMRS-12A2B-YR1* Motor 1
2002 M8X30 GT-SA Bolt 4
2003 HW0303276-1 Gear 1
2004 M6X60 Socket screw 1
2005 2H-6 Spring washer 1
2006 HW9280732-B Speed reducer 1
2007 M8X40 GT-SA Bolt 12
2008 HW0100503-1 L-arm 1
2009 M14X35 Socket screw 6
2010 M14 GT-SH washer 6
2011 M6X6 Socket screw 1
2012 HW0304457-1 Cover 1
2013 M6X8 APS Bolt 4
2014 M12X20 Socket screw 2
2015 2H-12 Spring washer 2
2016 HW0304456-1 Cover 1
2017 M6X12 Socket screw 4
2018 2H-6 Spring washer 4
2019 M6 Washer 4
2020 PMF6-01 Union 2
2021 PT1/8 Plug 2
1009 HW0101815-1 S-head 1

11-4

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 HW0483931

11.3 U-Axis Unit

11.3 U-Axis Unit

3006

3014
3015
3018
3025 3017
3030
3027 3022 3021 3010 3016 3012
3029 3011
3028
3023
3024

3007
3019
3013 3020
3019
3001
3002 3020
3026 3009
3008
3025

3003
3005
2008
3004

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HW0483931
11.3 U-Axis Unit

No. DWG No. Name Pcs

3001 SGMRS-06A2B-YR1* Motor 1
3002 M8X30 GT-SA Bolt 4
3003 HW0303277-1 Gear 1
3004 M4X50 Socket screw 1
3005 2H-4 Spring washer 1
3006 HW0100619-1 Casing 1
3007 HW9280738-B Speed reducer 1
3008 M6X35 GT-SA Bolt 12
3009 M10X30 GT-SA Bolt 6
3010 HW0200493-1 Cover 1
3011 M4X55 Socket screw 2
3012 2H-4 Spring washer 2
3013 M4X12 GT-SA Bolt 2
3014 HW9481087-A Gascket 1
3015 HW0404718-1 N-base 1
3016 M4X10 GT-SA Bolt 2
3017 M3X16 Round head 2
screw
3018 M3 Nut 2
3019 HW0404179-1 Stopper 2
3020 M4X16 GT-SA Bolt 4
3021 HW0404152-1 Support 1
3022 M4X10 GT-SA Bolt 2
3023 KQE10-03 Air joint 1
3024 PT3/8 Plug 1
3025 M6X6 Socket screw 1
3026 M10X20 GT-SA Bolt 2
3027 HW0404196-2 Washer 1
3028 M10X35 Socket screw 1
3029 2H-10 Spring washer 2
3030 PT1/8 Plug 1
2008 HW0100503-1 L-arm 1

11-6

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 HW0483931

11.4 R-Axis Unit

11.4 R-Axis Unit

5001
4029

4026
4027

4039
4036
4028 4035

4037 4038
4025
4033
4034

4031 4032

4030
4041 4022
4040
4017 4016 4019
4024
4023
4015 4018 4021
4020 4041
4012 4014
4011 4013 4007 4006 3006
4010 4022
4005
4004
4007 4024
4023

4009
4003 4008

4001
4002

11-7

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HW0483931
11.4 R-Axis Unit

No. DWG No. Name Pcs

4001 SGMPH-01A2A-YR1* Motor 1
4002 M5X12 Socket screw 4
4003 HW0404161-1 M-base 1
4004 M4X25 Socket screw 9
4005 2H-4 Spring washer 9
4006 MT6X1 Grease zerk 1
4007 HW0382277-A Speed reducer 1
4008 M3X16 Socket screw 12
4009 2H-3 Spring washer 12
4010 HW0404304-1 Gasket 1
4011 TC12227FKM Oil seal 1
4012 HW0404163-1 Fly wheel 1
4013 HW0404196-1 Washer 1
4014 M4X40 Socket screw 1
4015 2H-4 Spring washer 1
4016 HW0404164-1 Shaft 1
4017 M5X16 GT-SA Bolt 8
4018 6809ZZ Bearing 1
4019 HW0304348-1 Shaft 1
4020 HW0404717-1 Support 1
4021 M4X12 GT-SA Bolt 2
4022 HW0404503-1 Saddle 2
4023 M4X20 Socket screw 4
4024 2H-4 Spring washer 4
4025 HW0381872-A Cross roller 1
bearing
4026 M6X30 Socket screw 8
4027 2H-6 Spring washer 8
4028 M6X30 GT-SA Bolt 2
4029 M6X60 GT-SA Bolt 8
4030 HW0304455-1 Cover 1
4031 M4X16 GT-SA Bolt 6
4032 HW0404478-1 Cover 1
4033 M4X12 GT-SA Bolt 2
4034 M5X10 APS Bolt 1
4035 HW0404720-1 Cover 1
4036 M4X10 Socket screw 3
4037 EZ5036A0 Cap 1
4038 M6X6 Socket screw 1
4039 LP-M5 Plug 2
4040 M4X10 Round head 2
screw
4041 TA1-S8 Clamp 1
3006 HW0100619-1 Casing 1
5001 HW0100620-1 U-arm 1

11-8

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 HW0483931

11.5 Wrist Unit

11.5 Wrist Unit

5055
5054
5053

5051 5056
5050
5049
5047 5052
5034

5033 5027 5053

5048 5045
5024
5028
5026 5042
5029 5025 5023 5020 5041 5046
5040 5043
5030 5036 5039
5022 5044
5019 5038
5032 5021
5031 5018
5070 5064
5065 5035
5066
5063
5061 5062 5002
5037
5060
5003 5017
5016 5013 5012
5058
5059 5002
5011

5009
5057 5015 5008
5003 5014 5007
5004 5010
5001 5005
5006

5033

5034

11-9

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HW0483931
11.5 Wrist Unit

No. DWG No. Name Pcs

5061 M4X12 GT-SA Bolt 2
No. DWG No. Name Pcs 5062 TA1-S8 Clamp 1
5001 HW0100620-1 U-arm 1 5063 M4X8 Round head 1
screw
5002 SGMPH-01A2A-YR1* Motor 2
5064 M6X14 Socket screw 1
5003 M4X16 GT-SA Bolt 4
5065 2H-6 Spring washer 1
5004 HW0481429-A Pulley 1
5066 M6 Washer 1
5005 M4X12 Socket screw 1
5006 60S4.5M558 Belt 1
5007 M5X16 GT-SA Bolt 1
5008 HW0481692-A Pulley 1
5009 69022ZZ Bearing 1
5010 HW0403705-1 Housing 1
5011 M6X6 Socket screw 1
5012 M4X16 GT-SA Bolt 4
5013 HW0381646-A Speed reducer 1
5014 M4X12 GT-SA Bolt 4
5015 M4X16 GT-SA Bolt 9
5016 688A Bearing 1
5017 HW0404303-1 Coller 1
5018 6812LLU Bearing 1
5019 HW0404302-1 Shaft 1
5020 M3X12 GT-SA Bolt 2
5021 HW9381452-A Gear 1
5022 6811LLU Bearing 1
5023 HW0404266-1 Housing 1
5024 M4X12 GT-SA Bolt 4
5025 HW9482218-A Bearing 1
5026 HW9404988-1 B-cover 1
5027 M4X12 Socket screw 4
5028 HW9482220-A Pulley 1
5029 M4X12 GT-SA Bolt 1
5030 60S4.5M387 Belt 1
5031 HW9482352-A Pulley 1
5032 M4X12 Socket screw 1
5033 HW9200780-1 Cover 2
5034 M5X12 GT-SA Bolt 12
5035 HW0200491-1 Wrist base 1
5036 LP-M5 Plug 1
5037 M6X6 Socket screw 1
5038 M4X12 GT-SA Bolt 1
5039 HW9381384-A Gear 1
5040 HW9405199-1 B-nut 1
5041 SP-0120** Shim 1
5042 HW9481180-A Bearing 1
5043 HW0303912-1 Housing 1
5044 M6X6 Socket screw 1
5045 M6X6 Socket screw 1
5046 M4X12 GT-SA Bolt 8
5047 HW0382917-A Speed reducer 1
5048 M5X12 GT-SA Bolt 6
5049 HW0307678-1 Shaft 1
5050 HW9481024-A Bearing 1
5051 HW0307679-1 Flange 1
5052 M4X10 GT-SA Bolt 6
5053 HW0404550-1 Housing 1
5054 2H-4 Spring washer 4
5055 M4X30 Socket screw 4
5056 HW0404371-1 Bolt 1
5057 HW0404279-1 Block 1
5058 M4X20 Socket screw 2
5059 2H-4 Spring washer 2
5060 HW9406556-1 Support 1

11-10

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MOTOMAN-SSF2000
INSTRUCTIONS

HEAD OFFICE
2-1 Kurosaki-Shiroishi, Yahatanishi-ku, Kitakyusyu-shi, 806-0004, Japan
Phone +81-93-645-7745 Fax +81-93-645-7746
MOTOMAN INC. HEADQUARTERS
805 Liberty Lane, West Carrollton, OH 45449, U.S.A.
Phone +1-937-847-6200 Fax +1-937-847-6277
MOTOMAN ROBOTICS EUROPE AB
Franska Vagen 10, Box 4004, SE-390 04 Kalmar, Sweden
Phone +46-480-417800 Fax +46-480-417999
MOTOMAN ROBOTEC GmbH
Kammerfeld strasse 1, 85391 Allershausen, Germany
Phone +49-8166-90-100 Fax +49-8166-90-103
YASKAWA ELECTRIC KOREA CORPORATION
1F, Samyang Bldg. 89-1, Shinchun-dong, Donk-Ku, Daegu, Korea
Phone +82-53-382-7844 Fax +82-53-382-7845
YASKAWA ELECTRIC (SINGAPORE) PTE. LTD.
151 Lorong Chuan, #04-01, New Tech Park, Singapore 556741
Phone +65-6282-3003 Fax +65-6289-3003
YASKAWA ELECTRIC (MALAYSIA) SDN. BHD.
Unit 47-1 and 2. Jalan PJU 5/9, Dataran Sunway, Kota Damansara, 47810, Petailng Jaya Selangor, Malaysia
Phone +60-3614-08919 Fax +60-3614-08929
YASKAWA ELECTRIC (THAILAND) CO., LTD.
252/246, 4th Floor. Muang Thai-Phatra office Tower II Rechadapisek Road, Huaykwang Bangkok 10320, Thailand
Phone +66-2-693-2200 Fax +66-2-693-4200
SHOUGANG MOTOMAN ROBOT CO., LTD.
No.7,Yongchang-North Road, Beijing Economic and Technological and Development Area, Beijing 100076, China
Phone +86-10-6788-0541 Fax +86-10-6788-0542
MOTOMAN MOTHERSON ROBOTICS LTD.
910, DLF Galleria, DLF City Phase IV, Gurgaon - 122002 Haryama, india
Phone +91-124-414-8514 Fax +91-124-414-8016

YASKAWA ELECTRIC CORPORATION

YASKAWA

Specifications are subject to change without notice

for ongoing product modifications and improvements. C Printed in Japan October 2007 07-06

MANUAL NO.

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