MOTOMAN-EP4000N

INSTRUCTIONS
FOR INTER-PRESS HANDLING
TYPE: YR-EP4000N-W00, X00, Y00
(Supports T-axis high inertia. Fixed hand specifications)

TYPE:

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

MOTOMAN INSTRUCTIONS
MOTOMAN-EP4000N INSTRUCTIONS
NX100 INSTRUCTIONS
NX100 OPERATOR’S MANUAL
NX100 MAINTENACE MANUAL
The NX100 operator’s manuals above correspond to specific usage.
Be sure to use the appropriate manual.

Part Number: 158268-1CD

Revision: 0

YASKAWA ELECTRIC CORPORATION

MANUAL NO.

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MANDATORY
• This instruction manual explains operating instructions and mainte-
nance procedures primarily for the MOTOMAN-EP4000N.

• General items related to safety are listed in 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”, “MAN-
DATORY”, 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
programming pendant are pressed.
When the servo power is turned off, the SERVO ON LED on the program-
ming 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 programming 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 the pro-
gramming 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 programming pendant to the hook on the NX100 cabi-
net after use.

The programming 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 programming pendant, and manipulator
cables.
In this manual, the equipment is designated as follows:

Equipment Manual Designation

NX100 Controller NX100

NX100 Programming Pendant Programming pendant

Cable between the manipulator and the 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 B Warning Label A

WARNING

Nameplate

Moving parts
Warning label B
may cause
injury

Warning label A
Warning Label B

WARNING

Warning label A

Do not enter
robot
work area.

Nameplate

MOTOMAN
TYPE

PAYLOAD MASS
kg kg
ORDER NO. DATE

SERIAL NO.

YASKAWA ELECTRIC CORPORAION JAPAN

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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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.1.1 Using a Crane. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.2 Shipping Bolts and Brackets. . . . . . . . . . . . . . . . . . . . . . . . 2-3

3 Installation
3.1 Safeguarding Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3.2 Mounting Procedures for Manipulator Base . . . . . . . . . 3-2
3.2.1 Manipulator Base Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3.3 Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

4 Wiring
4.1 Grounding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.2 Manipulator Cable Connection . . . . . . . . . . . . . . . . . . . . . 4-2
4.2.1 Connection to the Manipulator . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4.2.2 Connection to the NX100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

5 Basic Specifications
5.1 Basic Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.2 Part Names and Working Axes . . . . . . . . . . . . . . . . . . . . . 5-2
5.3 Manipulator Base Dimensions . . . . . . . . . . . . . . . . . . . . . . 5-2
5.4 Dimensions and P-point Maximum Envelope . . . . . . . 5-3
5.5 B-Axis Operating Range. . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5.6 Alterable Operating Range . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

6 Allowable Load for Wrist Axis and Wrist Flange

6.1 Allowable Wrist Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.2 Wrist Flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

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7 System Application
7.1 Peripheral Equipment Mounts . . . . . . . . . . . . . . . . . . . . . 7-1
7.2 Internal User I/O Wiring Harness and Air Line . . . . . . 7-2

8 Electrical Equipment Specifications

8.1 Locations of Limit Switches . . . . . . . . . . . . . . . . . . . . . . . . 8-1
8.2 Internal Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3

9 Maintenance and Inspection

9.1 Inspection Schedule
(Manipulator in the Home Position: Refer to “Fig. 19”) . . . . . . . . . 9-1
9.2 Notes on Maintenance Procedures . . . . . . . . . . . . . . . . 9-6
9.2.1 Battery Pack Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-6
9.2.2 Grease Replenishment/Exchange for S-Axis
Speed Reducer and Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-8
„ Grease Replenishment (Refer to "Fig. 22 S-Axis
Speed Reducer and Gear Diagram".) . . . . . . . . . . . . . . . . . .9-8
„ Grease Exchange (Refer to "Fig. 22 S-Axis
Speed Reducer and Gear Diagram".) . . . . . . . . . . . . . . . . . .9-9
9.2.3 Grease Replenishment/Exchange for L-Axis
Speed Reducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-10
„ Grease Replenishment (Refer to "Fig. 23 L-Axis
Speed Reducer Diagram".) . . . . . . . . . . . . . . . . . . . . . . . . .9-10
„ Grease Exchange (Refer to "Fig. 23 L-Axis
Speed Reducer Diagram".) . . . . . . . . . . . . . . . . . . . . . . . . .9-11
9.2.4 Grease Replenishment/Exchange for U-Axis
Speed Reducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-12
„ Grease Replenishment (Refer to "Fig. 24 U-Axis
Speed Reducer Diagram".) . . . . . . . . . . . . . . . . . . . . . . . . .9-12
„ Grease Exchange (Refer to "Fig. 24 U-Axis
Speed Reducer Diagram".) . . . . . . . . . . . . . . . . . . . . . . . . .9-13
9.2.5 Grease Replenishment/Exchange for R, B-,
T-Axis Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-14
„ Grease Replenishment (Refer to "Fig. 25 R-, B-,
T-Axis Gear Diagram".) . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-14
„ Grease Exchange (Refer to "Fig. 25 R-, B-,
T-Axis Gear Diagram".) . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-15
9.2.6 Grease Replenishment/Exchange for R-Axis
Speed Reducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-16
„ Grease Replenishment (Refer to "Fig. 26 R-Axis
Speed Reducer Diagram".) . . . . . . . . . . . . . . . . . . . . . . . . .9-16
„ Grease Exchange (Refer to "Fig. 26 R-Axis
Speed Reducer Diagram".) . . . . . . . . . . . . . . . . . . . . . . . . .9-17

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9.2.7 Grease Replenishment/Exchange for B-Axis

Speed Reducer and Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-18
„ Grease Replenishment (Refer to "Fig. 27 B-Axis
Speed Reducer and Gear Diagram".). . . . . . . . . . . . . . . . . 9-18
„ Grease Exchange (Refer to "Fig. 27 B-Axis
Speed Reducer and Gear Diagram".). . . . . . . . . . . . . . . . . 9-19
9.2.8 Grease Replenishment/Exchange for T-Axis
Speed Reducer and Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-20
„ Grease Replenishment (Refer to "Fig. 28 T-Axis
Speed Reducer and Gear Diagram".). . . . . . . . . . . . . . . . . 9-20
„ Grease Exchange (Refer to "Fig. 28 T-Axis
Speed Reducer and Gear Diagram".). . . . . . . . . . . . . . . . . 9-21
9.2.9 Grease Replenishment for U-Axis Cross Roller Bearing . . . . 9-22
9.2.10 Grease Replenishment for Tapered Roller Bearing
in the Link Part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-23
9.2.11 Grease Replenishment for Balancer Link Part . . . . . . . . . . . 9-24
9.2.12 Notes for Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-25
„ Motors for S-, L-, U-, R-, B-, T-Axes . . . . . . . . . . . . . . . . . . 9-25

10 Recommended Spare Parts

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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
• Programming pendant
• Manipulator cables (six cables, between manipulator and NX100)

Connectors for manipulator cables are located on different positions depending on manipu-
NOTE lator types.

The back side

EP4000N-X00

Manipulator cable Manipulator cable

connector connector

The left side of the front The right side of the front
EP4000N-W00 EP4000N-Y00

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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 Check that the manipulator

SHOULD HAVE SAME ORDER NUMBER.
and the NX100 have the
same order number.
ORDER NO.

THE MANIPULATOR AND THE CONTROLLER

SHOULD HAVE SAME ORDER NUMBER.
ORDER NO.
NJ1529

WARNING
Do not open the door

ON
D
PPE
TRI
OFF
T
RESE

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

Fig. 1 Location of Order Number Labels

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2.1 Transporting Method

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.

2.1 Transporting Method

• Check that the eyebolts are securely fastened.

NOTE
• The weight of the manipulator is approximately 3200 kg including the shipping bolts and
brackets. Use a wire rope strong enough to withstand the weight.
• Attached eyebolts are designed to support the manipulator weight. Do not use them for
anything other than transporting the manipulator.
• Mount the shipping bolts and brackets in transporting the manipulator.
• Avoid exerting force on the arm or motor unit during transportation: use caution when
using transporting equipment other than a crane or forklift to avoid 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 ropes threaded through shipping bolts and
brackets. Be sure the manipulator is fixed with the shipping bolts and brackets before trans-
portation, and lift it in the posture as shown in "Fig. 2 Transporting Position".

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2.1 Transporting Method

B
C
A

Fig. 2 Transporting Position

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2.2 Shipping Bolts and Brackets

2.2 Shipping Bolts and Brackets

The manipulator is equipped with shipping bolts and brackets at points A, B and C ("Fig. 2
Transporting Position").

• The shipping bolts and brackets are painted yellow.

Position Bolt Type Pcs

A Hexagon socket head cap screw: M12 (length: 30 mm) 3

(Tensile strength: 1200 N/mm2 or more)

B Hexagon nut: M12 2

C Hexagon nut: M12 2

Before turning ON the power, check to be sure that the shipping bolts and brackets have
NOTE been removed. The shipping bolts and brackets then must be stored for future use, in the
event that the robot 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.

CAUTION
• Do not install or operate the manipulator which 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 "2.2 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 Safeguarding Installation

3.1 Safeguarding Installation

To insure safety, be sure to install safeguarding. They prevent unforeseen accidents with per-
sonnel and damage to equipment. The following term is quoted for your information and guid-
ance.
Responsibility for Safeguarding [ISO 10218]
The user of a manipulator or robot system shall ensure that safeguards are provided and used
in accordance with Sections 6, 7, and 8 of this standard. The means and degree of safeguard-
ing, including any redundancies, shall correspond directly to the type and level of hazard pre-
sented 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 manipulator base mount strong enough to
support the robot and withstand repulsion forces during acceleration and deceleration. Con-
struct a solid foundation with the appropriate thickness to withstand maximum repulsion forces
of the manipulator, referring to "Table 1 Maximum repulsion forces of the manipulator base
mount".
A base mount flatness must be kept at 0.5 mm or less: insufficient flatness of installation sur-
face may deform the manipulator shape and affect its functional abilities.

Connectors for manipulator cables are located on different positions depending on manipu-
NOTE lator types.
Confirm the correct position of the manipulator cable before Installing the manipulator.

The back side

EP4000N-X00

Manipulator cable Manipulator cable

connector connector

The left side of the front The right side of the front
EP4000N-W00 EP4000N-Y00

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3.2 Mounting Procedures for Manipulator Base

3.2.1 Manipulator Base Mount

Design and construct the manipulator base mount so that it can bear the torque shown in the
table below. The vibration in the manipulator base must be 4.9 m/s2 (0.5G) or less when the
manipulator is individually operated.
The manipulator base mount has 12 mounting holes. Mount the manipulator base firmly using
the hexagon socket head cap screws M24 (tensile strength: 1000 N/mm2 or more, recom-
mended length: 90 mm).

Table 1 Maximum repulsion forces of the manipulator base mount

c Maximum torque in horizontal rotation 88200 N·m or more

(S-axis moving direction) (9000 kgf·m)

d Maximum torque in vertical rotation 68600 N·m or more

(L-, U-axis moving directions) (7000 kgf·m)

2 Torque

1 Torque

Hexagon socket head cap

screw M24 (length: 90)
Spring washer

Washer

Manipulator Base

Manipulator base mount

45

Units: mm

Fig. 3 Installation Base

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3.3 Location

3.3 Location

When the manipulator is installed, it is necessary to satisfy the following environmental condi-
tions:

• Ambient temperature: 0 to 45°C.

• Humidity: 20 to 80%RH at constant temperature.
• Free from exposure to water, oil, or dust.
• Free from corrosive gas or liquid, or explosive gas.
• Free from large electrical noise (plasma).
• Shock or vibration from the press must be 9.8 m/s2 (1.0 G) or less.
• Free from excessive shock or vibration: 4.9 m/s2 (0.5G) or less when the manipulator is
operated individually (with no vibration from other equipment such as the press). (Exces-
sive vibration affects the mechanism.)
• Flatness for installation: 0.5 mm or less.

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4.1 Grounding

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 OFF the primary power supply, and put
up a warning sign such as: “DO NOT TURN ON THE POWER.”

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.

• Do not cover the cable with heat insulating material, and avoid multiple
cabling when laying manipulator cables from the manipulator to the
NX100.

Failure to observe this caution may result in burn caused by cable heat emission failure.

4.1 Grounding

Follow local regulations for grounding line size. A line of 8.0 mm2 or more is recommended.
Refer to "Fig. 4 Grounding Method" to connect the ground line directly to the manipulator.

• Never use this line sharing with other ground lines or grounding electrodes for other elec-
NOTE tric power, motor power, welding devices, etc.
• Where metal ducts, metallic conduits, or distributing racks are used for cable laying,
ground in accordance with Electric Equipment Technical Standards.

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4.2 Manipulator Cable Connection

A Bolt M8 (for grounding)

(Delivered with manipulator)

View A
Fig. 4 Grounding Method

4.2 Manipulator Cable Connection

As shown on "Fig. 5 Manipulator Cables", there are six cables for the power supply. Connect
these cables to the connectors on the manipulator base and the NX100, referring to "Fig. 5
Manipulator Cables".

4.2.1 Connection to the Manipulator

Before connecting the cables to the manipulator, verify the numbers: there are 1BC, 2BC,
3BC, 4BC, 5BC, and 6BC on both manipulator cables and the manipulator base connectors.
When connecting the cables, adjust the cable connector positions to the main key positions of
the manipulator, and insert the cables in the order of 2BC, 3BC, 4BC, 5BC, 6BC, and 1BC,
then set each lever downward until it clicks.

4.2.2 Connection to the NX100

Before connecting the cables to the NX100, verify the numbers: there are X11, X21, X22, X23,
X24, and X25 on both manipulator cables and the connectors on the NX100. When connect-
ing the cables, adjust the cable connector positions to the main key positions of the NX100,
and insert the cables in the order of X21, X22, X23, X24, X25, and X11, then set each lever
downward until it clicks.

CAUTION
• Do not cover the cable with heat insulating material, and avoid multiple
cabling when laying manipulator cables from the manipulator to the
NX100.

Failure to observe this caution may result in burn caused by cable heat emission failure.

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4.2 Manipulator Cable Connection

NX100 side Manipulator side

X11 1BC

1BC

1BC
X11

Encoder cable

X21 2BC

2BC

2BC
X21

Power cable

X22 3BC

3BC
3BC
X22

Power cable

X23 4BC

4BC
4BC
X23

Power cable

X24 5BC

5BC
5BC
X24

Power cable

X25 6BC

6BC
6BC
X25

Power cable

Fig. 5 Manipulator Cables

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4.2 Manipulator Cable Connection

7BC
AIR1 AIR2

1BC 2BC 3BC 4BC 5BC 6BC

Main key positions

Fig. 6 (a) Manipulator Cable Connectors (Manipulator Side)

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4.2 Manipulator Cable Connection

X11
X21
X22

X23

X24

X25

Fig. 6 (b) Manipulator Cable Connectors (NX100 Side)

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5.1 Basic Specifications

5 Basic Specifications

5.1 Basic Specifications

Table. 2 Basic Specifications*1
Item Model MOTOMAN-EP4000N-*0* MOTOMAN-EP4000N-*1*

Configuration Vertically Articulated

Degree of Freedom 6

Payload 200 kg

Repeatability2 ±0.5 mm

S-Axis (turning) -150° to +150°

L-Axis (lower arm) -122° to +25°

Motion U-Axis (upper arm) -70° to +53°

Range R-Axis (wrist roll) -360° to +360°

B-Axis (wrist pitch/yaw) -115° to +115°

T-Axis (wrist twist) -360° to +360°

S-Axis 1.57 rad/s, 90°/s

L-Axis 1.57 rad/s, 90°/s

Maximum U-Axis 1.57 rad/s, 90°/s

Speed R-Axis 1.40 rad/s, 80°/s
B-Axis 1.40 rad/s, 80°/s

T-Axis 2.79 rad/s, 160°/s

Mass 3200 kg
Temperature 0 to +45C°

Humidity 20 to 80% RH (non-condensing)

Ambient Vibration 9.8 m/s2 (1.0 G) or less
Conditions
• Free from corrosive gasses or liquids, or explosive gasses.
Others • Free from exposure to water, oil, or dust.
• Free from excessive electrical noise (plasma).
Power Requirements 22.5 kVA

*1 SI units are used in this table. However, gravitational unit is used in ().
*2 Conformed to ISO9283.

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5.2 Part Names and Working Axes

5.2 Part Names and Working Axes

S+

S-
L-

Rotary head
(S-head)

U- U+

L+

Base Lower arm

(L-arm)
R- R+

Upper arm
(U-arm)

Wrist

B- B+

Wrist flange

T- T+

Fig. 7 Part Names and Working Axes

5.3 Manipulator Base Dimensions

350±0.2
475 +0.018
12 dia. 0
70

dowel hole
410±0.2
860

760
640
410±0.2
45

640
28 dia. hole (12 holes)
A 350±0.2
12 dia.
+0.018
dowel hole 760
0
860 Units: mm

Fig. 8 Baseplate Dimensions (mm)

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5.4 Dimensions and P-point Maximum Envelope

5.4 Dimensions and P-point Maximum Envelope

0° 03
3 4-M10xP1.5, 25 depth
15 R1

44
110
R3505 300 380
15
0°
View A

2160

550 1100 250 260

1681
° 840.5 840.5
32 11
5°

12 P-Point Maximum
2° Envelope
°
606 53
773
573
758

25 °

A
0 0
°
53
449 509
70 °
2135

672
P-Point
300

1856
261 542 1803 1823 3505
B

373
0
3878 12-M12xP1.75, 25 depth

15° 15 ° 3 .25
0
° 0°
30 C.D
P.
30
30 °

°
30°

30°
30

30 °
°

30 ° °
30
+0.018
12 dia. 0 hole
(depth: 15)
View B Units: mm
Fig. 9 Dimensions and P-Point Maximum Envelope

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5.5 B-Axis Operating Range

5.5 B-Axis Operating Range

The B-axis operates keeping the constant angle to the center of U-arm as shown in "Fig. 10
B-Axis Operating Range".

Center of rotation: U-axis

Center of rotation: U-axis

Center of rotation: S-axis

Center of rotation:
B-axis
°5
11

11
° 5

Fig. 10 B-Axis Operating Range

5.6 Alterable Operating Range

The operating range of the S-axis can be altered according to the operating conditions as
shown in "Table 3 S-Axis Operating Range". If alteration is necessary, contact your Yaskawa
representative in advance.

Table 3 S-Axis Operating Range

Item Specifications

-150° to +150° (standard)

S-Axis -120° to +120°
Operating -90° to +90°
Range -60° to +60°
-30° to +30°

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6.1 Allowable Wrist Load

6 Allowable Load for Wrist Axis and Wrist

Flange

6.1 Allowable Wrist Load

The maximum pay load of the wrist axis is 200 kg. However, because there are limits on the
moment and the moment of inertia as shown in " Fig. 4 Allowable Inertia and Moment of Iner-
tia ", it is necessary for these conditions to be satisfied.

Also, note that in the case where the load is not a mass but rather a force, it is necessary to
study how to prevent the values in Table 4 from being exceeded.

Table 4 Allowable Inertia and Moment of Inertia

GD2/4 Overall moment of

Moment N•m
inertia of load kg·m2

R-axis 2205 430

B-axis 2205 430
T-axis 0 400

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6.2 Wrist Flange

6.2 Wrist Flange

It is recommended that the attachment be mounted inside the fitting to identify the alignment
marks. Fitting depth of inside and outside fittings must be 8 mm or less.
300 from P-point

+0.040
160 dia. 0 hole

0
315 dia.-0.089 hole

Tapped hole M12

(depth: 25)(12 holes)
15° 15 °
°
30 °
30 25
0
. D.
P.C
30 °

30
°
30°

30°

+0.018
12 dia. 0 hole
30

30 °

(depth: 15)
°

30 ° °
30
30°

Fig. 11 Wrist Flange

NOTE Wash off anti-corrosive paint (yellow) 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 and tapped holes are provided on the upper arm of the
manipulator as shown in "Fig. 12 Tapped Holes for Peripheral Equipment Mounts", for easier
installation of the user's system applications. Make efficient use of these mounts following the
conditions in "Table 5 Condition for Attachment".

100

17
160
B
Tapped hole M8 (pitch 1.25)
140 (depth: 15)(2 holes x 2 places)
1495.5

94
60
A
100

Tapped hole M8 (pitch 1.25)

(depth: 15)(2 holes x 2 places)
839.5

Units: mm

Fig. 12 Tapped Holes for Peripheral Equipment Mounts

Table 5 Condition for Attachment

Application Remarks

A Cabling Allowable load mass is 200 kg including

wrist load.

B Cabling 10 kg or less.
Valve mounting 25 N·m (2.5 kgf·m) or less for increased
moment amount of upper arm

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7.2 Internal User I/O Wiring Harness and Air Line

7.2 Internal User I/O Wiring Harness and Air Line

34 wires (0.5 mm2) and 2 air lines are used in the manipulator for the drives of the peripheral
devices mounted on the upper arm as described in "Fig. 13 Internal User I/O Wiring Harness
and Air Line".
The connector pins 1 to 34 are assigned as shown in the close-up drawing in Fig. 13.
Wiring must be performed by user.
• The allowable current for wires: 6.6 A or less for each wire.
(The total current value for pins 1 to 34 must be 60 A or
less.)
• The maximum pressure for the air lines: 490 kPa (5 kgf/cm2) or less for each line.
(The inside diameter: 8 mm.)

AIR2
AIR1
Connectors for internal
user I/O wiring harness:
JL05-2A28-21SC (socket
7BC
AIR1 AIR2

connector with a cap).

Prepare pin connector
JL05-6A28-21P.

Details on Connector Pin Numbers

1
AIR2

2
3
AIR1

4
5
6
Internal user I/O wiring harness: 7
0.5mm2 (34 wires) 8
9
10 Exhaust port B: tapped hole PT3/8
11
12 with a pipe plug
13
14
15 Exhaust port A: tapped hole PT3/8
16 with a pipe plug
17
Pins used 18
19
20
7BC
21 AIR1 AIR2
1 2 3 4 22
23
5 6 7 8 9
24
10 11 12 13 14 15 25 Connectors for internal
26 user I/O wiring harness:
16 17 18 19 20 21 22 27
28 JL05-2A28-21PC (pin
23 24 25 26 27 28
29 connector with a cap).
29 30 31 32 33 30
31 Prepare socket connector
34 35 36 32 JL05-6A28-21S.
33
34 Air inlet A: tapped hole PT1/2
with a pipe plug
Air inlet B: tapped hole PT1/2
with a pipe plug

Fig. 13 Internal User I/O Wiring Harness and Air Line

The same pin number (1-34) of two connectors is connected in the lead line of single 0.5mm2.

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8.1 Locations of Limit Switches

8 Electrical Equipment Specifications

8.1 Locations of Limit Switches

(1) "YR-EP4000N-**0"
Equipped with an overrun limit switch for the S-axis.
Refer to "Fig. 14 Locations of Limit Switches" for the location.
(2) "YR-EP4000N-**1"
Equipped with overrun limit switches for the S- and L-axes, and an interference limit
switch for the L- and U-axes.
Refer to "Fig. 14 Locations of Limit Switches" for the locations.

L-axis overrun limit switch

For YR-EP4000N- **1 only
S-axis overrun limit switch

L-U-axis interference limit switch

For YR-EP4000N- ** 2 only

Fig. 14 Locations of Limit Switches

(3) The L-axis overrun limit switch and the L-U-axis interference limit switch electrically
restrict the ranges of each subject axis motion by adjusting the dog position. The
mechanical stopper is effective at the P-point maximum envelope, and its position
cannot be changed.
(4) The power supply to the manipulator will be cut off once the limit switch is activated,
resulting in an emergency stop of the manipulator.
Refer to “8.9 Overrun / Tool Shock Sensor Releasing” in “NX100 INSTRUCTIONS”
to release the manipulator from the overrun status.
(5) The limit switches are set at the P-point maximum envelope before the shipment.

In case of re-adjusting the operating range of each subject axis, it is also required to
NOTE change the dog location and limit values in software. Contact your Yaskawa representative
if re-adjustment is required.

(6) Adjustable range of the L-axis overrun limit switch

As shown in "Fig. 15 L-axis Overrun Limit Switch Adjustable Range", L-axis is
adjustable within the range between 26° to the plus (+) direction and 123° to the
minus (-) direction. However, the least adjustable range of motion is 16°. The L-
axis can be set at any degrees within the above mentioned range as long as it is set
at 16° or more.

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8.1 Locations of Limit Switches

12
3°

[Example]
12
3°
L-axis rotation
center

Minus (

Under 16
Minus(-) side

-) side
Setting impossible

°
side

26°

°
Over 16
Plus(+) side

Plus (+)
26 °
Setting possible
L-arm

Fig. 15 L-axis Overrun Limit Switch Adjustable Range

(7) Adjustable range of the L-U-axis interference limit switch

The limit switch for the L- and U-axis interference is structured to check the interfer-
ence angle between the L- and U-axes. Set the interference angle between the L-
and U-axes within the range from 19° to 161° as shown in "Fig. 16 L-U-axis Interfer-
ence Limit Switch Adjustable Range".

U-axis rotation
center
19°

U-arm

161°

Fig. 16 L-U-axis Interference Limit Switch Adjustable Range

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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 con-
nector part.
For the numbers, types, and locations of the connectors, see "Fig. 17 Location and Numbers
of Connectors" and "Table 6 List of Connector Types". As to the internal connections between
the manipulator and the NX100, see connection diagrams in “Fig. 18 (a)” and
“Fig. 18 (b)” on the following pages.

AIR2
AIR1
Connector for internal user
I/O wiring harness
AIR1 AIR2
7BC
7BC
AIR2

7BC: Connector for internal user

AIR2

I/O wiring harness and air line

AIR1

Fig. 17 Location and Numbers of Connectors

Table 6 List of Connector Types

Name Type of Connector

Connector base: Connector for internal user I/O JL05-2A28-21PC

wiring harness (JL05-6A28-21S: Optional)

U-arm: Connector for internal user I/O JL05-2A28-21SC

wiring harness (JL05-6A28-21P: Optional)

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8.2 Internal Connections

POWER CABLE INTERNAL WIRE

0BT1 BAT1 Note:
0BT1 BAT1 R
K 1. This diagram shows the internal wiring for increasing the torque of the EP4000N.
NX 1BC(6X6) TYPE A
DATA+1 CN1-1
1BC(6X6) TYPE A
CN1-1 DATA+1
P No.7CN
CN-C DATA+1
2. As for the LS specification, part A is different.
DATA-1 CN1-2 P CN1-2 DATA-1 P -D DATA-1
-T BAT
P -S OBT PG S-AXIS
+5V-1 CN1-3 CN1-3 +5V-1 -H +5V

0V-1 CN1-4 CN1-4 0V-1 P

P -G 0V
-J FG1
OBT
BAT

No.8CN
DATA+2 CN2-1 CN2-1 DATA+2 CN-C DATA+2
DATA-2 CN2-2 P CN2-2 DATA-2 P -D DATA-2
-T BAT
P -S OBT PG L-AXIS
+5V-2 CN2-3 CN2-3 +5V-2 -H +5V

0V-2 CN2-4 CN2-4 0V-2 P

P -G 0V
FG2 CN2-5 CN2-5 FG2 -J FG2
OBT
BAT

No.9CN
DATA+3 CN3-1 CN3-1 DATA+3 CN-C DATA+3
DATA-3 CN3-2 P CN3-2 DATA-3 P -D DATA-3
-T BAT
P -S OBT PG U-AXIS
+5V-3 CN3-3 CN3-3 +5V-3 -H +5V

0V-3 CN3-4 CN3-4 0V-3 P

P -G 0V
-J FG3
OBT
BAT No.1CN
DATA+4 CN4-1 CN4-1 DATA+4 CN1-1 DATA+4
DATA-4 CN4-2 P CN4-2 DATA-4 P -2 DATA-4
-3 BAT
P -4 OBT PG R-AXIS
+5V-4 CN4-3 CN4-3 +5V-4 -5 +5V

0V-4 CN4-4 CN4-4 0V-4 P

P -6 0V
-7 FG4
OBT
BAT
No.2CN
DATA+5 CN5-1 CN5-1 DATA+5 CN2-C DATA+5
DATA-5 CN5-2 P CN5-2 DATA-5 P -D DATA-5
-T BAT
P -S OBT PG B-AXIS
+5V-5 CN5-3 CN5-3 +5V-5 -H +5V

0V-5 CN5-4 CN5-4 0V-5 P

P -G 0V
-J FG5
OBT
BAT
No.3CN
DATA+6 CN6-1 CN6-1 DATA+6 CN3-1 DATA+6
DATA-6 CN6-2 P CN6-2 DATA-6 P -2 DATA-6
-3 BAT
P -4 OBT PG T-AXIS
+5V-6 CN6-3 CN6-3 +5V-6 -5 +5V

0V-6 CN6-4 CN6-4 0V-6 P

P -6 0V
FG6 CN6-5 CN6-5 FG6 -7 FG6
OBT
BATTERY P
0BT4 BAT4 R BAT
K BAT4
0BT4

No.16CN
CN-1 B1 B1
-2 SS1 SS1
-3 BC1 BC1
+24V CN2-6 CN2-6 +24V -4 LA1 BC2 FOR LAMP(OPTION)
LB1 CN3-6 CN3-6 LB1 -5 LB1
BC2 CN4-6 CN4-6 BC2 -6 BC2 S-AXIS OVERRUN L.S.
0V CN5-6 CN5-6 0V LA1
B2
SS2 CN6-6 CN6-6 SS2 LB1
SS2
LC1 LA4 A
LB5 LB4

S-MOTOR S-GEAR1 U-MOTOR L-MOTOR

FOR FAN FOR FAN FOR FAN FOR FAN
ALM ALM ALM ALM
AL1 CN1-5 CN1-5 AL1 AL1 AL1 AL2 AL4 AL4 AL1 AL2 AL5 AL5 AL1 AL2 AL2 AL1 AL1 AL2 AL6
AL2 CN1-6 CN1-6 AL2 AL2 AL2 AL2 AL2 AL2 AL2 AL1 AL8 AL8 AL2 AL1 AL7 AL7 AL2 AL1 AL6
S-REDUCER2 S-GEAR3 S-GEAR2 L-REDUCER
E E ALM ALM ALM
ALM FOR FAN FOR FAN FOR FAN FOR FAN
AL2 AL2 AL2 AL2 AL1 AL3
AL2 AL2 AL2 AL2 AL1 AL3
S-REDUCER1
ALM FOR FAN

E BASE CASING
E E E E E E MANIPULATOR E

7BC(28-21) 7BC(28-21)
E E E
1 1
7BC-1
2 2
7BC-2
3 3
7BC-3
4 4
7BC-4
5 5
7BC-5
6 6
7BC-6
7
7BC-7 7
8
7BC-8 8
9
7BC-9 9
10
7BC-10
11 SP1
7BC-11
12 SP2 10
7BC-12
13 11
7BC-13
14 12
7BC-14
15 13
7BC-15
16 14
7BC-16
17 15
7BC-17
18 16
7BC-18
19 17
7BC-19
20 18
7BC-20
21
7BC-21
22
7BC-22
23 19
7BC-23
24 20
7BC-24
25 21
7BC-25
26 22
7BC-26
27 23
7BC-27
28 24
7BC-28
29 25
7BC-29
30 26
7BC-30
31 27
7BC-31
32 28
7BC-32
33 29
7BC-33
34 30
7BC-34

31
32
33
34

Fig. 18 (a) Internal Connection Diagram

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8.2 Internal Connections

2BC(6X3) TYPE B 2BC(6X3) TYPE B

E E

MU1 CN1-1 CN1-1 MU1

MU1 CN1-2 CN1-2 MU1
MU1 CN1-3 CN1-3 MU1
MU1 CN1-4 CN1-4 MU1
MU1 CN1-5 CN1-5 MU1
MU1 CN1-6 CN1-6 MU1
MU1 CN2-1 CN2-1 MU1
MU1 CN2-2 CN2-2 MU1
MU1 CN2-3 CN2-3 MU1

MV1 CN2-4 CN2-4 MV1

MV1 CN2-5 CN2-5 MV1
MV1 CN2-6 CN2-6 MV1
MV1 CN4-1 CN4-1 MV1
MV1 CN4-2 CN4-2 MV1
MV1 CN4-3 CN4-3 MV1
MV1 CN4-4 CN4-4 MV1
MV1 CN4-5 CN4-5 MV1
No.10CN
MV1 CN4-6 CN4-6 MV1
CN-A MU1
-B MV1
3BC(6X4) TYPE A 3BC(6X4) TYPE A
-C MW1 SM S-AXIS
-D ME1
E E

MW1 CN1-1 CN1-1 MW1

MW1 CN1-2 CN1-2 MW1
MW1 CN1-3 CN1-3 MW1
MW1 CN1-4 CN1-4 MW1 LA1 LA1
MW1 CN1-5 CN1-5 MW1 LB1 LB5 S-AXIS OVERRUN L.S.
MW1 CN1-6 CN1-6 MW1
LB1 LA2 LA3 LA3
MW1 CN3-1 CN3-1 MW1
MW1 CN3-2 CN3-2 MW1 L-AXIS OVERRUN L.S.
LC1 LC1 LB3 LB3
MW1 CN3-3 CN3-3 MW1

ME1 ME1 LA4 LA4 LA5 LA5

CN3-4 CN3-4
ME1 ME1 LB4 LB4 L AND U-AXIS INTERFERENCE L.S.
CN3-5 CN3-5
ME1 CN3-6 CN3-6 ME1
ME1 CN4-1 CN4-1 ME1
ME1 CN4-2 CN4-2 ME1
ME1 CN4-3 CN4-3 ME1
ME1 CN4-4 CN4-4 ME1
ME1 CN4-5 CN4-5 ME1 Limit switch specification of L-, U-axes (OPTION)
ME1 CN4-6 CN4-6 ME1 No.11CN
BA1 CN5-1 CN5-1 BA1 CN-A BA1
BB1 CN5-2 CN5-2 BB1 -B BB1 YB

4BC(8X4) TYPE 4BC(8X4) TYPE

E E

MU2 CN1-1 CN1-1 MU2

MU2 CN1-2 CN1-2 MU2
MU2 CN1-3 CN1-3 MU2
MU2 CN1-4 CN1-4 MU2
MU2 CN1-5 CN1-5 MU2
MV2 CN1-6 CN1-6 MV2
MV2 CN1-7 CN1-7 MV2
MV2 CN1-8 CN1-8 MV2
MV2 CN2-1 CN2-1 MV2 No.12CN
MV2 CN2-2 CN2-2 MV2 CN-A MU2
MW2 CN2-3 CN2-3 MW2 -B MV2
MW2 CN2-4 CN2-4 MW2 -C MW2 SM L-AXIS
MW2 CN2-5 CN2-5 MW2 -D ME2
MW2 CN2-6 CN2-6 MW2
MW2 CN2-7 CN2-7 MW2
ME2 CN2-8 CN2-8 ME2
ME2 CN4-1 CN4-1 ME2
ME2 CN4-2 CN4-2 ME2
ME2 CN4-3 CN4-3 ME2
ME2 CN4-4 CN4-4 ME2 No.13CN
BA2 CN6-1 CN6-1 BA2 CN-A BA2
-B BB2 YB
5BC(8X4) TYPE B 5BC(8X4) TYPE B
E E

MU3 CN1-1 CN1-1 MU3

MU3 CN1-2 CN1-2 MU3
MU3 CN1-3 CN1-3 MU3
MU3 CN1-4 CN1-4 MU3
MU3 CN1-5 CN1-5 MU3
MV3 CN1-6 CN1-6 MV3
MV3 CN1-7 CN1-7 MV3
MV3 CN1-8 CN1-8 MV3
MV3 CN2-1 CN2-1 MV3 No.14CN
MV3 CN2-2 CN2-2 MV3 CN-A MU3
MW3 CN2-3 CN2-3 MW3 -B MV3
MW3 CN2-4 CN2-4 MW3 -C MW3 SM U-AXIS
MW3 CN2-5 CN2-5 MW3 -D ME3
MW3 CN2-6 CN2-6 MW3
MW3 CN2-7 CN2-7 MW3
ME3 CN2-8 CN2-8 ME3
ME3 CN3-1 CN3-1 ME3
ME3 CN3-2 CN3-2 ME3
ME3 CN3-3 CN3-3 ME3
ME3 CN3-4 CN3-4 ME3 No.15CN
BA3 CN4-1 CN4-1 BA3 CN-A BA3
-B BB3 YB
6BC(8X6) TYPE A 6BC(8X5)(12 1) TYPE A
E E
No.4CN
MU4 CN1-1 CN1-1 MU4 CN4-1 MU4
MU4 CN1-2 CN1-2 MU4 2 MU4
MU4 CN1-3 CN1-3 MU4 3 MU4
MV4 CN1-4 CN1-4 MV4 4 MV4
MV4 CN1-5 CN1-5 MV4 5 MV4
MV4 CN1-6 CN1-6 MV4 6 MV4
MW4 CN1-7 CN1-7 MW4 7 MW4 SM R-AXIS
MW4 CN1-8 CN1-8 MW4 8 MW4
MW4 CN2-1 CN2-1 MW4 9 MW4
ME4 CN2-2 CN2-2 ME4 10 ME4
ME4 CN2-3 CN2-3 ME4 11 ME4
ME4 CN2-4 CN2-4 ME4 12 ME4
BA4 CN6-1 CN6-1 BA4 13 BA4
BB4 CN6-2 CN6-2 BB4 14 BB4 YB

MU5 CN4-1 CN4-1 MU5

MU5 CN4-2 CN4-2 MU5
MU5 CN4-3 CN4-3 MU5
MU5 CN4-4 CN4-4 MU5
MV5 CN4-5 CN4-5 MV5
MV5 CN4-6 CN4-6 MV5
MV5 CN4-7 CN4-7 MV5 No.5CN
MV5 CN4-8 CN4-8 MV5 CN-A MU5
MW5 CN5-1 CN5-1 MW5 -B MV5
MW5 CN5-2 CN5-2 MW5 -C MW5 SM B-AXIS
MW5 CN5-3 CN5-3 MW5 -D ME5
MW5 CN5-4 CN5-4 MW5 -E BA5
ME5 CN5-5 CN5-5 ME5 -F BB5 YB
ME5 CN5-6 CN5-6 ME5
ME5 CN5-7 CN5-7 ME5
ME5 CN5-8 CN5-8 ME5
BA5 CN6-3 CN6-3 BA5

No.6CN
MU6 CN2-5 CN2-5 MU6 CN6-1 MU6
MU6 CN2-6 CN2-6 MU6 2 MU6
MU6 CN2-7 CN2-7 MU6 3 MU6
MV6 CN2-8 CN2-8 MV6 4 MV6
MV6 CN3-1 CN3-1 MV6 5 MV6 AC1 AC1
MV6 CN3-2 CN3-2 MV6 6 MV6
MW6 CN3-3 CN3-3 MW6 7 MW6 SM T-AXIS AC2 AC2 FAN S-MOTOR
MW6 CN3-4 CN3-4 MW6 8 MW6
MW6 CN3-5 CN3-5 MW6 9 MW6
AC1 AC1
ME6 CN3-6 CN3-6 ME6 10 ME6
ME6 CN3-7 CN3-7 ME6 11 ME6 AC2 AC2 FAN S-GEAR1
ME6 CN3-8 CN3-8 ME6 12 ME6
BA6 CN6-4 CN6-4 BA6 13 BA6
14 BB6 YB AC1 AC1
AC2 AC2 FAN U-GEAR

AC1 CN6-5 CN6-5 AC1 AC1 AC1 AC1 AC1 AC1 AC1 AC1 AC1 AC1 AC1
AC2 CN6-6 CN6-6 AC2 AC2 AC2 AC2 AC2 AC2 AC2 AC2 AC2 AC2 AC2 FAN L-MOTOR

AC1 AC1 AC1 AC1

AC2 AC2 FAN S-REDUCER1 AC2 AC2 FAN L-REDUCER

AC1 AC1 AC1 AC1 AC1 AC1

AC2 AC2 FAN S-REDUCER2 AC2 AC2 AC2 AC2 FAN S-GEAR2

AC1 AC1

Fig. 18 (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 OFF the main power
supply, and put up a warning sign. (ex. DO NOT TURN ON THE POWER.)

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.

• Do not remove the motor, and do not release the brake.

Failure to observe this caution may result in injury from unexpected turning of the manipu-
lator’s arm.

• The battery pack must be connected before removing encoder 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 classified into six levels as shown in "Table 7 Inspection Items". Con-
duct periodical inspections according to the inspection schedule in this table.
In the table, the inspection items are categorized by three types of operations: operations
which can be performed by personnel authorized by the user, operations which can be per-
formed by personnel being trained, and operations which can be performed by service com-
pany personnel.
Only specified personnel are to do inspection work.

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9.1 Inspection Schedule

• The inspection interval depends on the total servo operation time.

NOTE • 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.
• The speed reducers for the S-, L-, and U-axes are recommended to be replaced in the
secondary inspection (which is to be done in 18000-hour cycle) as a preventive mainte-
nance. The replacement should be made in less than 18000-hour cycle, depending upon
the operation pattern.

Table 7 Inspection Items

Schedule Inspection Charge

Items*4 Method Operation
500H 3000H 9000H 18000H Specified Service
Daily Person
Licensee
Company
Cycle Cycle Cycle Cycle

Check alignment
c Alignment mark { { { { Visual
mark accordance
and damage at the
{ { {
home position.

Check for damage

d External leads { { { { Visual and deterioration of { { {
leads.

Clean the work area

if dust or spatter is
Manipulator
e (whole exterior)
{ { { { Visual present. Check for { { {
damage and outside
cracks.

f L, U-axis motors { { { { Visual

Check for
grease leakage.*5
{ { {

Manipulator Tighten loose

g base mounting { { { Spanner screws. Replace if
necessary.
{ { {
screws

Screw- Tighten loose

Cover mount-
h ing screws
{ { { driver, screws. Replace if { { {
Wrench necessary.

S, L, U, R, B, T- Check for loose con-

i axis motor { { { Manual nectors and tighten if
necessary.
{ { {
connectors

j Connector base { { { Manual

Check for loose con-
nectors.
{ { {

Internal wiring Remove the cover

k harness in { { Visual and check for wear. { {
S-axis

Internal wiring Remove the cover

l harness protec- { { Visual and check for wear.
Apply grease.
{ {
tive spring

Check for loose nuts

Visual,
L-axis or shafts, and tighten
balancer
{ { Grease
if necessary. Supply
{ {
Gun
grease.

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9.1 Inspection Schedule

Table 7 Inspection Items

Schedule Inspection Charge

Items*4 Method Operation
500H 3000H 9000H 18000H Specified Service
Daily Person
Licensee
Company
Cycle Cycle Cycle Cycle

Check for conduc-

tion between the
main connector of
base and each con-
Internal wiring nector with manually
Multimeter
harness*2 { shaking the wiring { {
harness.
Check for wear
of protective spring*1
Replace the wire
(18000H cycle).

Driver, Check for dirt, dam-

Limit switch dog Wrench, age, looseness.
(S-axis)
{ { Multimeter Tighten if necessary.
{ {
Check the operation.

Driver, Check for dirt, dam-

Limit switch Wrench, age, looseness.
(L-axis)
{ { Multimeter Tighten if necessary.
{ {
Check the operation.

L, U-axis inter- Driver, Check for dirt, dam-

Wrench, age, looseness.
ference limit { { Multimeter Tighten if necessary.
{ {
switch Check the operation.

Visual, Check for backlash of

L, U-axis arm Manual bearings by moving
the L, U-axes back
connection { and forth, and up and
{ {
parts down. Supply
grease.

Replace if the result

Battery pack in
manipulator
{ Multimeter of voltage check is { {
2.8 V or less.

Check for malfunc-

tion. (Replace if nec-
S-axis speed Grease essary.)
reducer
{ Gun Exchange grease*3
{ {
(9000H cycle). See
Par. 9.2.2.

Check for malfunc-

tion. (Replace if nec-
L, U-axis speed Grease essary.)
reducers
{ Gun Exchange grease*3
{ {
(9000H cycle). See
Par. 9.2.3 and 9.2.4.

Check for malfunc-

tion. (Replace if nec-
R, B, T-axis Grease essary.)
gears
{ Gun Exchange grease*3
{ {
(9000H cycle). See
Par. 9.2.5.

Check for malfunc-

tion. (Replace if nec-
R-axis Grease essary.)
speed reducer
{ Gun Exchange grease*3
{ {
(9000H cycle). See
Par. 9.2.6.

Check for malfunc-

tion. (Replace if nec-
B, T-axis speed essary.)
Grease
reducers, { Gun
9.2.8. { {
B, T-axis gears Exchange grease*3
(9000H cycle). See
Par. 9.2.7 and 9.2.8.

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9.1 Inspection Schedule

Table 7 Inspection Items

Schedule Inspection Charge

Items*4 Method Operation
500H 3000H 9000H 18000H Specified Service
Daily Person
Licensee
Company
Cycle Cycle Cycle Cycle

Check for malfunc-

tion. (Replace if nec-
L-axis cross Grease essary.)
roller bearing
{ Gun Replenish grease*3
{ {
(3000H cycle). See
Par. 9.2.9.

Check for malfunc-

Taperd roller tion. (Replace if nec-
bearing in the essary.)
Grease
link part bal- { Gun
Replenish grease*3 { {
ancer connec- (3000H cycle). See
tion part Par. 9.2.10 and
9.2.11.

Overhaul { {

*1 When checking for conduction with a multimeter, remove connectors on encoder side for each axis from the
motor.
*2 The internal wiring harness is to be replaced at 18000H inspection (at overhaul).
*3 For the grease, refer to "Table 8 Inspection Parts and Grease Used".
*4 Inspection numbers correspond to the numbers in "Fig. 19 Inspection Parts and Inspection Numbers".

Table 8 Inspection Parts and Grease Used

No. Grease Used Inspected Parts

18, 19, Speed reducers for all axes

Molywhite RE No. 00
20,21,22 B- and T-axis gears

L-axis cross roller bearing

11, 16, 23 Alvania EP Grease 2 Tapered roller bearing in the link part
L-axis balancer

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

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 2 7 1 L-Axis
4
19
5 6

Note: The manipulator is in the home position.

2
9.1 Inspection Schedule

23 15
19

7 4
2
7
16 16 20

7
14
11 U-Axis 1
AIR2
AIR1

9-5
S-Axis
1 18
10 12
9 13

10
17
6
8

21

6
1 R-Axis

1 B-Axis
22

Fig. 19 Inspection Parts and Inspection Numbers

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9.2 Notes on Maintenance Procedures

9.2 Notes on Maintenance Procedures

9.2.1 Battery Pack Replacement

Two battery packs are installed in the position described in "Fig. 20 Battery Location". If a bat-
tery alarm shows up on the NX100, replace the battery according to the following procedure:

Battery pack on S-, L-, U-axis side

(HW9470932-A)

Battery pack on R-, B-, T-axis side

(HW9470932-B)

7BC
A B
OBT1
BAT1 OBT4
BAT4

1BC 2BC 3BC 4BC 5BC 6BC

Fig. 20 Battery Location

See step 6 Batterypack before replacement

See step 7

0BT1 b a 0BT1
BAT1 a b BAT1

Internal wires for 0BT1 b a 0BT1

S-,L-, U-axes
BAT1 a b BAT1

See step 4 New battery pack

See step 5
a: Crimped contact-pin (pin)
b: Crimped contact-pin (socket)

Fig. 21 (a) Battery Connection for S-, L-, U-Axes

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9.2 Notes on Maintenance Procedures

See step 6 Batterypack before replacement

See step 7

0BT4 b a 0BT4
BAT4 a b BAT4

Internal wires for 0BT4 b a 0BT4

R-, B-, T-axes
BAT4 a b BAT4

See step 4 New battery pack

See step 5
a: Crimped contact-pin (pin)
b: Crimped contact-pin (socket)

Fig. 21 (b) Battery Connection for R-, B-, T-Axes

1. Turn OFF the NX100 main power supply.

2. Remove the plate from the connector base and pull out the battery pack to replace it
with a new battery pack.
3. Unscrew the battery pack mounting screws on the battery holder, and remove the bat-
tery pack.
4. Remove the electrical tape (insulation tape) protecting the connection part of the bat-
tery pack in the manipulator.
5. Connect the new battery pack.
6. Remove the old battery pack.

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

7. Protect the connection part of the battery pack in the manipulator with electrical tape
(insulation tape).
8. Fix the battery pack with screws, and put the connector base back on the manipulator.

NOTE Pay attention not to pinch the cable when the plate is being installed.

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9.2 Notes on Maintenance Procedures

9.2.2 Grease Exchange for S-Axis Speed Reducer and

Gear

S-axis gear unit

Grease exhaust port

(Hexagon socket head plug PT3/8)

S-axis speed
reducer

Grease inlet
(Grease zerk A-PT1/4)

Fig. 22 S-Axis Speed Reducer and Gear Diagram

„ Grease Exchange (Refer to "Fig. 22 S-Axis Speed Reducer and

Gear Diagram".)
1. Remove the plugs from the injection and discharge ports.

If grease is added with the plug on, the grease will go inside the motor and may damage it.
NOTE Never fail to remove the plug before the grease injection.
Do not install a connector, hose, or other part on the discharge port because this may
cause trouble such as dropout of the oil seal.

2. Install a grease zerk A-PT1/4 on the injection port.(The grease zerk A-PT1/4 is packed
together with the main body before the product is shipped.)
3. Inject the grease into the grease inlet using a grease gun.

Grease type: Molywhite RE No. 00

Amount of grease: 11700 cc
Grease pump air supply pressure: 0.3 MPa max
Grease injection quantity: 8 g/s max

4. The grease exchange is completed when new grease appears in the grease exhaust
port. The new grease can be distinguished from the old grease by its color.
5. Before putting the plug back on the grease exhaust port, move the S-axis for a few
minutes to discharge the excess grease.

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6. Wipe the discharged grease with a cloth and reinstall the plug on the Lo grease
exhaust port. Tighten the plug with a tightening torque of 23 N·m (2.34 kgf·m). (Apply
Three Bond 1206C on the thread part of the plug.)

If you install the plug while grease is being discharged, the grease will enter the motor,
NOTE resulting in a breakdown.Be sure to confirm that all of the grease has been discharged
before installing the plug.

7. Remove the grease zerk from the injection port, and then install the plug.Tighten the
plug with a tightening torque of 23 N·m (2.34 kgf·m). (Apply Three Bond 1206C on the
thread part of the plug.)

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9.2 Notes on Maintenance Procedures

9.2.3 Grease Exchange for L-Axis Speed Reducer

Grease exhaust port

(Hexagon socket head plug PT1/8)

L-axis speed reducer

Grease inlet
(Grease zerk A-PT1/8)

Fig. 23 L-Axis Speed Reducer Diagram

„ Grease Exchange (Refer to "Fig. 23 L-Axis Speed Reducer Dia-

gram".)
1. Make the L-arm posture as shown in “Fig. 23 L-Axis Speed Reducer Diagram”.
2. Remove the plugs from the injection and discharge ports.

NOTE If grease is added with the plug on, the grease will go inside the motor and may damage it.
Never fail to remove the plug before the grease injection.

3. Install a grease zerk A-PT1/8 on the injection port.(The grease zerk A-PT1/8 is packed
together with the main body before the product is shipped.)
4. Inject the grease into the grease inlet using a grease gun.

Grease type: Molywhite RE No. 00

Amount of grease: 2600 cc

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9.2 Notes on Maintenance Procedures

5. The grease exchange is completed when new grease appears in the grease exhaust
port. The new grease can be distinguished from the old grease by its color.
6. Before putting the plug back on the grease exhaust port, move the L-axis for a few min-
utes to discharge the excess grease.
7. Wipe the discharged grease with a cloth and reinstall the plug on the Lo grease
exhaust port. Tighten the plug with a tightening torque of 5 N·m (0.51 kgf·m). (Apply
Three Bond 1206C on the thread part of the plug.)

If you install the plug while grease is being discharged, the grease will enter the motor,
NOTE resulting in a breakdown.Be sure to confirm that all of the grease has been discharged
before installing the plug.

8. Remove the grease zerk from the injection port, and then install the plug.Tighten the
plug with a tightening torque of 5 N·m (0.51 kgf·m). (Apply Three Bond 1206C on the
thread part of the plug.)

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9.2.4 Grease Exchange for U-Axis Speed Reducer

A A

Section A-A

U-axis speed
reducer

Grease exhaust port

(Hexagon socket head plug PT1/8)

Grease inlet
(Grease zerk A-PT1/8)

Fig. 24 U-Axis Speed Reducer Diagram

„ Grease Exchange (Refer to "Fig. 24 U-Axis Speed Reducer Dia-

gram".)
1. Make the L-arm posture as shown in “Fig. 23 U-Axis Speed Reducer Diagram”.
2. Remove the plugs from the injection and discharge ports.

NOTE If grease is added with the plug on, the grease will go inside the motor and may damage it.
Never fail to remove the plug before the grease injection.

3. Install a grease zerk A-PT1/8 on the injection port.(The grease zerk A-PT1/8 is packed
together with the main body before the product is shipped.)
4. Inject the grease into the grease inlet using a grease gun.

Grease type: Molywhite RE No. 00

Amount of grease: 3490 cc

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5. The grease exchange is completed when new grease appears in the grease exhaust
port. The new grease can be distinguished from the old grease by its color.
6. Before putting the plug back on the grease exhaust port, move the U-axis for a few
minutes to discharge the excess grease.
7. Wipe the discharged grease with a cloth and reinstall the plug on the Lo grease
exhaust port. Tighten the plug with a tightening torque of 5 N·m (0.51 kgf·m). (Apply
Three Bond 1206C on the thread part of the plug.)

If you install the plug while grease is being discharged, the grease will enter the motor,
NOTE resulting in a breakdown.Be sure to confirm that all of the grease has been discharged
before installing the plug.

8. Remove the grease zerk from the injection port, and then install the plug.Tighten the
plug with a tightening torque of 5 N·m (0.51 kgf·m). (Apply Three Bond 1206C on the
thread part of the plug.)

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9.2 Notes on Maintenance Procedures

9.2.5 Grease Exchange for R, B-, T-Axis Gears

Grease inlet Grease exhaust port

(Grease zerk A-PT1/8) (Hexagon socket head plug PT1/8)

Fig. 25 R-, B-, T-Axis Gear Diagram

„ Grease Exchange (Refer to "Fig. 25 R-, B-, T-Axis Gear Diagram".)

1. Remove the plugs from the injection and discharge ports.

NOTE If grease is injected with the plug on, the grease will go outside the grease box and may
cause a damage. Never fail to remove the plug before the grease injection.

2. Install a grease zerk A-PT1/8 on the injection port.(The grease zerk A-PT1/8 is packed
together with the main body before the product is shipped.)
3. Inject the grease into the grease inlet using a grease gun.

Grease type: Molywhite RE No. 00

Amount of grease:5200 cc

4. Before putting the plug back on the Go grease exhaust port, move the R-, B-, T-axes
for a few minutes to discharge the excess grease.
5. Wipe the discharged grease with a cloth and reinstall the plug on the Go grease
exhaust port. Tighten the plug with a tightening torque of 5 N·m (0.51 kgf·m). (Apply
Three Bond 1206C on the thread part of the plug.)

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9.2 Notes on Maintenance Procedures

9.2.6 Grease Exchange for R-Axis Speed Reducer

Grease inlet
(Hexagon socket head
plug PT1/8)
R-axis speed reducer

Grease exhaust port

(Hexagon socket head plug PT1/8)

Fig. 26 R-Axis Speed Reducer Diagram

„ Grease Exchange (Refer to "Fig. 26 R-Axis Speed Reducer Dia-

gram".)
1. Remove the plugs from the injection and discharge ports.

NOTE If grease is injected with the plug on, the grease will go outside the grease box and may
cause a damage. Never fail to remove the plug before the grease injection.

2. Install a grease zerk A-PT1/8 on the injection port.(The grease zerk A-PT1/8 is packed
together with the main body before the product is shipped.)
3. Inject the grease into the grease inlet using a grease gun.

Grease type: Molywhite RE No. 00

Amount of grease: 2330 cc

4. The grease exchange is completed when new grease appears in the grease exhaust
port. The new grease can be distinguished from the old grease by its color.
5. Before putting the plug back on the grease exhaust port, move the R-, B-, T-axes for a
few minutes to discharge the excess grease.
6. Wipe the discharged grease with a cloth and reinstall the plug on the Lo grease
exhaust port. Tighten the plug with a tightening torque of 4.9 N·m (0.5 kgf·m). (Apply
Three Bond 1206C on the thread part of the plug.)
7. Remove the grease zerk from the injection port, and then install the plug.Tighten the
plug with a tightening torque of 4.9 N·m (0.5 kgf·m). (Apply Three Bond 1206C on the
thread part of the plug.)

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9.2 Notes on Maintenance Procedures

9.2.7 Grease Exchange for B-Axis Speed Reducer and

Gear

Grease exhaust port

(Hexagon socket head plug PT1/8)
Grease inlet
(Hexagon socket head plug PT1/8)

B-axis speed reducer

Fig. 27 B-Axis Speed Reducer and Gear Diagram

„ Grease Exchange (Refer to "Fig. 27 B-Axis Speed Reducer and

Gear Diagram".)
1. Remove the plugs from the injection and discharge ports.

NOTE If grease is injected with the plug on, the grease will go outside the grease box and may
cause a damage. Never fail to remove the plug before the grease injection.

2. Install a grease zerk A-PT1/8 on the injection port.(The grease zerk A-PT1/8 is packed
together with the main body before the product is shipped.)
3. Inject the grease into the grease inlet using a grease gun.

Grease type: Molywhite RE No. 00

Amount of grease: 1300 cc

4. The grease exchange is completed when new grease appears in the grease exhaust
port. The new grease can be distinguished from the old grease by its color.
5. Before putting the plug back on the grease exhaust port, move the R-, B-, T-axes for a
few minutes to discharge the excess grease.
6. Wipe the discharged grease with a cloth and reinstall the plug on the Lo grease
exhaust port. Tighten the plug with a tightening torque of 4.9 N·m (0.5 kgf·m). (Apply
Three Bond 1206C on the thread part of the plug.)
7. Remove the grease zerk from the injection port, and then install the plug.Tighten the
plug with a tightening torque of 4.9 N·m (0.5 kgf·m). (Apply Three Bond 1206C on the
thread part of the plug.)

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9.2 Notes on Maintenance Procedures

9.2.8 Grease Exchange for T-Axis Speed Reducer and

Gear

Grease inlet
(Hexagon socket head plug PT1/8)

T-axis speed reducer

Grease exhaust port

(Hexagon socket head plug PT1/16)

Fig. 28 T-Axis Speed Reducer and Gear Diagram

„ Grease Exchange (Refer to "Fig. 28 T-Axis Speed Reducer and

Gear Diagram".)
1. Remove the plugs from the injection and remove the bolts from the discharge ports.

NOTE If grease is injected with the plug on, the grease will go outside the grease box and may
cause a damage. Never fail to remove the plug before the grease injection.

2. Install a grease zerk A-PT1/8 on the injection port.(The grease zerk A-PT1/8 is packed
together with the main body before the product is shipped.)
3. Inject the grease into the grease inlet using a grease gun.

Grease type: Molywhite RE No. 00

Amount of grease: approx. 1100 cc

4. The grease exchange is completed when new grease appears in the grease exhaust
port. The new grease can be distinguished from the old grease by its color.
5. Before putting the plug back on the grease exhaust port, move the R-, B-, T-axes for a
few minutes to discharge the excess grease.
6. Wipe the discharged grease with a cloth and reinstall the plug on the Lo grease
exhaust port. Tighten the plug with a tightening torque of 4.9 N·m (0.5 kgf·m). (Apply
Three Bond 1206C on the thread part of the plug.)
7. Remove the grease zerk from the injection port, and then install the plug.Tighten the
plug with a tightening torque of 4.9 N·m (0.5 kgf·m). (Apply Three Bond 1206C on the
thread part of the plug.)

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9.2 Notes on Maintenance Procedures

9.2.9 Grease Replenishment for U-Axis Cross Roller

Bearing

U-axis cross roller bearing

L-arm

Exhaust port
(Hexagon socket head plug PT1/8)

Grease inlet Uc
(Grease zerk A-PT1/8)

Fig. 29 U-Axis Cross Roller Bearing Diagram

1. Remove the plug from the exhaust port. (Refer to "Fig. 29 U-Axis Cross Roller Bearing
Diagram".)
2. Install a grease zerk A-PT1/8 on the injection port.(The grease zerk A-PT1/8 is packed
together with the main body before the product is shipped.)
3. Inject the grease into the grease inlet using a grease gun.

Grease type: Alvania EP Grease 2

Amount of grease: 64 cc

NOTE The exhaust port is for AIR exhaust: the grease is not exhausted from the exhaust port.
Do not inject excessive grease into the grease inlet.

4. Reinstall the plug on the exhaust port. Tighten the plug with a tightening torque of 5
N·m (0.51 kgf·m). (Apply Three Bond 1206C on the thread part of the plug.)
5. Remove the grease zerk from the injection port, and then install the plug.Tighten the
plug with a tightening torque of 5 N·m (0.51 kgf·m). (Apply Three Bond 1206C on the
thread part of the plug.)

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9.2 Notes on Maintenance Procedures

9.2.10 Grease Replenishment for Tapered Roller Bearing in

the Link Part

Exhaust port Ho (2 ports)

(Hexagon socket head Tapered roller bearing in
plug PT1/8) the link part (2 bearings)
Exhaust port Ho (2 ports)
(Hexagon socket head
Grease inlet Hi in the link plug PT1/8)
Grease inlet Hi in the link part (2 inlets)
part (2 inlets) (Grease zerk A-PT1/8)
(Grease zerk A-PT1/8)

Tapered roller bearing in

the link part (2 bearings) Tapered roller bearing in
the link part (2 bearings)

Exhaust port Ho (2 ports)

(Hexagon socket head
plug PT1/8)

Grease inlet Hi in the link part (2 inlets)

(Grease zerk A-PT1/8)

Fig. 30 Link Part

1. Remove the plugs from the exhaust ports on link parts (6 exhaust ports). (Refer to "Fig.
30 Link Part".)
2. Install a grease zerk A-PT1/8 on the injection port.(The grease zerk A-PT1/8 is packed
together with the main body before the product is shipped.)
3. Inject the grease into the grease inlet using a grease gun

Grease type: Alvania EP Grease 2

Amount of grease: 9 cc
(18 cc for the initial supply)

NOTE The exhaust port is for AIR exhaust: the grease is not exhausted from the exhaust port.
Do not inject excessive grease into the grease inlet.

4. Reinstall the plug on each exhaust port. Tighten the plug with a tightening torque of 5
N·m (0.51 kgf·m). (Apply Three Bond 1206C on the thread part of the plug.)
5. Remove the grease zerk from the injection port, and then install the plug.Tighten the
plug with a tightening torque of 5 N·m (0.51 kgf·m). (Apply Three Bond 1206C on the
thread part of the plug.)

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9.2 Notes on Maintenance Procedures

9.2.11 Grease Replenishment for Balancer Link Part

Exhaust port Vo (2 ports)

(Hexagon socket head plug PT1/8)

Grease inlet Vi in the link part

(1 inlet)
(Grease zerk A-PT1/8)

Needle bearing in the link part

Exhaust port Vo (2 ports)

(Hexagon socket head cap screw M6)

Tapered roller bearing in

the link part (2 bearings) Grease inlet Vi in the link part (2 inlets)
(Grease zerk A-PT1/8)

Fig. 31 Balancer Link Part

1. Remove the plugs from the Vo exhaust ports on link parts (4 exhaust ports). (Refer to
"Fig. 31 Balancer Link Part".)
2. Install a grease zerk A-PT1/8 on the injection port.(The grease zerk A-PT1/8 is packed
together with the main body before the product is shipped.)
3. Inject the grease into the grease inlet using a grease gun

Grease type: Alvania EP Grease 2

Amount of grease: 10 cc

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9.2 Notes on Maintenance Procedures

4. Reinstall the plug on each exhaust port. Tighten the plug with a tightening torque of 5
N·m (0.51 kgf·m). (Apply Three Bond 1206C on the thread part of the plug.)
5. Remove the grease zerk from the injection port, and then install the plug.Tighten the
plug with a tightening torque of 5 N·m (0.51 kgf·m). (Apply Three Bond 1206C on the
thread part of the plug.)

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9.2 Notes on Maintenance Procedures

9.2.12 Notes for Maintenance

Connecting the new battery pack before removing the old one so that the encoder absolute
data will not disappear.
Before connecting the battery units of the S-, L-, U-, and B-axis motors and the R- and T-axis
motors, refer to "Fig. 32 Backup Battery Pack Connection for Motor".

„ Motors for S-, L-, U-, B-Axes

The connector for the battery unit connection is attached to the main body of the motor for the
SLBU axis.
Refer to the following procedure for connecting the battery unit.

1. Remove a cap attached to the battery backup connector of the motor encoder by
removing the cover mounting screws.
2. Connect the SLUB axis battery unit (HW9470917-A) to the battery backup connector
on the motor body.(In this condition, disconnect the connector of the motor detector,
and then carry out maintenance and inspection.)
3. After carrying out maintenance and inspection, confirm that all of the connectors are
connected, and then disconnect the battery unit connecting cable and the battery unit
for the motor.
4. Remove the cap provided on the battery backup connector on the motor body.

„ Motors for R-, T-Axes

A battery backup connector (insertion pin terminal) is installed on the end of the cable for the
RT axis motor detector. (It has BAT and OBT markers.)
Refer to the following procedure for connecting the battery unit.

1. It connects in the connector (marker of BAT and OBT) for the battery backup in the
point of the cable for the motor detector and it connects it with battery unit
(HW9470917-B) for the RT axes. (In this condition, disconnect the connector of the
motor detector, and then carry out maintenance and inspection.)
2. After the maintenance check, confirm all the connectors are connected properly, then
remove the battery pack.

NOTE Do not remove the battery pack in the connector base.

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9.2 Notes on Maintenance Procedures

S-, L-, U-, B-Axes Motor

Motor

Power connector
Motor detector connector

0BT b a 0BT*

BAT a b BAT*

HW9470917(Battery unit)

Battery back-up connector

a: Crimped contact-pin (pin)
b: Crimped contact-pin (socket)

R-, T-Axes Motor

Detector

Motor

Motor cable etc.

Internal wire

Power connector

Connection b OBT4
OBT a a BAT4
BAT b
before removing connector.

Connect battery to
encoder to save the data

CAUTION

Detector connector Battery unit

CAUTION label
Connection status
0BT a b 0BT4
BAT b a BAT4

a: Crimped contact-pin (pin)

b: Crimped contact-pin (socket)

Fig. 32 Backup Battery Pack Connection for Motor

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9.2 Notes on Maintenance Procedures

0BT a b 0BT
BAT b a BAT

Fig. 33 Battery Pack Connection

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

Fig. 34 Caution Label

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 HW1480129

10 Recommended Spare Parts

It is recommended to keep the parts and components in the following table in stock as spare
parts for the MOTOMAN-EP4000N.
Product performance can not be guaranteed in case of using the spare parts other than the
recommended parts listed below.

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 To replace parts in Rank B or Rank C, contact your Yaskawa representative.

Table. 9 Spare Parts for the Motoman-EP4000N

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

Battery Pack HW9470932-A Yaskawa For S, L, U-axes

A 1 Electric 1 1
Corporation

Battery Pack HW9470932-B Yaskawa For R, B, T-axes

A 2 Electric 1 1
Corporation

Grease Molywhite Yaskawa For all axes’

A 3 RE No. 00 Electric 16kg - speed reducers
Corporation and wrist unit

Grease Alvania EP Showa Shell For tapered roller

A 4 16kg -
Grease 2 Sekiyu K.K. bearings

S-Axis HW0280730-A Yaskawa

B 5 Speed Reducer Electric 1 1
Corporation

S-Axis HW0308653-1 Yaskawa

B 6 Input Gear Electric 1 1
Corporation

L-, U-Axis HW0280731-A Yaskawa

B 7 Speed Reducers Electric 1 2
Corporation

L-, U-Axis HW0302975-1 Yaskawa

B 8 Input Gear Electric 1 2
Corporation

R-Axis HW0380393-B Yaskawa

B 9 Speed Reducer Electric 1 1
Corporation

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Table. 9 Spare Parts for the Motoman-EP4000N

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

B-Axis HW0381033-A Yaskawa

B 10 Speed Reducer Electric 1 1
Corporation

T-axis HW0380794-A Yaskawa

B 11 Speed Reducer Electric 1 1
Corporation

Wrist Unit HW0170875-A Yaskawa

B 12 Electric 1 1
Corporation

AC Servomotor for HW0385741-A Yaskawa

C 13 S-Axis (SGMGH-1AA2A- Electric 1 1
Y3*) Corporation

AC Servomotor for HW0385742-A Yaskawa

C 14 L-and U-Axes (SGMGH-75A2A- Electric 1 2
Y3*) Corporation

AC Servomotor for HW0385743-A Yaskawa

C 15 R- and T-Axes (SGMGH-13A2A- Electric 1 2
YR7*) Corporation

AC Servomotor for HW0385744-A Yaskawa

C 16 B-Axis (SGMGH-44A2A- Electric 1 1
YR4*) Corporation

Wiring Harness in HW0171309-A Yaskawa

C 17 Manipulator Electric 1 1
Corporation

Cooling Fan HW9370631-E Yaskawa Completed with

C 18 Electric 1 1 lead terminal
Corporation treatment

Cooling Fan HW9480688-A Yaskawa Completed with

C 19 Electric 1 8 lead terminal
Corporation treatment

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MOTOMAN-EP4000N
INSTRUCTIONS

HEAD OFFICE
2-1 Kurosakishiroishi, Yahatanishi-ku, Kitakyushu 806-0004 Japan
Phone +81-93-645-7745 Fax +81-93-645-7746

YASKAWA America Inc. MOTOMAN Robotics Division

805 Liberty Lane, West Carrollton, OH 45449, U.S.A.
Phone +1-937-847-6200 Fax +1-937-847-6277

YASKAWA Nordic AB
Franska vagen 10, Box 4004, 390 04 Kalmar, Sweden
Phone +46-480-417800 Fax +46-480-417999

YASKAWA Europe GmbH Robotics Division

Kammerfeld strasse 1, 85391 Allershausen, Germany
Phone +49-8166-90-100 Fax +49-8166-90-103

YASKAWA Electric Korea Co., Ltd.

7F, Doore Bldg.; 24, Yeoido-Dong Youngdungpo-ku, Seoul, KOREA
Phone +82-2-784-7844 Fax +82-2-784-8495

YASKAWA Electric (Singapore) PTE Ltd.

151 Lorong Chuan, #04-02A, New Tech Park, Singapore 556741
Phone +65-6282-3003 Fax +65-6289-3003

YASKAWA Electric (Thailand) Co., Ltd.

252/246, 4th Floor. Muang Thai-Phatra Office Tower II Rachadaphisek 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 E&T Development Area, China 100176
Phone +86-10-6788-2858 Fax +86-10-6788-2878

MOTOMAN Motherson Robotics Ltd.

Plot No.195-196, 1st Floor, Sec.4 IMT Manesar, Gurgaon 122050, Haryana
Phone +91-124-475-8500 Fax +91-124-414-8016

Specifications are subject to change without notice

for ongoing product modifications and improvements.

C Printed in Japan July 2010 10-07

YASKAWA ELECTRIC CORPORATION

MANUAL NO.

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