Motomanms 165

MOTOMAN-MS165
INSTRUCTIONS
TYPE:
YR-MS165/MH180-A00 (STANDARD SPECIFICATION)
Upon receipt of the product and prior to initial operation, read these instructions thoroughly, and
retain for future reference.
MOTOMAN INSTRUCTIONS
MOTOMAN-MS165 INSTRUCTIONS
DX200 INSTRUCTIONS
DX200 OPERATOR’S MANUAL (for each purpose)
The DX200 operator’s manual above corresponds to specific usage. Be sure to use the appropriate manual.
Part Number: 167109-1CD

Revision: 5
MANUAL NO.
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Copyright © 2018, 2017, 2016, 2015 Yaskawa America, Inc.
Terms of Use and Copyright Notice

All rights reserved. This manual is freely available as a service to
Yaskawa customers to assist in the operation of Motoman robots, related
equipment and software This manual is copyrighted property of Yaskawa
and may not be sold or redistributed in any way. You are welcome to copy
this document to your computer or mobile device for easy access but you
may not copy the PDF files to another website, blog, cloud storage site or
any other means of storing or distributing online content.
Printed in the United States of America
First Printing, 2018
Yaskawa America, Inc.

Motoman Robotics Division
100 Automation Way
Miamisburg, OH 45342
Phone: 937-847-6200
www.motoman.com
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• This instruction manual is intended to explain mainly on the

mechanical part of the MOTOMAN-MS165 for the application to the
actual operation and for proper maintenance and inspection. It
describes on safety and handling, details on specifications,
necessary items on maintenance and inspection, to explain
operating instructions and maintenance procedures. Be sure to
read and understand this instruction manual thoroughly before
installing and operating the manipulator.
• General items related to safety are listed in Chapter 1: Safety of the
DX200 Instructions. To ensure correct and safe operation, carefully
read the DX200 Instructions before reading this manual.
• 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
representative 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 product's warranty.
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We suggest that you obtain and review a copy of the ANSI/RIA National
Safety Standard for Industrial Robots and Robot Systems (ANSI/RIA
R15.06-2012). You can obtain this document from the Robotic Industries
Association (RIA) at the following address:
Robotic Industries Association
900 Victors Way
P.O. Box 3724
Ann Arbor, Michigan 48106
TEL: (734) 994-6088
FAX: (734) 994-3338
www.roboticsonline.com
Ultimately, well-trained personnel are the best safeguard against
accidents and damage that can result from improper operation of the
equipment. The customer is responsible for providing adequately trained
personnel to operate, program, and maintain the equipment. NEVER
ALLOW UNTRAINED PERSONNEL TO OPERATE, PROGRAM, OR
REPAIR THE EQUIPMENT!
We recommend approved Yaskawa training courses for all personnel
involved with the operation, programming, or repair of the equipment.
This equipment has been tested and found to comply with the limits for a
Class A digital device, pursuant to part 15 of the FCC rules. These limits
are designed to provide reasonable protection against harmful
interference when the equipment is operated in a commercial
environment. This equipment generates, uses, and can radiate radio
frequency energy and, if not installed and used in accordance with the
instruction manual, may cause harmful interference to radio
communications.
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Notes for Safe Operation

Read this manual carefully before installation, operation, maintenance, or
inspection of the MOTOMAN-MS165.
In this manual, the Notes for Safe Operation are classified as “DANGER”,
“WARNING”, “CAUTION”, “MANDATORY”, or “PROHIBITED”.
Indicates an imminent hazardous

DANGER situation which, if not avoided, could
result in death or serious injury to
personnel.
Indicates a potentially hazardous

WARNING situation which, if not avoided, could
result in death or serious injury to
personnel.
Indicates a potentially hazardous

situation which, if not avoided, could
result in minor or moderate injury to
personnel and damage to
equipment. It may also be used to
alert against unsafe practices.
Always be sure to follow explicitly

the items listed under this heading.
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.
To ensure safe and efficient operation at all times, be sure

to follow all instructions, even if not designated as
“DANGER”, “WARNING” and “CAUTION” .
DANGER
• 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 these safety precautions may result in death or
serious injury from unexpected turning of the manipulator's arm.
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WARNING
• Before operating the manipulator, check that servo power is turned
OFF pressing the emergency stop buttons on the front door of the
DX200 and the programming pendant.
When the servo power is turned OFF, the SERVO ON LED on the
programming 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.
Fig. : 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.
Fig. : Release of Emergency Stop
• Observe the following precautions when performing teaching

operations within the P-point maximum envelope of the
manipulator:
– Be sure to use a lockout device to the safeguarding when going
inside. Also, display the sign that the operation is being
performed inside the safeguarding and make sure no one closes
the safeguarding.
– View the manipulator from the front whenever possible.
– Always follow the predetermined operating procedure.
– Keep in mind the emergency response measures against the
manipulator’s unexpected motion toward you.
– 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 person is present in the P-point maximum envelope
of the manipulator and that you are in a safe location before:
– Turning ON the power for the DX200.
– Moving the manipulator with the programming pendant.
– Running the system in the check mode.
– Performing automatic operations.
Injury may result if anyone enters the P-point maximum envelope of the
manipulator during operation. Always press an emergency stop button
immediately if there is a problem.
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• Perform the following inspection procedures prior to conducting

manipulator 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 cabinet
of the DX200 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 Warning Labels in the
DX200 Instructions before operating the manipulator.
Definition of Terms Used Often in This Manual

The MOTOMAN is the YASKAWA industrial robot product.
The MOTOMAN usually consists of the manipulator, the controller, the
programming pendant, and supply cables.
In this manual, the equipment is designated as follows:
Equipment Manual Designation
DX200 controller DX200
DX200 programming pendant Programming pendant
Cable between the manipulator and the Manipulator cable
controller
Description of the Operation Procedure

In the explanation of the operation procedure, the expression “Select • • •”
means that the cursor is moved to the object item and the SELECT key is
pressed, or that the item is directly selected by touching the screen.
Registered Trademark
In this manual, names of companies, corporations, or products are
trademarks, registered trademarks, or brand names for each company or
corporation. The indications of (R) and TM are omitted.
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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 manipulator. Prior to operating the manipulator, confirm the
contents.
Note: Taking the maintenance-relevant trainings offered by YASKAWA is
indispensable for replacing the L-axis of the balancer-equipped
manipulator.
Fig. : Warning Label Locations
Nameplate
(On the manipulator manufactured after June 2014)
WARNING Label C
Nameplate
(On the manipulator
manufactured by May 2014)
WARNING Label A
WARNING Label B WARNING Label B
WARNING Label C
Nameplate: WARNING Label A:

MODEL
MOTOMAN-
WARNING
TYPE
PAYLOAD MASS Moving parts

kg kg
ORDER NO. DATE may cause
SERIAL NO. injury
YASKAWA ELECTRIC CORPORATION
2-1 Kurosakishiroishi, Yahatanishi-ku,
Kitakyushu 806-0004 Japan
MADE IN JAPAN NJ3878
WARNING Label B:
WARNING Label C:
DANGER WARNING
Do not enter
Do not remove the motor,and do not robot
release the brake. Failure to observe
this caution may result in injury from work area.
unexpected turning of the manipulator arm.
Please contact your Yaskawa representive.
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Safeguarding Tips
All operators, programmers, maintenance personnel, supervisors, and
anyone working near the system 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 equipment, the operator's manuals, the system equipment, and
options and accessories should be permitted to operate this
equipment.
• Improper connections can damage the equipment. All connections
must be made within the standard voltage and current ratings of the
equipment.
• The system must be placed in Emergency Stop (E-Stop) mode
whenever it is not in use.
• In accordance with ANSI/RIA R15.06-2012, 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).
Mechanical Safety Devices

The safe operation of this equipment is ultimately the users 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 R15.06-2012 safety standards, and other local codes
that may pertain to the installation and use of this 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 barriers
• Door interlocks
• Emergency stop palm buttons located on operator station
Check all safety equipment frequently for proper operation. Repair or
replace any non-functioning safety equipment immediately.
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Programming, Operation, and Maintenance Safety

All operators, programmers, maintenance personnel, supervisors, and
anyone working near the system 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 equipment should be permitted to program, or maintain the system.
All personnel involved with the operation of the equipment must
understand potential dangers of operation.
• Inspect the equipment 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.
• Check the E-Stop button on the operator station for proper operation
before programming. The equipment 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.
• Any modifications to the controller unit can cause severe personal
injury or death, as well as damage to the robot! Do not make any
modifications to the controller unit. Making any changes without the
written permission from Yaskawa will void the warranty.
• Some operations require a standard passwords and some require
special passwords.
• The equipment allows modifications of the software for maximum
performance. Care must be taken when making these modifications.
All modifications made to the software will change the way the
equipment operates and can cause severe personal injury or death,
as well as damage parts of the system. Double check all
modifications under every mode of operation to ensure that the
changes have not created hazards or dangerous situations.
• 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 equipment. All connections
must be made within the standard voltage and current ratings of the
equipment.
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Maintenance Safety
Turn the power OFF and disconnect and lockout/tagout all electrical
circuits before making any modifications or connections.
Perform only the maintenance described in this manual. Maintenance
other than specified in this manual should be performed only by Yaskawa-
trained, qualified personnel.
Summary of Warning Information

This manual is provided to help users establish safe conditions for
operating the equipment. Specific considerations and precautions are also
described in the manual, but appear in the form of Dangers, Warnings,
Cautions, and Notes.
It is important that users operate the equipment in accordance with this
instruction manual and any additional information which may be provided
by Yaskawa. Address any questions regarding the safe and proper
operation of the equipment to Yaskawa Customer Support.
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Customer Support Information

If you need assistance with any aspect of your MS165 system, please
contact Yaskawa Customer Support at the following 24-hour telephone
number:
(937) 847-3200
For routine technical inquiries, you can also contact Yaskawa Customer
Support at the following e-mail address:
techsupport@motoman.com
When using e-mail to contact Yaskawa Customer Support, please provide

a detailed description of your issue, along with complete contact
information. Please allow approximately 24 to 36 hours for a response to
your inquiry.
Please use e-mail for routine inquiries only. If you have an

urgent or emergency need for service, replacement parts,
or information, you must contact Yaskawa Customer
Support at the telephone number shown above.
Please have the following information ready before you call Customer
Support:
• System MS165
• Primary Application ___________________________
• Controller DX200
• Software Version Access this information on the

Programming Pendant’s LCD
display screen by selecting {MAIN
MENU} - {SYSTEM INFO} -
{VERSION}
• Robot Serial Number Located on the robot data plate
• Robot Sales Order Number Located on the DX200 controller

data plate
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Contents
Table of Contents
1 Product Confirmation ...................................................................................................................... 1-1
1.1 Contents Confirmation ....................................................................................................... 1-1
1.2 Order Number Confirmation .............................................................................................. 1-2
2 Transport......................................................................................................................................... 2-1
2.1 Transport Method .............................................................................................................. 2-2
2.1.1 Using a Crane....................................................................................................... 2-2
2.2 Shipping Bolts and Brackets.............................................................................................. 2-3
2.3 Cushioning Material for Transport ..................................................................................... 2-3
3 Installation....................................................................................................................................... 3-1
3.1 Safeguarding Installation ................................................................................................... 3-2
3.2 Mounting Procedures for Manipulator Base ...................................................................... 3-2
3.2.1 Mounting Example................................................................................................ 3-4
3.3 Location ............................................................................................................................. 3-5
4 Wiring.............................................................................................................................................. 4-1
4.1 Grounding .......................................................................................................................... 4-1
4.2 Cable Connection .............................................................................................................. 4-2
4.2.1 Connection to the Manipulator.............................................................................. 4-2
4.2.2 Connection to the DX200 ..................................................................................... 4-2
5 Basic Specifications ........................................................................................................................ 5-1
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 Stopping Angles and Times for S-, L- and U-Axes ............................................................ 5-4
5.5.1 Stop Category 0: Stopping Angles and Times...................................................... 5-4

5.5.1.1 Position 100% ......................................................................................... 5-4
5.5.1.2 Position 66% ........................................................................................... 5-5
5.5.1.3 Position 33% ........................................................................................... 5-6
5.5.2 Stop Category 1: Stopping Angles and Times...................................................... 5-7

5.5.2.1 Position100% .......................................................................................... 5-7
5.5.2.2 Position 66% ........................................................................................... 5-8
5.5.2.3 Position 33% ........................................................................................... 5-9
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5.6 Alterable Operating Range .............................................................................................. 5-10
5.6.1 Components for Altering Operating Range......................................................... 5-11
5.6.2 Notes on the Mechanical Stopper Installation .................................................... 5-12
5.6.3 Adjustment to the Pulse Limitation of S-Axis ...................................................... 5-12
6 Allowable Load for Wrist Axis and Wrist Flange ............................................................................. 6-1
6.1 Allowable Wrist Load ......................................................................................................... 6-1
6.2 Wrist Flange....................................................................................................................... 6-3
7 System Application.......................................................................................................................... 7-1
7.1 Peripheral Equipment Mounts............................................................................................ 7-1
7.2 Internal User I/O Wiring Harness and Air Line................................................................... 7-2
8 Electrical Equipment Specification .................................................................................................. 8-1
8.1 Position of Limit Switch ...................................................................................................... 8-1
8.1.1 Specification of Limit Switch ................................................................................. 8-1
8.1.2 Position of Limit Switch......................................................................................... 8-1
8.1.3 Setting of Operation Range .................................................................................. 8-2

8.1.3.1 S-Axis Operation Range.......................................................................... 8-2
8.1.3.2 L-Axis Operation Range .......................................................................... 8-2
8.1.3.3 Setting Range of LU-Axes Interference Angle......................................... 8-3
8.2 Internal Connections .......................................................................................................... 8-4
9 Maintenance and Inspection ........................................................................................................... 9-1
9.1 Inspection Schedule........................................................................................................... 9-1
9.2 Battery Pack Replacement ................................................................................................ 9-5
9.3 Grease Exchange .............................................................................................................. 9-7
9.3.1 Notes on Grease Exchange Procedures .............................................................. 9-7
9.3.2 List of Necessary Items ........................................................................................ 9-8
9.3.3 Grease Exchange ................................................................................................. 9-9

9.3.3.1 Grease Exchange for S-, L-, U-, R-, B-, and T-Axes Speed Reducer .....9-9
9.3.4 Grease Replenishment for Gas Balancer Link Part............................................ 9-14
9.4 Gas Maintenance Procedure in the Gas Balancer........................................................... 9-15
9.4.1 Notes on Gas Maintenance Procedure in the Gas Balancer ..............................9-15
9.4.2 Gas Pressure Inspection .................................................................................... 9-16

9.4.2.1 Adequate Gas Pressure ........................................................................ 9-16
9.4.2.2 Necessary Device.................................................................................. 9-17
9.4.2.3 Inspection Procedures........................................................................... 9-17
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9.4.3 Gas Discharging Procedure .......................................................................... 9-19

9.4.3.1 Necessary Devices................................................................................ 9-19
9.4.3.2 Gas Discharging Procedures
9.4.4 Gas Injecting Procedure ..................................................................................... 9-22

9.4.4.1 Necessary Devices................................................................................ 9-22
9.4.4.2 Gas Injecting Procedures ...................................................................... 9-22
9.5 Notes for Maintenance..................................................................................................... 9-24
9.5.1 Battery Pack Connection .................................................................................... 9-24
10 Recommended Spare Parts........................................................................................................ 10-1
11 Parts List ..................................................................................................................................... 11-1
11.1 S-Axis Unit ..................................................................................................................... 11-1
11.2 L-Axis Unit ..................................................................................................................... 11-3
11.3 URBT-Axes Unit ............................................................................................................ 11-6
11.4 U-Arm Unit ..................................................................................................................... 11-8
11.5 Wrist Unit ..................................................................................................................... 11-10
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MS165 1 Product Confirmation
1.1 Contents Confirmation
1 Product Confirmation
CAUTION
• Confirm that the manipulator and the DX200 have the same order
number. 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 are given separately):
• Manipulator
• DX200
• Programming pendant
• Manipulator cables
(2 cables between the DX200 and the Manipulator)
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MS165 1 Product Confirmation

1.2 Order Number Confirmation
1.2 Order Number Confirmation

Check that the order number of the manipulator corresponds to the
DX200. The order number is located on a label as shown below.
Fig. 1-1: Location of Order Number Labels
Label (Enlarged View)
THE MANIPULATOR AND THE CONTROLLER Check that the manipulator

SHOULD HAVE SAME ORDER NUMBER.
and the DX200 have the
same order number.
ORDER NO.
25'(512
࢜㸫ࢲࡢྠ୍1R࡜᥋⥆ࡋᚚ౑⏝㢪࠸ࡲࡍࠋ
0RWRPDQᮏయ࡜ࢥࣥࢺ࣮ࣟࣛࡣࠊୗグ
View A (Enlarged View)
(a) DX200 (Front View) (b) Manipulator (Top View)

(On the manipulator manufatctured after Feb. 2016)
(b) Manipulator (Side View)

(On the manipulator manufactured by Jan. 2016)
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MS165 2 Transport
2 Transport
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 transport.
The system consists of precision components. Failure to observe this
caution may adversely affect performances.
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MS165 2 Transport
2.1 Transport Method
2.1 Transport Method
• The weight of the manipulator is approximately 1070 kg

including the shipping bolts and brackets. Use a wire rope
strong enough to withstand the weight.
• Shipping bolts and brackets are designed to support the
manipulator weight. Do not use them for anything other
NOTE than transporting the manipulator.
• 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, forklift, or other equipment. Fail-
ure to observe this instruction may result in injury.
2.1.1 Using a Crane

As a rule, the manipulator should be lifted by a crane with four wire ropes
when removing it from the package and moving it. Be sure that the
manipulator is fixed with the shipping bolts and brackets before transport,
and lift it in the posture as shown in fig. 2-1 “Transporting Position” .
Fig. 2-1: Transporting Position
Shipping bolts and bracket (4 pieces)

(Fixed to the manipulator
before shipment.)
B
Hexagon head screw M20
(length: 70)(8 screws)
(Fixed to the manipulator before shipment.)
Factory setting for angle and pulse of each axis

Axis S L U R B T
Angle 0 -60㺽 -86㺽 0 +116㺽 0
Pulse 0 -183758 -217225 0 286142 0
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MS165 2 Transport
2.2 Shipping Bolts and Brackets
2.2 Shipping Bolts and Brackets

The manipulator is provided with shipping bolts and brackets.
(fig. 2-2 “Shipping Bolts and Brackets” ).
Fig. 2-2: Shipping Bolts and Brackets
Hook
176
87
4xR20
Side view Front view
• The shipping brackets are painted in yellow.
If operating the manipulator with shipping bolts and brack-

ets attached, the shipping bolts and brackets interfere with
NOTE the manipulator and that may cause a damage to the
manipulator. Make sure to remove the shipping bolts and
brackets before operation.
2.3 Cushioning Material for Transport

The manipulator is provided with the cushioning materials for transport at
section A and B. (See fig. 2-3 “Cushioning Materials for Transport” .)
Fig. 2-3: Cushioning Materials for Transport
Casing
L-arm
U-arm
A L-arm
S-head mechanical stopper
• A rubber cushion is respectively wedged at the section A and B.
Before turning ON the power, check to be sure that the

cushioning materials for transport are removed.
NOTE
In the event that the manipulator must be moved again, to
avoid its main body from being damaged, the cushioning
materials such as rubber plate, etc. must be used.
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MS165 3 Installation
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 tool or the workpiece
held by its fully extended arm will not reach the wall, safeguarding,
or controller.
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 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 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. It prevents unforeseen
accidents with personnel and damage to equipment. Refer to the quoted
clause for your information and guidance.
Responsibility for Safeguarding (ISO10218)

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 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 reaction forces
during acceleration and deceleration.
Construct a solid foundation with the appropriate thickness to withstand
maximum reaction forces of the manipulator referring to table 3-1
“Manipulator Reaction Force and Torque” .
A baseplate flatness 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 instructed in
chapter 3.2.1 “Mounting Example” .
Table 3-1: Manipulator Reaction Force and Torque

Horizontal rotation Vertical rotation
Reaction force FH Torque MH Reaction force FV Torque MV
Emergency stop 24000N 37630 N•m 15680N 49000 N•m

(2500kgf) (3840 kgf•m) (1600kgf) (5000 kgf•m)
Acceleration/deceleration 6370N 9400 N•m 4900N 22050 N•m
(650kgf) (960 kgf•m) (500kgf) (2250kgf•m)
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Fig. 3-1: Manipulator Reaction Force and Torque
MV
FV
MH
FH
3.2.1 Mounting Example

For the first process, anchor the baseplate firmly to the ground. The
baseplate should be rugged and durable to prevent shifting of the
manipulator or the mounting fixture. It is recommend to prepare a
baseplate of 50 mm or more thick, and anchor bolts of M20 or larger size.
The manipulator base is tapped for eight mounting holes; securely fix the
manipulator base to the baseplate with eight hexagon socket head cap
screws M20 (80 mm long is recommended). Next, fix the manipulator
base to the baseplate. Tighten the hexagon socket head cap screws and
anchor bolts firmly so that they will not work loose during the operation.
Refer to fig. 3-2 “Mounting the Manipulator on Baseplate” .
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Fig. 3-2: Mounting the Manipulator on Baseplate
Hexagon socket head cap screw

M20 (8 screws)
Spring washer
Washer
Manipulator base
40
Baseplate
Flatness: 0.5mm or less
Units: mm
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3.3 Location
3.3 Location
When installing a manipulator, it is necessary to satisfy the following
environmental conditions:
• Ambient temperature: 0 to + 45C
• Humidity: 20 to 80%RH (no-condensing)
• Free from dust, soot, oil, or water
• Free from corrosive gas or liquid, or explosive gas or liquid.
• Free from excessive vibration
(Vibration acceleration: 4.9 m/s2 [0.5 G] or less)
• Free from large electrical noise (plasma)
• Flatness for installation: 0.5 mm or less
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MS165 4 Wiring
4.1 Grounding
4 Wiring
WARNING
• Ground resistance must be 100  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.
• Do not cover the cable or allow it to tangle. Keep the cable as
straight as possible.
Failure to observe this caution may result in preventing heat of the
cable from being discharged.
4.1 Grounding
Follow electrical installation standards and wiring regulations for
grounding. A ground wire of 5.5 mm2 or more is recommended.
Refer to fig. 4-1 “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 electric power, motor
power, welding devices, etc.
NOTE
• Where metal ducts, metallic conduits, or distributing racks
are used for cable laying, ground in accordance with elec-
trical installation standards.
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MS165 4 Wiring
4.2 Cable Connection
Fig. 4-1: Grounding Method

A
Bolt M8 (for grounding)

5.5mm2 or more
Delivered with manipulator
View A

Two manipulator cables are delivered with the manipulator; an encoder
cable for detection (1BC) and power cable (2BC).
(Refer to fig. 4-2 “Manipulator Cables” .)
Connect these cables to the manipulator base connectors and to the
DX200. Refer to fig. 4-3(a) “Manipulator Cable Connectors (Manipulator
Side)” and fig. 4-3(b) “Manipulator Cable Connection (DX200 Side)” .
4.2.1 Connection to the Manipulator

Before connecting three cables to the manipulator, verify the numbers on
both manipulator cables and the connectors on the connector base of the
manipulator. When connecting, adjust the cable connector positions to
the main key positions of the manipulator, and insert cables in the order of
2BC, then1 BC. After inserting the cables, depress the lever until it clicks.
4.2.2 Connection to the DX200

Before connecting cables to the DX200, verify the numbers on both
manipulator cables and the connectors on the DX200. When connecting,
insert the cables in the order of X21, then X11 and depress each lever low
until it clicks.
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MS165 4 Wiring
Fig. 4-2: Manipulator Cables
The DX200 Side The Manipulator Side
1BC
X11
X11 1BC
1BC
Encoder Cable
The DX200 Side The Manipulator Side
$%
*9
:
X21 2BC
2BC
Power Cable
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MS165 4 Wiring
Fig. 4-3(a): Manipulator Cable Connectors (Manipulator Side)

Key positions
Key positions
Connector Details
(Manipulator Side)
Fig. 4-3(b): Manipulator Cable Connection (DX200 Side)
X11
X21
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MS165 5 Basic Specifications
5.1 Basic Specifications
5 Basic Specifications
5.1 Basic Specifications

Table 5-1: Basic Specifications1)
Item Model MOTOMAN-MS165
Flange for Cable Processing2) Not Equipped Equipped
Application Spot Welding
Structure Vertically Articulated
Degree of Freedom 6
Payload 180 kg 165 kg
Repeatability3) ±0.2 mm
Range of Motion S-Axis (turning) -180° - +180°
L-Axis (lower arm) -60° - +76°
U-Axis (upper arm) -147° - +90°
R-Axis (wrist roll) -360° - +360° -210° - +210°
B-Axis (wrist pitch/yaw) -130° - +130° -125° - +125°
T-Axis (wrist twist) -360° - +360° -210° - +210°
Maximum Speed S-Axis 2.18 rad/s, 125°/s
L-Axis 2.01 rad/s, 115°/s
U-Axis 2.18 rad/s, 125°/s
R-Axis 3.18 rad/s, 182°/s
B-Axis 3.05 rad/s, 175°/s
T-Axis 4.63 rad/s, 265°/s
4)
Allowable Moment R-Axis 1000 N•m (102 kgf•m) 951 N•m (97 kgf•m)
B-Axis 1000 N•m (102 kgf•m) 951 N•m (97 kgf•m)
T-Axis 618 N•m (63 kgf•m)
Allowable Inertia R-Axis 90 kg•m2 88 kg•m2
(GD2/4) B-Axis 90 kg•m2 88 kg•m2
T-Axis 46.3 kg•m2
Approx. Mass 970 kg
Protective Structure Basic axis: IP54 or equivalent
Wrist axis only: IP67 or equivalent
Ambient Conditions Temperature 0° C to 45° C
Humidity 20 to 80% RH (non-condensing)
Vibration Acceleration 4.9 m/s2 or less (0.5 G)
Others Free from corrosive gasses or liquids, or explosive gasses
Free from exposure to water, oil, or dust
Free from excessive electrical noise (plasma)
Power Requirements 5.0 kVA
Noise5) 76 dB
1 SI units are used in this table. However, gravitational unit is used in ( ).
2 Specification changes when the manipulator is equipped with a flange for cable processing.
(Refer to fig. 5-3 “Dimensions and P-Point Maximum Envelope” .)
3 Conformed to ISO9283
4 Refer to table chapter 6.1 “Allowable Wrist Load” for details on the permissible moment of inertia.
5 Conformed to ISO6926
1, Measurement is carried out when the maximum load is mounted to the manipulator and
operated in the maximum speed.
2, Measurement is carried out:
-between 1.2m and 1.5m above the ground.
-400mm away from the P-point maximum envelope.
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5.2 Part Names and Working Axes
5.2 Part Names and Working Axes

Fig. 5-1: Part Names and Working Axes
U+
R+ B+ T+
R- B- T-
U-
L- L+
S+
S-
5.3 Manipulator Base Dimensions

Fig. 5-2: Manipulator Base Dimensions
+0.021
20 0 dia. (2 reamed holes)
Fitting surface (Pin hole for manipulator
500
positioning)
250 ±0.1
420
185 ±0.1
230 ±0.1 230±0.1

40
500
420
320
185 ±0.1
22 dia. (8 through holes)

(For fixing the manipulator) 295 ±0.1
Units: mm
A 745
Fitting surface
View A
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5.4 Dimensions and P-Point Maximum Envelope
5.4 Dimensions and P-Point Maximum Envelope

Fig. 5-3: Dimensions and P-Point Maximum Envelope
Flange for cable processing
R71
180°
3
276
R2702
180°
15
R5
View A
3673
970 2702
3061
P-point maximum
envelope
(290) 344
325 1225 225
220
300 153
P-point
1
41
R2
2450
° 76
2253
1150
60 °
957
33°
598
650
4° 40
9
0
276 349
332
970
1441
0
713
761
710
562
577
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5.5 Stopping Angles and Times for S-, L- and U-Axes
Following data on stopping angle and time for each axis measured under
the standard of ISO10218.
5.5.1 Stop Category 0: Stopping Angles and Times
5.5.1.1 Position 100%
Fig. 5-4: Stop Category 0, Position 100% : Stopping Angle and Time for
Each Axis
(a)S-Axis
Stop Category 0, Position 100% Stop Category 0, Position 100%

㻠㻜㻝㻚㻜
㻟㻡㻜㻚㻥
㻜㻚㻤
㻟㻜
㻿㼠㼛㼜㼜㼕㼚㼓㻌㼍㼚㼓㼘㼑㼇㼐㼑㼓㼉
㻿㼠㼛㼜㼜㼕㼚㼓㻌㼠㼕㼙㼑㼇㼟㼑㼏㼉
㻜㻚㻣
㻞㻡㻜㻚㻢
㻞㻜㻜㻚㻡
㻝㻡㻜㻚㻠
㻜㻚㻟
㻝㻜
㻜㻚㻞
㻡㻜㻚㻝
㻜㻜㻚㻜
㻜㻞㻜㻠㻜㻢㻜㻤㻜㻝㻜㻜㻝㻞㻜㻜㻞㻜㻠㻜㻢㻜㻤㻜㻝㻜㻜㻝㻞㻜
㻿㼜㼑㼑㼐㼇㼐㼑㼓㻛㼟㼉㻿㼜㼑㼑㼐㼇㼐㼑㼓㻛㼟㼉
㻸㼛㼍㼐㻝㻜㻜㻑㻸㼛㼍㼐㻢㻢㻑㻸㼛㼍㼐㻟㻟㻑㻸㼛㼍㼐㻝㻜㻜㻑㻸㼛㼍㼐㻢㻢㻑㻸㼛㼍㼐㻟㻟㻑
(b)L-Axis

㻠㻜㻝㻚㻜
㻟㻡㻜㻚㻥
㻜㻚㻤
㻟㻜
㻜㻚㻣
㻞㻡㻜㻚㻢
㻞㻜㻜㻚㻡
㻝㻡㻜㻚㻠
㻜㻚㻟
㻝㻜
㻜㻚㻞
㻡㻜㻚㻝
㻜㻜㻚㻜
(c)U-Axis

㻠㻜㻝㻚㻜
㻟㻡㻜㻚㻥
㻜㻚㻤
㻟㻜
㻜㻚㻣
㻞㻡
㻜㻚㻢
㻞㻜㻜㻚㻡
㻝㻡㻜㻚㻠
㻜㻚㻟
㻝㻜
㻜㻚㻞
㻡
㻜㻚㻝
㻜㻜㻚㻜
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5.5.1.2 Position 66%

Each Axis
(a)S-Axis

㻠㻜㻝㻚㻜
㻟㻡㻜㻚㻥
㻜㻚㻤
㻟㻜
㻜㻚㻣
㻞㻡㻜㻚㻢
㻞㻜㻜㻚㻡
㻝㻡㻜㻚㻠
㻜㻚㻟
㻝㻜
㻜㻚㻞
㻡㻜㻚㻝
㻜㻜㻚㻜
(b)L-Axis

㻠㻜㻝㻚㻜
㻟㻡㻜㻚㻥
㻜㻚㻤
㻟㻜
㻜㻚㻣
㻞㻡㻜㻚㻢
㻞㻜㻜㻚㻡
㻜㻚㻠
㻝㻡
㻜㻚㻟
㻝㻜
㻜㻚㻞
㻡㻜㻚㻝
㻜㻜㻚㻜
(c)U-Axis

㻠㻜㻝㻚㻜
㻟㻡㻜㻚㻥
㻜㻚㻤
㻟㻜
㻜㻚㻣
㻞㻡㻜㻚㻢
㻞㻜㻜㻚㻡
㻜㻚㻠
㻝㻡
㻜㻚㻟
㻝㻜
㻜㻚㻞
㻡㻜㻚㻝
㻜㻜㻚㻜
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Each Axis
(a)S-Axis

㻟㻡
㻜㻚㻡
㻟㻜
㻜㻚㻠
㻞㻡
㻞㻜㻜㻚㻟
㻝㻡
㻜㻚㻞
㻝㻜
㻜㻚㻝
㻡
㻜㻜㻚㻜
(b)L-Axis

㻟㻡㻜㻚㻡
㻟㻜
㻜㻚㻠
㻞㻡
㻜㻚㻟
㻞㻜
㻝㻡㻜㻚㻞
㻝㻜
㻜㻚㻝
㻡
㻜㻜㻚㻜
(c)U-Axis

㻟㻡㻜㻚㻡
㻟㻜
㻜㻚㻠
㻞㻡
㻜㻚㻟
㻞㻜
㻝㻡㻜㻚㻞
㻝㻜
㻜㻚㻝
㻡
㻜㻜㻚㻜
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5.5.2 Stop Category 1: Stopping Angles and Times
NOTE Stopping angles and times at Stop category 1 are not

subjected to the load of the manipulator.
5.5.2.1 Position100%
Fig. 5-7: Stop Category 1: Position 100% Stopping Angle and Time for
Each Axis
(a)S-Axis
㻡㻜㻝㻚㻜
㻠㻡㻜㻚㻥
㻠㻜㻜㻚㻤
㻟㻡㻜㻚㻣
㻟㻜㻜㻚㻢
㻞㻡㻜㻚㻡
㻞㻜㻜㻚㻠
㻝㻡㻜㻚㻟
㻝㻜㻜㻚㻞
㻡㻜㻚㻝
㻜㻜㻚㻜
Note) Note depends on the load.

(b)L-Axis

㻠㻜㻝㻚㻜
㻟㻡㻜㻚㻥
㻜㻚㻤
㻟㻜
㻜㻚㻣
㻞㻡㻜㻚㻢
㻞㻜㻜㻚㻡
㻝㻡㻜㻚㻠
㻜㻚㻟
㻝㻜
㻜㻚㻞
㻡㻜㻚㻝
㻜㻜㻚㻜

(c)U-Axis
㻠㻜㻝㻚㻜
㻟㻡
㻜㻚㻤
㻟㻜
㻞㻡
㻜㻚㻢
㻞㻜
㻝㻡㻜㻚㻠
㻝㻜
㻜㻚㻞
㻡
㻜㻜㻚㻜
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Each Axis
(a)S-Axis

㻣㻜㻝㻚㻞
㻝㻚㻝
㻢㻜㻝㻚㻜
㻜㻚㻥
㻡㻜
㻜㻚㻤
㻠㻜㻜㻚㻣
㻜㻚㻢
㻟㻜㻜㻚㻡
㻜㻚㻠
㻞㻜
㻜㻚㻟
㻝㻜㻜㻚㻞
㻜㻚㻝
㻜㻜㻚㻜

(b)L-Axis

㻠㻜㻝㻚㻜
㻟㻡㻜㻚㻥
㻜㻚㻤
㻟㻜
㻜㻚㻣
㻞㻡㻜㻚㻢
㻞㻜㻜㻚㻡
㻝㻡㻜㻚㻠
㻜㻚㻟
㻝㻜
㻜㻚㻞
㻡㻜㻚㻝
㻜㻜㻚㻜

(c)U-Axis

㻠㻜㻝㻚㻜
㻟㻡㻜㻚㻥
㻜㻚㻤
㻟㻜
㻜㻚㻣
㻞㻡
㻜㻚㻢
㻞㻜㻜㻚㻡
㻝㻡㻜㻚㻠
㻜㻚㻟
㻝㻜
㻜㻚㻞
㻡
㻜㻚㻝
㻜㻜㻚㻜
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Each Axis
(a)S-Axis

㻡㻜㻝㻚㻜
㻠㻡㻜㻚㻥
㻠㻜㻜㻚㻤
㻟㻡㻜㻚㻣
㻟㻜㻜㻚㻢
㻞㻡㻜㻚㻡
㻞㻜㻜㻚㻠
㻝㻡㻜㻚㻟
㻝㻜㻜㻚㻞
㻡㻜㻚㻝
㻜㻜㻚㻜
㻜㻞㻜㻠㻜㻢㻜㻤㻜㻝㻜㻜㻝㻞㻜㻝㻠㻜㻜㻞㻜㻠㻜㻢㻜㻤㻜㻝㻜㻜㻝㻞㻜㻝㻠㻜

(b)L-Axis

40 1.0
0.9
35
0.8
Stopping angle[deg]
30
Stopping time[sec]
0.7
25 0.6
20 0.5
0.4
15
0.3
10
0.2
5 0.1
0.0
00 20 40 60 80 100 120 0 20 40 60 80 100 120
Speed[deg/s] Speed[deg/s]

(c)U-Axis

㻠㻜㻝㻚㻜
㻟㻡㻜㻚㻥
㻜㻚㻤
㻟㻜
㻜㻚㻣
㻞㻡
㻜㻚㻢
㻞㻜㻜㻚㻡
㻝㻡㻜㻚㻠
㻜㻚㻟
㻝㻜
㻜㻚㻞
㻡
㻜㻚㻝
㻜㻜㻚㻜
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5.6 Alterable Operating Range

The operating range of the S-axis can be altered in accordance with the
operating conditions as shown in table 5-2 “S-Axis Operating Range” .
If alteration is necessary, contact your YASKAWA representative in
advance.
Table 5-2: S-Axis Operating Range

Item Specifications
S-Axis Operating Range -180° - +180° (standard)
-150° - +150°
-120° - +120°
-90° - +90°
-60° - +60°
-30° - +30°
* The interval between stoppers must be 60° or more.
5.6.1 Components for Altering Operating Range

Arrange the components listed in fig. 5-10 “The Components of the S-
Axis Stopper” , when modifying the angle of S-axis.
(1) Pin (drawing No. HW0402104-1) (1 pin)
(2) Stopper (drawing No. HW1405450-1) (1 stopper)
(3) Hexagon socket head cap screw M16
(length: 35 mm) (4 screws)
(Tensile strength: 1200N/mm2 or more)
(4) Conical spring washer 2H-16 (4 washers)
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Fig. 5-10: The Components of the S-Axis Stopper

Hexagon socket head cap screws M16
(4 screws)(length: 35)
(tensile strength: 1200 N/mm2 or more)
Conical spring washer 2H-16 (4 washers)
Stopper
HW1405450-1
Section A-A
Pin
HW0402104-1
A A
5.6.2 Notes on the Mechanical Stopper Installation

For S-Axis mechanical stopper, install the stopper (drawing No.
HW1405450-1) with the pin which is used bottom up (drawing No.
HW0402104-1) as in fig. 5-10 “The Components of the S-Axis Stopper” .
DO NOT forget to apply Locktite 243 to the thread part of the pin before
inserting it into the stopper.
Mount the stopper to the S-head with four hexagon socket head cap
screws M16 (length: 35 mm) and tighten the screws with the tightening
torque of 348 N•m (tensile strength: 1200 N/mm2 or more). The stopper is
to be installed as shown in the fig. 5-10 when the operating range is
±180°.
The stopper can be installed by every 15 degree pitch, however, to avoid

the mechanical troubles caused by interference between stoppers (e.g.
±15°, ±165°), install the S-axis mechanical stopper referring to table 5-3
“The Settable Angle for S-Axis Stopper” .
1. Apply the specified components when mounting the S-

NOTE Axis mechanical stopper.
2. TURN OFF the electric power supply before mounting.
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5.6.3 Adjustment to the Pulse Limitation of S-Axis

Apply the Instruction for “DX200 INSTRUCTIONS chapter 8.17 Changing
the Parameter Setting (manual No. RE-CTO-A220)” as a part of reference
materials for adjusting the programming pendant when modifying the
range of motion of S-Axis.
The limitation to the pulse (Pulse Soft Limit + 1st Axis) : SICxG400
The limitation to the pulse (Pulse Soft Limit - 1st Axis) : SICxG408
Degree 0 15 30 45 60 75 90

Number of 0 28672 57344 86016 114688 143360 172032
Pulse
Degree 105 120 135 150 165 180

Number of 200704 229376 258048 286720 315392 344064
Pulse
* Refer to chapter 5.6 “Alterable Operating Range” .
Adjust both of the pulse limitation and the angle of S-Axis

NOTE mechanical stopper as modifying the range of motion for
machinery.
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The Angle of S-Axis Stopper for + Direction

5 Basic Specifications
5-13
The Angle of S-Axis Stopper for - Direction

Table 5-3: The Settable Angle for S-Axis Stopper
…Settable angle
Table 5-3 "The Settable Angle for S-Axis Stopper" indicates the angle range
…Non settable angle which allows S-axis to be set for + direction and - direction angles.
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Fig. 5-11(a): The Properly-Mounted Models for S-Axis Stopper
Hexagon socket head

cap screw fixing positions
Installation at 180
Hexagon socket head

Installation at 165
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Fig. 5-11(b): The Properly-Mounted Models for S-Axis Stopper
Hexagon socket head

Installation at 150
Hexagon socket head

Installation at 135
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Fig. 5-11(c): The Properly-Mounted Models for S-Axis Stopper
Hexagon socket head

Installation at 120
Hexagon socket head

Installation at 105
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Fig. 5-11(d): The Properly-Mounted Models for S-Axis Stopper
Hexagon socket head

Installation at 90
Hexagon socket head

Installation at 75
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Fig. 5-11(e): The Properly-Mounted Models for S-Axis Stopper
Hexagon socket head

Installation at 60
Hexagon socket head

Installation at 45
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Fig. 5-11(f): The Properly-Mounted Models for S-Axis Stopper
Hexagon socket head

Installation at 30
Hexagon socket head

Installation at 15
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Fig. 5-11(g): The Properly-Mounted Models for S-Axis Stopper
Hexagon socket head

Installation at 0
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MS165 6 Allowable Load for Wrist Axis and Wrist Flange
6.1 Allowable Wrist Load
6 Allowable Load for Wrist Axis and Wrist Flange

The allowable wrist load including the weight of the mount/gripper is as
follows at each specification.
YR-MS165/MH180-A00
: 180 kg maximum (without flange for cable processing specification)
(Refer to fig. 5-3 “Dimensions and P-Point Maximum Envelope” .)
: 165 kg maximum (with flange for cable processing specification)
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 fig. 6-1(a) “Allowable Wrist Load
(without flange for cable processing specification)” and fig. 6-1(b)
“Allowable Wrist Load (with flange for cable processing specification)” .
Contact your YASKAWA representative for further information or
assistance.
Table 6-1(a): Allowable Wrist Load (without flange for cable processing
specification1))
Axis Moment N•m (kgf•m)2) GD2/4 Total Moment of Inertia kg•m2
R-Axis 1000 (102) 90
B-Axis 1000 (102) 90
T-Axis 618 (63) 46.3
1 Refer to fig. 5-3.
2 ( ): Gravitational unit
Table 6-1(b): Allowable Wrist Load (with flange for cable processing
specification1))
Axis Moment N•m (kgf•m)2) GD2/4 Total Moment of Inertia kg•m2
R-Axis 951 (97) 88
B-Axis 951 (97) 88
T-Axis 618 (63) 46.3
1 Refer to fig. 5-3.
2 ( ): Gravitational unit
When the volume load is small, refer to the moment arm rating shown in
fig. 6-1 “Moment Arm Rating” .
The allowable total moment of inertia is calculated when the moment is at
the maximum. Contact your YASKAWA representative beforehand when
only moment of inertia, or load moment is small and moment of inertia is
large. Also, when the load mass is combined with an outside force,
contact your YASKAWA representative beforehand.
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Fig. 6-1: Moment Arm Rating
Without flange for cable processing spec.
LT(mm)
1200
40kg
1000
60kg
800 80kg
100kg
600
130kg
400 165kg
P-point
200 180kg R-, T-axis
center of rotation
400 600 800 10001200 1400 1600LB(mm)
200
400
600
800
1000
1200
LT(mm)
B-axis center of rotation
With flange for cable processing spec.

LT(mm)
1200
40kg
1000
60kg
800 80kg
100kg
600
130kg
400
P-point 165kg
200 R-, T-axis
center of rotation
400 600 800 10001200 1400 1600 LB(mm)
200
400
600
800
1000
1200
LT(mm)
B-axis center of rotation
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6.2 Wrist Flange
6.2 Wrist Flange

The wrist flange dimensions are shown in fig. 6-2 “Wrist Flange” . In
order to see the alignment mark, it is recommended that the attachment
be mounted inside the fitting. Fitting depth of inside and outside must be 8
mm or less.
Fig. 6-2: Wrist Flange
+0.015
10 0 dia.
(2 holes) (depth: 8 mm) +0.015
9 0 dia.
(2 holes) (depth: 8 mm)

dia.
-0.025
0

160 M10 (6 holes) (depth: 14mm)

dia.
M10 (6 holes) (depth: 14mm)

+0.030
0

63
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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MS165 7 System Application
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. 7-1 “Installing Peripheral
Equipment” for easier installation of the user’s system applications.
The following conditions shall be observed to attach or install peripheral
equipment. (Refer to table 7-1 “Conditions for Installation” .)
Fig. 7-1: Installing Peripheral Equipment
A3 Tapped hole M8
344 92 (4 holes) (depth: 14mm)
255 40 A3 Tapped hole M5
60
(2 holes) (depth: 9mm)
A1 Tapped hole M8
45
120
27.5
12.5
195
220
344 92
60 A3 Tapped hole M6
45
120
(2holes) (depth: 11mm)

27.5
12.5
195
220
255 40
50 220
20
20
25
B Tapped hole M12

B Tapped hole M20 (4 holes) (depth: 24mm)
270
(4 holes) (depth: 39mm) 50 220 45 45
163
305
A2 Tapped hole M6
305
25
20
50
170 170 45 170 170
45
20
234 234 234 234

270
163
B Tapped hole M20

305
305
A2 Tapped hole M8 (4 holes) (depth: 39mm)

50
170 170 170 170

234 234 234 234
Table 7-1: Conditions for Installation

Application Note
A1, Cable processing 30 kg max.
A2, 3 flange and valve, 49 N•m (5 kgf•m) max. for moment increase
etc. amount of upper arm
B Others 250 kg max.
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7.2 Internal User I/O Wiring Harness and Air Line

The internal user I/O wires (0.75 mm2 x 11 wires, 0.5 mm2 x 12 wires), the
cables for the external axis (2.0 mm2 x 4 cables, 0.75 mm2 x 2 cables, 0.2
mm2 x 6 cables), and an air line are used in the manipulator for the drives
of the peripheral devices mounted on the upper arm as shown in fig. 7-2
“Connectors for Internal User I/O Wiring Harness and Air Line” .
The connector pins, and the terminals are assigned as shown in fig. 7-2
and fig. 7-3 “Details of the Connector Pin Numbers” . Wiring must be
performed by user.
The allowable current for internal user 16.1A or less / wire. (2.0 mm2)
I/O wiring harness 5.0A or less / wire. (0.75 mm2)
3.5A or less / wire. (0.5 mm2)
2.3A or less / wire. (0.2 mm2)
The maximum pressure for the air line 490 kPa (5 kgf/cm2) or less
(The air line inside diameter: 8.0mm)
Fig. 7-2: Connectors for Internal User I/O Wiring Harness and Air Line
Key positions
Exhaust port (air flow)

Tapped holes PT3/8 with pipe plug
Connector for the external axis

(Power cable):
JL05-2A18-1SC (socket connector with cap). Connector for internal user
Prepare pin connector: JL05-6A18-1P. I/O wiring harness (Base):
JL05-2A24-28PC (pin connector with cap).
Connector for the external axis (Encoder cable):
Prepare socket connector: JL05-6A24-28S.
JL05-2A20-29SC(socket connector with cap).
Prepare pin connector: JL05-6A20-29P. Air inlet (air flow)
Connector for internal Tapped holes PT3/8
I/O wiring harness (Casing): with pipe plug
JL05-2A24-28SC (socket connector with cap).
Prepare pin connector: JL05-6A24-28P.
View A
A
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Fig. 7-3: Details of the Connector Pin Numbers
1
P
2
0.5mm2 Pins used P 9 0.2mm2
(6 pins) 10 (6 pins)
11
P
12
0.5mm 2 15 Shielded wire
(6 pins)

0.75mm2
Pins used (11 pins) Pin details for external axis encoder cable
2.0mm2
(4 pins)
0.75mm2
Pins used (2 pins)
Pin details for internal user I/O wiring harness Shielded wire
Pin details for external axis power cable
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MS165 8 Electrical Equipment Specification
8.1 Position of Limit Switch
8 Electrical Equipment Specification
8.1.1 Specification of Limit Switch

1. The interference limit switch at S-, L- and U-axes electrically limit the
operating range of respective axes by adjusting the position of the dog
using the limit switch.
The positions of the mechanical limits (mechanical stoppers) at S-, L-
and U-axes are changeable.
When the limit switch is activated, the power supply to the manipulator
is interrupted, then the manipulator makes an emergency stop as a
result. Refer to “DX200 INSTRUCTIONS chapter 8.9 Overrun/Tool
Shock Sensor Releasing” for releasing the status of this overrun.
2. The range of S-, L- and U-axes limit switches are set to the maximum
operating range before shipping.
In case of re-adjusting the operating range of each subject

NOTE axis, it is also required to change the dog location and limit
values in software. Contact your YASKAWA representative
if re-adjustment is required.
8.1.2 Position of Limit Switch

The limit switches are optional. For the S, L, and U-Axes with limit
switches specifications, L.S. are located on S-Axis, L-Axis, and U-Axis
respectively.
For the location, refer to fig. 8-1 “Location of Limit Switches” . The
inspection and adjustment of the limit switches should be made after
removing the cover.
Fig. 8-1: Location of Limit Switches
U-axis interference
limit switch
S-axis overrun
limit switch
L-axis overrun limit switch
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8.1.3 Setting of Operation Range
8.1.3.1 S-Axis Operation Range

By the S-axis limit switch, S-axis operation range can be set to those
ranges mentioned in table 5-2 “S-Axis Operating Range” .
8.1.3.2 L-Axis Operation Range

By the L-axis limit switch, the L-axis operation range can be set to any
angles within -61° to +77° as mentioned in the figure below.
Fig. 8-2: L-Axis Overrun Limit Switch Setting Range
Negative side Positive side
° +7
-61 7°
8.1.3.3 Setting Range of LU-Axes Interference Angle

L- and U-axes interference limit switches are designed to check the
interference angle of L- and U-axes.
As shown in fig. 8-3 “LU-Axes Interference Angle” , the operation range of
U-axis can be set to any angles within -87° to +91°.
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Fig. 8-3: LU-Axes Interference Angle
+9
1°
Positive side
7°
-8
Negative side
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8.2 Internal Connections

Highly reliable connectors are equipped on each connection part of the
manipulator to enable easy removal and installation for maintenance and
inspection. For the number and location of connectors, see fig. 8-4
“Locations and Numbers of Connectors” .
Diagrams for Internal connections of the manipulator are shown in
fig. 8-5(a) “Internal Connection Diagram” and fig. 8-5(b) “Internal
Connection Diagram” .
Fig. 8-4: Locations and Numbers of Connectors
Connector for external axis

(Power cable)
Connector for external axis
(Encoder cable)
Connector for internal user

I/O wiring harness
Connector for
internal user I/O
wiring harness
(Base)
1BC 2BC
Table 8-1: List of Connector Types

Name Type of Connector
Connector Base Connector for internal JL05-2A24-28PC
user I/O wiring harness (JL05-6A24-28S: Optional)
U-arm Connector for internal JL05-2A24-28SC
user I/O wiring harness (JL05-6A24-28P: Optional)
Connector for external axis JL05-2A20-29SC
(Encoder cable) (JL05-6A20-29P: Optional)
Connector for external axis JL05-2A18-1SC
(Power cable) (JL05-6A18-1P: Optional)
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Fig. 8-5(a): Internal Connection Diagram
0BT 1 0BAT11 17 0BAT1

Notes K R P BAT
0BT
2
3
BAT11
0BAT12
18
19
BAT1
0BAT2
LA1 LA1
K R P BAT 4 BAT12 20 BAT2 LB1 LB1 S-AXIS OVERRUN L.S. connected to A1 part
21 0BAT3
22 BAT3 LB1 LA2
For the limit switch specification, the connection of the section 23
LB2 LB2 L-AXIS OVERRUN L.S.
24
connected to A2 part
A and B parts are changed as follows: 0BT
K R P BAT
5
6
0BAT21
BAT21
25
26
0BAT4
BAT4 LB2 LA3
0BT 7 0BAT22 27 0BAT5 LB1 LB3
K R P BAT 8 BAT22 28 BAT5 L AND U-AXIS INTERFERENCE L.S.
29 0BAT6 connected to A3 part
30 BAT6
1 31 0BAT7 LC1 LC1
2 32
1
BAT7
PG0V1
LD1 LD1 S-AXIS OVERRUN L.S connected to B1 part
3
2 PG5V1
4
3 PG0V2 LD1 LC2
5
6 4 PG5V2 LD2 LD2
7 5 PG0V3
8 6 PG5V3 LD2 LC3
7 PG0V4
8 PG5V4 LD1 LD3 L AND U-AXIS INTERFERENCE L.S.
1BC 1BC(10P×4) 9 PG0V5 connected to B3 part
No.22CN X 10 PG5V5
DX200 CN1-5 +24V
0V P
CN1-5
CN1-4
+24V
0V
-1
-3
+24V
0V
1
3
11
12
PG0V6
PG5V6
SLU-axes with Limit Switch Specification
CN1-4
13 PG0V7
+24V CN1-10 +24V -2 +24V 2 14 PG5V7
CN1-10
0V P CN1-9 0V -4 0V 4 15
CN1-9
16 No.1CN LA1 LA1
SPG+1 CN1-1 SPG+1 1CN-1 DATA+1
CN1-1
CN1-2
SPG-1 P CN1-2 SPG-1 No.16CN S P -2 DATA-1
LB1 LB1 S-AXIS OVERRUN L.S. connected to A1 part
-1 BAT1 -6 BAT
LB1 LA2
-2
-3
0BAT1
PG5V1
P -5
-4
OBT
+5V
PG S-axis L-AXIS OVERRUN L.S.
LB2 LB2
-4 PG0V1 P -9 0V
FG1 CN1-3 FG1 -10 FG1 LC1
connected to A2 part
CN1-3 LC1
OBT
BAT
LD1 LD1 S-AXIS OVERRUN L.S connected to B1 part
No.2CN LD1 LC2
CN1-6 SPG+2
SPG-2 P
CN1-6
CN1-7
SPG+2
SPG-2 No.17CN L P
2CN-1
-2
DATA+2
DATA-2 LD2 LD2 L-AXIS OVERRUN L.S.
CN1-7
-1 BAT2 -6 BAT connected to B2 part
-2
-3
0BAT2
PG5V2
P -5
-4
OBT
+5V
PG L-axis SL-axes with Limit Switch Specification
-4 PG0V2 P -9 0V
FG2 CN1-8 FG2 -10 FG2
CN1-8
OBT LA1 LA1
BAT
No.3CN
LB1 LB1 S-AXIS OVERRUN L.S. connected to A1 part
CN2-1 LC1 LC1
SPG-3 P CN2-2 SPG-3 No.18CN U P -2 DATA-3
CN2-2
-1 BAT3 -6 BAT LD1 LD1 S-AXIS OVERRUN L.S connected to B1 part
-2 0BAT3 P -5 OBT PG U-axis
-3 PG5V3 -4 +5V
CN2-3 FG3 CN2-3 FG3

-4 PG0V3 P -9
-10
0V
FG3
S-axis with Limit Switch Specification
OBT
BAT
No.4CN
CN2-6
SPG-4 P CN2-7 SPG-4 No.19CN R P -2 DATA-4
CN2-7
-1 BAT4 -6 BAT
-2 0BAT4 P -5 OBT PG R-axis
-3 PG5V4 -4 +5V
-4 PG0V4 P -9 0V
FG4 CN2-8 FG4 -10 FG4
CN2-8
OBT
BAT
No.5CN
CN3-1
SPG-5 P CN3-2 SPG-5 No.20CN B P -2 DATA-5
CN3-2
-1 BAT5 -6 BAT
-2
-3
0BAT5
PG5V5
P -5
-4
OBT
+5V
PG B-axis
-4 PG0V5 P -9 0V
CN3-3 FG5 CN3-3 FG5 -10 FG5
OBT
BAT
No.6CN
CN3-6 No.21CN T
SPG-6 P CN3-7 SPG-6 P -2 DATA-6
CN3-7
-1 BAT6 -6 BAT
-2
-3
0BAT6
PG5V6
P -5
-4
OBT
+5V
PG
T-axis
-4 PG0V6 P -9 0V
FG6 CN3-8 FG6 -10 FG6
CN3-8
LC1 LD1 OBT
BAT
CN4-1
CN4-1 +24V LA1 LB1 B1
P CN4-6 LB1
CN4-6
LB1
LB2
LA2
LB2 A2
LD1 LC2
CN4-2
A1 LD2 LD2 B2
CN4-2 SS2
SS2 LB2
P CN4-7
CN4-7 SS1 LB1
LA3
LB3 A3
LD2
LC3
LD1 LD3 B3
BC1
CN4-3
CN4-8
BC2
AL2 P
CN4-3
CN4-8
BC2 BC2
FOR LAMP (OPTIONAL)
0V CN4-10 0V
CN4-10 No.7CN(20-29)
SPG+7 CN4-4 SPG+7 1
CN4-4 SPG-7 2 SPG+7
P CN4-5 SPG-7 P
CN4-5 FG7 CN4-9 FG7 10 SPG-7
CN4-9
CN2-4 +24 P 9 0V GUN
CN2-4 P LD1 11 5V
CN2-5
CN2-5 P 12 BAT
CN2-9
CN2-9 P CN2-10 +24 15 0BAT
CN2-10 0V 0V FG7
CN3-4 No.23CN 7 E
CN3-4 5V P 5V
CN3-5 -2 0BAT7
CN3-5 0V CN3-9 0V
CN3-9 5V P 5V -1 BAT7
CN3-10
CN3-10 -4
E PG0V7
-3
PG5V7
E E E E E E E E
E BASE
S1(24-28) MANIPULATOR CASING No.8CN(24-28)
E
E
1 SP1
1 P 2 SP2
2 3
3 SP3
P 4
4 SP4
5 SP5
5 P 6
6 SP6
7 SP7
7
P 8 SP8
8
9 SP9
9
P 10
10 SP10
11
11
SP11
INTERNAL WIRE
P 12
12 SP12
13
13 SP13
14
14 SP14
15 SP15
15
16 SP16
16
17 SP17
17 18
18 SP18
19
19 SP19
20 SP20
20
21 SP21
21
22 SP22
22 23
23 SP23
AIR
FOR FIELDBUS CABLE TUBE
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Fig. 8-5(b): Internal Connection Diagram
2BC 2BC(8PX3+12PX3)
E E
E-8 MU1 E-8 MU1

E-7 MU1 E-7 MU1
MV1 E-2 MV1 No.9CN
E-2 MV1 MV1 9CN-A MU1
E-1 E-1
MW1 E-6 MW1 -B MV1
E-6
E-5 MW1 E-5 MW1 -C MW1 SM S-AXIS
-D ME1
ME1 E-4 ME1
E-4 ME1 ME1
E-3 E-3 -1 BA1
B-5 BA1 B-5 BA1 -2 BB1 YB
B-10 BB1 B-10 BB1
F-8 MU2 F-8 MU2

F-7 MU2 F-7 MU2
MV2 F-2 MV2 No.10CN
F-2 MV2 F-1 MV2 10CN-A MU2
F-1 -B MV2
MW2 F-6 MW2
F-6
F-5 MW2 F-5 MW2 -C
-D
MW2
ME2
SM L-AXIS
F-4 ME2 F-4 ME2
F-3 ME2 F-3 ME2 -1 BA2
D-8 MU3 D-8 MU3

D-7 MU3 D-7 MU3
MV3 D-4 MV3 No.11CN
D-4 MV3 D-3 MV3 11CN-A MU3
D-3 -B MV3
D-6 MW3 D-6 MW3
D-5 MW3
ME3
D-5
D-2
MW3
ME3
-C
-D
MW3
ME3
SM
U-AXIS
D-2 D-1
D-1 ME3 ME3 -1 BA3
No.12CN
A-6 MU4 A-6 MU4 12CN-A MU4
MV4 A-3 MV4 -B MV4
A-3
A-1 MW4 A-1 MW4 -C
-D
MW4
ME4
SM R-AXIS
A-5 ME4 A-5 ME4
BA4 B-2 BA4 -1 BA4
B-2 -2 YB
B-9 BB4 B-9 BB4 BB4
No.13CN
C-11 MU5 C-11 MU5 13CN-A MU5
MV5 C-9 MV5 -B MV5
C-9
C-7 MW5 C-7 MW5 -C
-D
MW5
ME5
SM
B-AXIS
C-8 ME5 C-8 ME5
B-12 BA5 B-12 BA5 -1 BA5
-2 BB5 YB
No.14CN
MU6 C-6 MU6 14CN-A MU6
C-6 -B MV6
MV6 C-4 MV6
C-4
C-2 MW6 C-2 MW6 -C
-D
MW6
ME6
SM T-AXIS
ME6 C-5 ME6
C-5
BA6 B-11 BA6 -1 BA6
B-11 -2 BB6 YB
No15CN(18-1)
E
A-11 MU7 A-11 MU7 1

MU7
A-9 MV7 A-9 MV7 2
MV7
MW7 A-2 MW7 3
A-2
ME7 A-4 ME7 4
MW7 GUN
A-4 ME7
BA7 B-8 BA7 5
B-8 BA7
BB7 B-7 BB7 6
B-7 BB7
PE
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MS165 9 Maintenance and Inspection
9.1 Inspection Schedule
9 Maintenance and Inspection
DANGER
• 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 these safety precautions may result in death or
serious injury from unexpected turning of the manipulator's arm.
WARNING
• Before maintenance or inspection, be sure to turn the main power
supply 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
• The battery pack must be connected before removing detection
connector when maintenance and inspection.
Failure to observe this caution may result in the loss of home position
data.

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 9-1 “Inspection Items” .
In table 9-1, the inspection items are categorized by three types of
operations: operations which can be performed by personnel authorized
by the user, operations to be performed by trained personnel, and
operations to be performed by service company personnel. Only
specified personnel shall perform the inspection work.
• The inspection interval depends on the total servo opera-

tion time.
• For any different or special applications, the inspection
process should be developed on an case-by-case basis.
NOTE • For axes which are used very frequently (in handling appli-
cations, etc.), it is recommended that inspections be con-
ducted at shorter intervals. Contact your YASKAWA
representative.
• To maintain the sealing performance, small quantity of oil
used may leak from the bottom part of the gas balancer.
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Table 9-1: Inspection Items (Sheet 1 of 2)
Items1) Schedule Method Operation Inspection
Charge
12000H Cycle
1000H Cycle
6000H Cycle
Personnel
Company
Specified
Licensee
Service
24000H
36000H
Daily
1 Alignment mark
• Visual Check alignment mark accordance at the home position.
Check for damage.
• • •

2 External lead
• Visual Check for damage and deterioration of leads.
• • •
3 Working area and manipulator
• Visual Clean the work area if dust or spatter is present. Check for damage and
outside cracks.
• • •
4 Motors for L- and U-axes
• Visual Check for grease leakage.2)
• • •
5 Baseplate mounting bolts
• Spanner
Wrench
Tighten loose bolts. Replace if necessary.
• • •
6 Cover mounting screws
• Screwdriver, Tighten loose bolts. Replace if necessary.
• • •
9-2
Wrench
7 S-,L-,U-axes motor connector
• Manual Check for loose connectors and tighten if necessary.
• • •
8 Connector base
• Manual Check for loose connectors.
• • •
9 Gas Balancer
• Grease Gun Replenish grease to the gas balancer link part.
See chapter 9.3.4 .
• •
• Specific tools Inspect the gas pressure in the gas balancer. Discharge, inject the gas
for maintenance See chapter 9.4
• •
10 Wire harness in manipulator
(SLU-axis wires)
• Check for conduction between the main connector of base and
intermediate connector with manually shaking the wires. Check for
• •
(RBT-axis wires) wear of protective spring.3)
HW1482308
• Replace4)
•
11 Battery pack in manipulator
• Replace the battery pack when the battery alarm occurs or the
manipulator drove for 36000H.
• •
12 S-axis speed reducer,
S-axis gear
• • Grease Gun Check for malfunction. (Replace if necessary.)
Replace grease5) (12000H cycle). See chapter 9.3.3.1 .
• •
13 L-axis speed reducer,
• •
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Table 9-1: Inspection Items (Sheet 2 of 2)
MS165
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Items1) Schedule Method Operation Inspection
Charge
12000H Cycle
1000H Cycle
6000H Cycle
Personnel
Company
Specified
Licensee
Service
24000H
36000H
Daily
14 U-axis speed reducer,
• •
15 R-axis speed reducer
• •

16 B- and T-axes speed reducer,
B- and T-axes gear
• •
17 Overhaul
• •
1 Inspection No. correspond to the numbers in fig. 9-1 “Inspection Items” .
2 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.
3 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
9-3
side for each axis from the motor. Otherwise, the home position may be lost. (Refer to chapter 9.5 “Notes for Maintenance” .)
4 Wire harness in manipulator to be replaced at 24000H inspection.
5 For the grease, refer to table 9-2 “Inspection Parts and Grease Used” .
Table 9-2: Inspection Parts and Grease Used

No. Grease Used Inspected Parts
12, 13, 14, 15, 16 Molywhite RE No. 00 Speed Reducers for all Axes R-, B-, and T-Axes gears
HW1482308
9 Alvania EP Grease 2 Balancer
The numbers in the above table correspond to the numbers in table 9-1 “Inspection Items” .
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Fig. 9-1: Inspection Items
MS165
5
1
T-AXIS
S-AXIS
1
16
15

2
6 14
1 1
9-4
10
R-AXIS B-AXIS
1
6 U-AXIS
1
L-AXIS
13
7
9
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7
2
11
4
6
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12
8
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9.2 Battery Pack Replacement

The battery packs are installed in the position shown in fig. 9-2(a) “Battery
Location (Back View)” and fig. 9-2(b) “Battery Location (Top View)” .
If a battery alarm occurs in the DX200, replace the battery in accordance
with the following procedure:
Fig. 9-2(a): Battery Location (Back View)
Plate
Plate fixing screw M4
Connector base Base
Fig. 9-2(b): Battery Location (Top View)
Battery pack
Circuit board
Fig. 9-3: Battery Connection

Battery pack
See replacing step 5. before replacement
Connector
Circuit board
See replacing step 4.
(Type: SGDR-EFBA02A)
New battery pack
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1. Turn OFF the DX200 main power supply.

2. Remove the plate fixing screws and the plate on the connector base,
then pull the battery pack out to replace it with the new one.
3. Remove the battery pack from the battery holder.
4. Connect the new battery pack to the unoccupied connector on the
board.
5. Remove the old battery pack from the circuit board.
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 to the holder.

7. Reinstall the plate.
NOTE Do not allow plate to pinch the cables when reinstalling the
plate.
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9.3 Grease Exchange
9.3 Grease Exchange
9.3.1 Notes on Grease Exchange Procedures

Make sure to follow the instructions listed below at grease exchange.
Failure to observe the following notes may result in damage to motor and
speed reducer.
• If grease is injected without removing the plug from the

grease exhaust port, the grease will leak inside a motor, or
an oil seal of a speed reducer will come off. Make sure to
remove the plug or it may result in a failure.
Also, when using a tube, the length must be 150 mm or
shorter and the inside diameter must be 6 mm or longer.
If the tube is too long, the exhaust resistance at the tube
part is increased, and the inner pressure of the grease
bath is raised. It may result in coming off of an oil seal.
• Make sure to use a grease pump to inject grease. Set the
grease injection rate to 7 g/s or less. (Air supply
pressure to the grease pump: 0.3 MPa or less (rough
standard)) If not, an oil seal of a speed reducer will come
off, and it may result in a failure.
• When using extrusion air for discharging the grease, set
air supply pressure at 0.025 MPa or less.
If not, an oil seal of a speed reducer will come off, and it
NOTE may result in a failure.
• Make sure to fill the hose on the grease inlet with grease
beforehand to prevent air from leaking into the speed
reducer.
• After injecting grease, discharge the specified amount of
grease. If insufficient, the inner pressure is raised during
the operation, and grease may leak. When discharged
too much, the speed reducer is not lubricated sufficiently
during the operation, and it may cause the early failure of
the speed reducer.
• When filling/exchanging grease, the grease may flow out
from the grease inlet or the grease exhaust port. Prepare
a container to receive the grease and a waste cloth to
wipe the grease in advance.
• After mounting a speed reducer or a motor, leave it 30
minutes or more and inject grease. If grease is filled
before the sealing bond is hardened, it may cause the
grease leakage.
WARNING
• When operating the manipulator, do not enter into the working area
of the manipulator. Injury may result if anyone enter into the
working area during operation.
CAUTION
• When using extrusion air for discharging the grease, the grease
may be vigorously discharged from the exhaust port. Perform an
operation such as using a tube at the grease exhaust port to pour
into an appropriate container.
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9.3 Grease Exchange
9.3.2 List of Necessary Items

Prepare necessary items as indicated in table 9-3 “List of Necessary
Items” . “S”, “L”, “U”, “R”, and “BT” in the table mean axes for grease
exchange to each axis, and “Casing” means R-, B-, and T-gear in a casing
for grease exchange.
Table 9-3: List of Necessary Items
Items When exchanging
the grease of each axis
S L U Casing R BT
Grease zerk A-PT1/4 
Grease zerk A-PT1/8    
Hexagon bit tool, width across flat: 5     
Hexagon bit tool, width across flat: 6 
Hexagon bit tool, width across flat: 8    
Torque wrench (Range of use: 4.9 N•m - 23 N•m)      
Torque wrench, Extension bar for hexagon bit (30 mm or longer) 
ThreeBond 1206C      
Recommended grease lubricator: Powerlube P3C by Macnaught      
Air supply (air supply pressure: 0.3 MPa or less)      
Joint and hose for grease discharging (Approx. 150 mm)      
Container for grease discharging (Checking the cubical content (cc) inside      
this container should be available.)
Regulator for grease discharging (Recommendation: ARP30-02G by SMC)      
Weight scale (Minimum display should be 1 g. Range of use: 0 g - 2,000 g)      
9.3.3 Grease Exchange
9.3.3.1 Grease Exchange for S-, L-, U-, R-, B-, and T-Axes Speed Reducer
1. Before injecting/discharging grease, the posture of the manipulator
must be set. Make the posture as indicated in fig. 9-4 “Recommended
Posture of Each Axis While Injecting” to remove the plugs of the
grease inlets and the grease exhausting ports. (Refer to fig. 9-5 “Plug
Position of S- and L-axis Speed Reducer” , fig. 9-6 “Plug Position of
U-axis Speed Reducer and R-, B-, and T-gear in a casing” , and
fig. 9-7 “Plug Position of R-, B-, and T-axis” .) If it is difficult to make
the recommended posture because of external cabling or etc., adjust
the posture as much as possible to make the position of grease inlet
located in the lower part and the position of exhaust port located in the
upper part. Thus, grease can be filled/exchanged more properly as the
recommended posture.
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9.3 Grease Exchange
Fig. 9-4: Recommended Posture of Each Axis While Injecting
At filling grease to R,B,T-axis gear in the casing

At filling grease to R-axis
At filling grease to U-axis At filling grease to B, T-axis
S-axis: Arbitrary S-axis: Arbitrary
L-axis: Arbitrary L-axis: Arbitrary
U-axis: 0 degree (U-arm, vertical to ground) U-axis: 0 degree (U-arm, vertical to ground)
R-axis: Arbitrary R-axis: 0 degree (0 pulse)
B-axis: Arbitrary B-axis: 0 degree (0 pulse)
T-axis: Arbitrary T-axis: 0 degree (0 pulse)
At filling grease to L-axis

S-axis: Arbitrary
L-axis: 0 degree (0 pulse)
U-axis: Arbitrary
R-axis: Arbitrary
B-axis: Arbitrary
T-axis: Arbitrary
At filling grease to S-axis

S-axis: Arbitrary
L-axis: Arbitrary
U-axis: Arbitrary
R-axis: Arbitrary
B-axis: Arbitrary
T-axis: Arbitr ary
Fig. 9-5: Plug Position of S- and L-axis Speed Reducer
L-axis grease exhaust port

Hexagon socket head plug PT3/8
L-axis grease inlet
S-axis grease exhaust port

S-axis grease inlet

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9.3 Grease Exchange
Fig. 9-6: Plug Position of U-axis Speed Reducer and R-, B-, and T-gear in a casing
R-, B-, T-gear inside the casing grease exhaust port

U-axis grease exhaust port

R-, B-, T-gear inside the casing grease inlet

U-axis grease inlet

Fig. 9-7: Plug Position of R-, B-, and T-axis

B-, T-axis grease exhaust port
R-axis grease exhaust port

B-, T-axis grease inlet
R-axis grease inlet
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9.3 Grease Exchange
2. Install the grease zerk to the grease inlet. (Refer to fig. 9-5 “Plug
Position of S- and L-axis Speed Reducer” , fig. 9-6 “Plug Position of
U-axis Speed Reducer and R-, B-, and T-gear in a casing” , and
fig. 9-7 “Plug Position of R-, B-, and T-axis” .) (The grease zerk is
delivered with the manipulator.)
3. Inject grease through the grease inlet using a grease gun.
– Grease type: Molywhite RE No.00
– Recommended grease lubricator: Powerlube P3C by Macnaught
– Grease injection rate: 7 g/s or less
When the grease is discharged at 2 times/s from the lubricator, set
the discharge amount as 3.5 g/time or less. (Rough standard)
– Air supply pressure of grease pump: 0.3 MPa or less
(Rough standard)
Table 9-4: Amount of Grease to Inject (as a guide only)

Grease exchanging point Amount of Grease to Inject
(as a guide only)
S-axis 4350 g
L-axis 2180 g
U-axis 2180 g
R-, B-, T-gear in the casing 2260 g
R-axis 1910 g
B-and T-axis 1130 g
4. The old grease is discharged from the grease exhaust port. At this
time, stop injection when the mixture of the old grease and the new
grease in an equal ratio is seen.
5. Discharge the specified amount of grease from the grease inlet or
grease exhaust port (Refer to table 9-5 “Amount of Grease
Discharged from Each Axis” .). In order to exhaust specified amount
of grease, receive discharged grease by a container, and then
measure the weight of discharged grease by weighing the container till
the amount reaches to the specified amount.
Use one of the following methods to discharge grease.
Discharging method 1: Extruding the grease by air injected from the
exhaust port.
– Connect the joint and the hose to the grease inlet.
– Connect the regulator to the grease exhaust port.
– Extrude the grease by injecting the air from the exhaust port.
(Extrusion air pressure: 0.025 MPa or less)
If the grease is not discharged enough by extruding air, operate the
manipulator again as shown in table 9-6 “Teaching Operation of Each
Axis” .
Discharging method 2: Sucking out the grease from the exhaust port.
– Leave the inlet open and insert the tube into the exhaust port.
– Discharge the grease by suction using the tube.
(Suction pressure: 0.025 MPa or less)
If the grease is not discharged enough by suction, operate the manipulator
again as shown in table 9-6.
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9.3 Grease Exchange
Table 9-5: Amount of Grease Discharged from Each Axis

Grease exchanging point Amount of exhausted grease
[g] [cc]
S-axis 0 [Unnecessary] 0 [Unnecessary]
L-axis 240±30 275±35 (240 to 310)
U-axis 295±40 340±45 (295 to 385)
R-, B-, T-gear in the casing 115±15 130±15 (115 to 145)
R-axis 95±10 110±15 (95 to 125)
B- and T-axis 55±5 65±10 (55 to 75)
Table 9-6: Teaching Operation of Each Axis

Grease exchanging point Operation angle Teaching
at teaching operation speed
L-axis L-axis ±45°
U-axis U-axis ±45°
R-axis ±90° Arbitrary
R-, B-, T-gear in the casing,
B-axis ±45°
R-, B- and T-axis
T-axis ±90°
6. For the point where grease is exchanged, perform a playback

operation indicated in table 9-7 “Running-in Operation of Each Axis”
for running-in the speed reducer with the grease.
At this time, in case grease is discharged during the operation, remove
the grease zerk from the grease inlet, clean and degrease the tap part
and the thread part of the plug. And then, apply ThreeBond 1206C to
the thread part of the plug to mount the plug to the grease inlet.
Tighten the plug with the tightening torque indicated in table 9-8 “Plug
Type and Tightening Torque of Each Axis” . Also, discharge the
excess grease not to increase the inner pressure of the speed reducer.
Attach a bag to receive grease such as indicated in fig. 9-8 “Grease
Receiving Bag (Rough Standard)” , and then perform the running-in
operation.
Table 9-7: Running-in Operation of Each Axis

Grease exchanging point Running-in operation
Operation angle Operation speed Timer after Operation
each operation time
S-axis S-axis ±45° MOVJ VJ= 50.00 1.0s 15 minutes
L-axis L-axis ±45° MOVJ VJ= 50.00 1.0s 15 minutes
U-axis U-axis ±45° MOVJ VJ= 50.00 1.0s 15 minutes
R-axis± 90°
R-, B-, and T-gear in the casing
B-axis± 45° MOVJ VJ= 50.00 1.0s 15 minutes
R-, B-, and T-axis
T-axis± 90°
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9.3 Grease Exchange
Table 9-8: Plug Type and Tightening Torque of Each Axis

Grease exchanging point Plug for grease inlet Plug for grease exhaust port
Plug type Tightening torque Plug type Tightening torque
S-axis PT1/4 12.0 N•m (1.2 kgf•m)
L-axis
U-axis PT3/8 23 N•m (2.34 kgf•m)
R-, B-, and T-gear in the
PT1/8 4.9 N•m (0.5 kgf•m)
casing
R-axis
PT1/8 4.9 N•m (0.5 kgf•m)
B- and T-axis
Fig. 9-8: Grease Receiving Bag (Rough Standard)
Grease receiving bag

Cut one corner to remove air.
To prevent grease from scattering from the cut corner,
cover the receiving bag with a plastic bag etc. without
being sealed.
Bond for fixing a grease receiving bag
Tube (inside dia.: 6 mm or more)
Union (inside dia.: 6 mm or more)

PT3/8 or PT1/8
7. Wipe the discharged grease using a waste cloth. After cleaning and
degreasing the tap part and the thread part of the plug, apply
ThreeBond 1206C to the thread part of the plug. Mount the plug to the
grease exhaust port, and tighten it with the tightening torque indicated
in table 9-8 “Plug Type and Tightening Torque of Each Axis” .
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9.3 Grease Exchange
9.3.4 Grease Replenishment for Gas Balancer Link Part

Fig. 9-9: Gas Balancer Link Part
Link 2 Grease exhaust port

(Hexagon socket head plug PT1/8)
Link 2 Grease inlet
Link 2 Bearing
Link 1 Bearing
Link 1 Grease inlet

Link 1 Grease exhaust port

1. Remove the plugs from the grease inlets and from the grease exhaust
ports of the link and .
2. Inject grease through the grease inlets of the link and using a
grease gun.
– Grease type: Alvania EP Grease 2
– Amount of grease: to the link : 8 cc
(30 cc for 1st supply)
to the link : 8 cc
(16 cc for 1st supply)
3. Wipe the discharged grease with a cloth at the grease exhaust ports
and reinstall the plugs to the exhaust ports of the link and . Apply
ThreeBond 1206C to the thread part of the plugs, and tighten the plugs
with a tightening torque of 4.9 N•m (0.5 kgf•m).
4. Reinstall the plugs to the grease inlets of the link and . Apply
ThreeBond 1206C to the thread part of the plugs, and tighten the plugs
with a tightening torque of 4.9 N•m (0.5 kgf•m.)
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9.4 Gas Maintenance Procedure in the Gas Balancer
9.4.1 Notes on Gas Maintenance Procedure in the Gas Balancer

Be sure to read the following precautions thoroughly and understand the
contents before performing gas inspections or discharging/injecting gas.
Failure to observe this may cause malfunctions of the gas balancer or
occurrence of accidents or injury.
DANGER
• This gas balancer uses high-pressure nitrogen gas.
• Do not inject other gas than nitrogen gas to this gas balancer.
Failure to observe this may cause malfunctions of the gas balancer
or occurrence of accidents or injury.
• There is a possibility of suffocation accident in the high-density
nitrogen gas environment. For this reason, enough ventilation is
required when performing the operations.
• Before inspecting the gas pressure in the gas balancer or discharg-
ing/filling the gas from/into the gas balancer, confirm that the L-axis
motor brake is appropriately functioning and L-axis is firmly fixed so
that it will not rotate.
Failure to observe this may cause very dangerous situation due to
releasing of the L-axis motor brake. Because the L-axis without
retaining force leads the L-arm to rotate by the lengthened or short-
ened gas balancer.
CAUTION
• When handling high-pressure gas, sufficient caution and observing
of the related laws and local government regulations are required.
• For gas filling devices, contact your YASKAWA service
representative.
NOTE To maintain the sealing performance, small quantity of oil

used may leak from the bottom part of the gas balancer.
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9.4.2 Gas Pressure Inspection
MANDATORY
• Perform the gas pressure inspection every 6000H.
• Operation of the manipulator with inadequate gas pressure gas
balancer may cause failure or breakage.
9.4.2.1 Adequate Gas Pressure

Adequate nitrogen gas pressure in the gas balancer varies depending on
the temperature. Refer to table 9-9 “Adequate Gas Pressure per Gas
Balancer Surface Temperature” .
Table 9-9: Adequate Gas Pressure per Gas Balancer Surface Temperature
Gas balancer
surface -10° -5° 0° 5° 10° 15° 20° 25° 30° 35° 40° 45° 50° 55° 60°
temperature
Adequate gas
pressure 10.5 10.8 11.1 11.4 11.6 11.9 12.2 12.4 12.7 13.0 13.2 13.5 13.8 14.1 14.4
(MPa)
Fig. 9-10: Adequate Gas Pressure per Gas Balancer Surface Temperature
13.2
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9.4.2.2 Necessary Device
Prepare following devices when checking the gas pressure.

• Gas filling device: HW1485204
The device includes:
Digital pressure gauge: GC64-173
Quick connector: 10-358-6297
• Thermometer (for measuring the gas balancer surface)
9.4.2.3 Inspection Procedures
DANGER
Before inspecting the gas pressure in the gas balancer or discharging/
filling the gas from/into the gas balancer, confirm that the L-axis motor
brake is appropriately functioning and L-axis is firmly fixed so that it will
not rotate. Failure to observe this may cause very dangerous situation
due to releasing of the L-axis motor brake. Because the L-axis without
retaining force leads the L-arm to rotate by the lengthened or shortened
gas balancer.
1. Move the manipulator to the home position and turn OFF the power
supply of the DX200.
2. Remove the cover and the hexagon socket head screw plug M6 with
flange, which are mounted to the gas inlet, and insert the quick
connector.
3. Connect the gas filling device to the quick connector after confirming
that the blowdown valve, needle valve, and gate valve of the gas filling
device are firmly closed.
4. Check the temperature of the gas balancer surface.
5. Slowly open the needle valve of the gas filling device, and then check
that the pressure indicated on the digital pressure gauge is satisfying
the value shown in table 9-9 “Adequate Gas Pressure per Gas
Balancer Surface Temperature” . Depending on the value, procedures
after this are subject to change.
Case 1: When the value is exceeding the adequate value
→ Discharge the gas till the value satisfies the adequate
value.
(Refer to chapter 9.4.3 “Gas Discharging Procedure” .)
Case 2: When the value is lower than the adequate value by
0.5 MPa or more.
→ Inject the gas till the value satisfies the adequate
value.
(Refer to chapter 9.4.4 “Gas Injecting Procedure” .)
Other than Case 1 and 2 :
→ Proceed to Step 6.
6. Close the needle valve of the gas filling device, and then remove the
gas filling device from the quick connector.
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7. Remove the quick connector and mount the cover, then tighten the
hexagon socket head screw plug M6 with flange by using a tightening
torque of 4.9 N•m (0.5 kgf•m).
8. Mount the cover and tighten the hexagon socket head cap screws M4
(length: 6mm) with a tightening torque of 2.8 N•m (0.29 kgf•m.)
9. Turn ON the power supply of the DX200.
Fig. 9-11: Gas in Gas Balancer Pressure Inspection
A part
Gas inlet/gas exhaust port
Hexagon socket head cap screw M4 (length: 6 mm)(2 screws)

Conical spring washer 2L-4 (2 washers)
Cover㸦HW1405134-1㸧
Surface temperature measuring point

Hexagon socket head screw plug M6
㸦㸧
Measure on the surface with flange
of the gas balancer
after removing the cover.
A part
Enlarged figure
9.4.3 Gas Discharging Procedure
MANDATORY
• Discharge all gas from the gas balancer when in the following
cases.
– When dismounting the gas balancer from the manipulator.
– When air-flight the gas balancer.
(It is treated as a hazardous material when the gas balancer is
air-flight with gas filled.)
9.4.3.1 Necessary Devices

Prepare following devices when discharging gas
Valve of the service gauge: SS-1KS4
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9.4.3.2 Gas Discharging Procedures
DANGER
Before discharging/filling the gas from/into the gas balancer, confirm
that the L-axis motor brake is appropriately functioning and L-axis is
firmly fixed so that it will not rotate. Failure to observe this may cause
very dangerous situation due to releasing of the L-axis motor brake.
Because the L-axis without retaining force leads the L-arm to rotate by
the lengthened or shortened gas balancer.
MANDATORY
• When discharging the gas, the blowdown valve must not be fully
opened. Take time and discharge gas little by little. If the
blowdown valve is fully opened with high internal pressure, the non-
return valve in the gas balancer can be damaged.
 When Discharging All Gas

connector.
4. Slowly open the needle valve.
5. Discharge gas a small amount at a time by slowly releasing the
blowdown valve.
6. Close the needle valve and blowdown valve, and then remove the gas
filling device from the quick connector.
 When Discharging Gas for Adjusting Pressure

connector.
5. Slowly open the needle valve.
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6. Discharge gas by slowly releasing the blowdown valve until the gas
pressure is the value shown in table 9-9 “Adequate Gas Pressure per
Gas Balancer Surface Temperature” .
After discharging/injecting gas, wait for a few minutes to

NOTE stabilize the gas pressure, and then measure the gas pres-
sure.
7. Close the needle valve and blowdown valve, and then remove the gas
filling device from the quick connector.
Fig. 9-12: Gas Discharging Operation
A part


㸦㸧
of the gas balancer
A part
Enlarged figure
9.4.4 Gas Injecting Procedure
9.4.4.1 Necessary Devices

Prepare following devices when injecting gas
• Nitrogen gas cylinder
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9.4.4.2 Gas Injecting Procedures
DANGER
Before discharging/filling the gas from/into the gas balancer, confirm
that the L-axis motor brake is appropriately functioning and L-axis is
firmly fixed so that it will not rotate. Failure to observe this may cause
very dangerous situation due to releasing of the L-axis motor brake.
Because the L-axis without retaining force leads the L-arm to rotate by
the lengthened or shortened gas balancer.
2. Remove the cover and the hexagon socket head screw plug with
connector.
5. Connect the nitrogen gas cylinder to the gas filling device.
6. Release the valve of the nitrogen gas cylinder, and then set the gas
pressure slightly higher than the adequate pressure shown in table 9-9
“Adequate Gas Pressure per Gas Balancer Surface Temperature” by
rotating the regulator handle of the gas filling device.
7. Slowly open the needle valve of the gas filling device.
8. Release the gate valve of the gas filling device to inject gas until the
gas pressure indicated by the digital pressure gauge is slightly higher
than the adequate pressure shown in table 9-9.
9. Close the gate valve of the gas filling device, wait for the gas pressure
in the gas balancer to stabilize, and then confirm that the gas pressure
is the adequate pressure shown in table 9-9 “Adequate Gas Pressure
per Gas Balancer Surface Temperature” .
If the pressure is higher than the adequate pressure, discharge the
gas gradually and stabilize the gas pressure, then confirm that the gas
pressure finally reached the adequate value.
After discharging/injecting gas, wait for a few minutes to

NOTE stabilize the gas pressure, and then measure the gas pres-
sure.
10. Close needle valve of the gas filling device and the valve of the
nitrogen gas cylinder.
11. Disconnect the gas filling device from the quick connector.
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14. Release the blowdown valve of the gas filling device and regulator,
and then discharge the gas in the hose.
15. Disconnect the gas filling device from the nitrogen gas cylinder.
Fig. 9-13: Gas Injecting Operation
A part


㸦㸧
of the gas balancer
A part
Enlarged figure
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9.5 Notes for Maintenance
When performing maintenance such as replacement of a

wire harness in the manipulator, the encoder connector may
be necessary to be removed. In this case, be sure to con-
nect the battery pack to the battery backup connector
before removing the encoder connector.
NOTE
Removing the encoder connector without connecting the
battery pack leads to disappearance of the encoder
absolute data.
For the battery pack connection, refer to fig. 9-14 “Battery
Pack Connection” .
9.5.1 Battery Pack Connection

The connectors (crimped contact-pin) for the battery backup are installed
at the end point of the motors (BAT and OBT are marked). Connect the
battery packs according to the following procedure.
1. Removed the cap attached to the battery backup connector of the
motors.
2. Connect the battery packs (HW9470932-A) with the battery backup
connectors (BAT and OBT are marked) located at the end point of the
cables for the encoder. (Under this condition, remove the encoder
connector and carry out the maintenance checks).
3. Confirm all connectors connected after the maintenance check, and
remove the battery packs. Install the caps attached to the battery
backup connectors of the motors.
NOTE Do not remove the battery pack in the connector base.
9-23 HW1482308
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Fig. 9-14: Battery Pack Connection

Motor
Motor power connector

Connector for the encoder
0BT b a 0BT*
BAT a b BAT*
Battery Pack: HW9470932-A
Connector for the battery backup

a:Insertion-type pin terminal (Pin)
b:Insertion-type pin terminal (Socket)
9-24 HW1482308
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MS165 10 Recommended Spare Parts
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-MS165. Product
performance cannot 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 YAS-

KAWA representative.
Table 10-1: Spare Parts for the YR-MS165/MH180-A00 (Sheet 1 of 2)

Rank Part Name Type Manufacturer Qty Qty Remarks
sNo. per
Unit
A 1 Grease Molywhite RE No. 00 YASKAWA Electric 16 kg - For all axes
Corporation speed reducers
and wrist units
A 2 Grease Alvania EP Grease 2 Showa Oil Co.,Ltd. 16 kg - For balancer joint
part
A 3 Liquid Gasket Three Bond 1206C Three Bond Co., Ltd. 1 1
A 4 Sealing Bond for Locktite 518 Henkel Japan Ltd. 1 -
Flange
A 5 Battery Pack HW0470360-A YASKAWA Electric 1 1
Corporation
A 6 Battery Pack HW9470932-A YASKAWA Electric 6 - For wire harness
Corporation in manipulator
replacing
B 7 Replacement Kit Y005C- YASKAWA Electric 1 1
for S-Axis Speed MSMH180A00S Corporation
Reducer
for L-Axis Speed MSMH180A00L Corporation
Reducer
for U-Axis Speed MSMH180A00U Corporation
Reducer
for R-Axis Speed MSMH180A00R Corporation
Reducer
for B-Axis Speed MSMH180A00B Corporation
Reducer
for T-Axis Speed MSMH180A00T Corporation
Reducer
B 13 Gas Balancer HW1382567-A YASKAWA Electric 1 1
Corporation
10-1 HW1482308
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MS165 10 Recommended Spare Parts
Table 10-1: Spare Parts for the YR-MS165/MH180-A00 (Sheet 2 of 2)

Rank Part Name Type Manufacturer Qty Qty Remarks
sNo. per
Unit
B 14 Wrist Unit HW1171565-A YASKAWA Electric 1 1
Corporation
C 15 AC Servo Motor SGMRV-37ANA- YASKAWA Electric 1 3
for S-, L-, and YR1* Corporation
U-Axes HW0388670-A
C 16 AC Servo Motor SGMRV-13ANA- YASKAWA Electric 1 3
for R-, B-and T- YR1* Corporation
Axes HW0388933-A
C 17 Internal Wire HW1171456-A YASKAWA Electric 1 1
Harness Corporation
C 18 Connector Base HW1371448-A YASKAWA Electric 1 1
Set Corporation
C 19 Limit Switch for HW1470807-A YASKAWA Electric 1 1 Lead terminal
S-axis Corporation treatment
completion
C 20 Limit Switch for HW1470430-B YASKAWA Electric 1 1 Lead terminal
L-axis Corporation treatment
completion
C 21 Limit Switch for HW1470430-C YASKAWA Electric 1 1 Lead terminal
U-axis Corporation treatment
completion
C 22 Circuit Board SGDR-EFBA02A YASKAWA Electric 1 1
Corporation
10-2 HW1482308
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MS165 11 Parts List
11.1 S-Axis Unit
11 Parts List
11.1 S-Axis Unit

Fig. 11-1: S-Axis Unit
1031
1012 1032
1003 1002
1018
1019
1027
1028
1001 1046
1004
1005
1013
1006
1016
1030 1024
1029 1025
1015
1045
1022
1023
1009
1020
1034 1021
1033
1011 1008
1017
1010
1047 1045 1041

1026
1043 1044
1042
1007
1038
1039
1014
1036
1035 1037
1040
11-1 HW1482308
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MS165 11 Parts List

11.1 S-Axis Unit
Table 11-1: S-Axis Unit

No. DWG No. Name Pcs
1001 HW0388208-B Speed reducer 1
1002 SGMRV-37ANA-YR1* Motor 1
1003 TC12015014 Oil seal 1
1004 STW-50 Retaining ring C-type 1
1005 6310 Bearing 1
1006 HW1303369-1 Gear 1
1007 HW1100520-1 Base 1
1008 HW1100521-1 S head 1
1009 HW1303370-1 Pipe 1
1010 HW9404863-1 Stopper 1
1011 HW9404486-1 Shaft 1
1012 MSTH12-30 Pin 1
1013 MSTH12-30 Pin 2
1014 KQ2L10-01S Union 1
1015 PT3/8 (STAINLESS) Hexagon socket head plug 1
1016 G415 O ring 1
1017 G130 O ring 1
1018 M12X50 Hexagon socket head cap screw 16
1019 SW2H-12 Conical spring washer 16
1021 2L-8 Conical spring washer 1
1025 GT-SH-16 Washer 12
1026 EZ5002A0 Cap 1
1027 HW1303371-1 Spacer 1
1028 HW1404226-1 Fly wheel 1
1032 2H-12 Conical spring washer 4
1033 M6X12 (TRIVALENT Cross head APS bolt 5
CHROMATE)
1034 HW1404239-1 Cover 1
1035 HW1404229-1 Cover 1
1038 HW1404228-1 Cover 1
1039 M6X12 (TRIVALENT Cross head APS bolt 6
CHROMATE)
1040 M6 (STAINLESS) Washer 2
1041 HW1405450-1 Stopper 1
1044 HW0402104-1 Pin 1
1045 HW1405853-1 Pipe 2
1046 M6X30 GT-SA bolt 2
1047 HW1405024-1 Gasket 1
11-2 HW1482308
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MS165 11 Parts List
11.2 L-Axis Unit
11.2 L-Axis Unit

Fig. 11-2: L-Axis Unit
2062
2061 2078
2053 2022
2007 2004
2016
2028 2015 2045
2011
2010 2028
2008 2028 2046
2079 2047
2078
2009 2054
2026
2026 2025 2017 2001
2025
2026 2026
2025 2025 2006
2026
2078
2025
2042
2068
2067
2069 2066
2044
2077
2076
2064
2063 2034
2028
2043 2033
2056
2057 2023
2058 2027 2002
2059
2005
1008
2060
2003
2031
2032
2038
2072 2029
2030
2025
2078
2026
2071
2021
2070 2022
2026 2007
2025 2018
2008 2028
2079 2028
2011
2010 2062
2075
2053 2061
2028
2009 2016
2074
2073 2026
2025
11-3 HW1482308
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MS165 11 Parts List

11.2 L-Axis Unit
Table 11-2: L-Axis Unit (Sheet 1 of 2)

2001 HW1382455-C Speed reducer 1
2003 HW9482447-A Oil seal 1
2004 HW1100591-1 L-arm 1
2005 HW1304057-1 Gear 1
2006 AS568-275 O ring 1
2007 VB75956 Oil seal 2
2008 VB60787 Oil seal 2
2009 22212EAE4 Bearing 2
2010 G105 O ring 2
2015 HW1305071-1 Shaft 1
2016 HW1303707-1 Clevis 2
2017 HW1304162-1 Spacer 1
2018 HW1305071-2 Shaft 1
2021 HW1405133-1 Spacer 1
2022 HW1482236-A OILES bearing 2
2038 HW1304368-1 Cover 1
2042 HW1303711-A Support 1
2043 HW1382567-A Balancer 1
2044 HW1404713-1 Cover 1
2045 HW1404712-1 Cover 1
2053 M6X10 Flush screw 4
2054 HW1304161-1 Spacer 1
2056 HW1303630-1 Shaft 1
2057 HW0408806-2 Washer 1
2058 HW0483320-C Bolt 1
2059 HW1404554-1 Shaft 1
2060 ISTW10 Retaining ring 1
2063 SLH-M6X12 Low head socket head cap screw 4
2066 HW1405134-1 Cover 1
11-4 HW1482308
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MS165 11 Parts List
11.2 L-Axis Unit
Table 11-2: L-Axis Unit (Sheet 2 of 2)

2069 HW1304369-A Cover 1
2072 M6 Washer 3
2075 HW1406698-1 Cover 1
2078 MSTH6-20 Pin 4
2079 HW1406482-1 B holder 2
1008 HW1100521-1 S head 1
11-5 HW1482308
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MS165 11 Parts List

11.3 URBT-Axes Unit
11.3 URBT-Axes Unit

Fig. 11-3: URBT-Axes Unit
T-axis 3010
R-axis 3010
3027
3027
3003 3007
3011
3011 3009 3031
3009 3029
3029 3030
3001
3028 3008
3008 3005
3004
B-axis 3010 3002
3013
3014
3027
3012
3006 3015
3011
3009
3029 4016
3014
3008 4001
3026
3009
3014 3034
3033
3032
3035
3036
3037
3023
3025
3016
3024
2004
3020
3019
3022
3021
3018
3017
3032
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MS165 11 Parts List
11.3 URBT-Axes Unit
Table 11-3: URBT-Axes Unit

3001 HW0402391-1 Collar 1
3002 HW0402406-1 Collar 1
3003 HW1303889-1 Gear 1
3004 ISTW-36 Retaining ring 1
3005 HW0402390-1 Collar 1
3006 HW1303377-1 Gear 1
3007 HW1303378-1 Gear 1
3012 HW1100592-1 Casing 1
3013 HW9482447-A Oil seal 1
3016 HW0388209-F Speed reducer 1
3018 SW2H-12 Conical spring washer 16
3023 HW0481083-A Bolt 1
3024 ISTW-12 Retaining ring 1
3025 HW1303890-1 Gear 1
3026 G270 O ring 1
3027 Y507212.5 Oil seal 3
3028 TAFI405520 Bearing 1
3029 HW0401506-1 Plate 3
3030 IRTW-55 Retaining ring 1
3033 HW1404759-1 Cover 1
3035 HW9482306-E Shaft 1
3036 HW9481343-A Shaft 1
3037 HW0408806-1 Washer 1
2004 HW1100591-1 L-arm 1
4001 HW1100593-1 U-arm 1
4016 HW0100173-2 Housing 1
11-7 HW1482308
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MS165 11 Parts List

11.4 U-Arm Unit
11.4 U-Arm Unit

Fig. 11-4: U-Arm Unit
3012
4024
4021 4025
4022
4002
4019 4023
4027
4035
4027
4016
4012
4008 4030
4018
4017
4010 4006
4030 4007
4020 4014
4033 4011
4013
4032
4031
4005
4001
4003
4034 4004
4009
4029
4028
4036
4026
11-8 HW1482308
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MS165 11 Parts List
11.4 U-Arm Unit
Table 11-4: U-Arm Unit

4001 HW1100593-1 U-arm 1
4002 HW0401508-1 Plate 1
4003 6810DDU Bearing 1
4004 WR50 Retaining ring 1
4005 AC2847F3*NOK* Oil seal 1
4006 NK25/20R Needle bearing 1
4007 WR20 Circlip 1
4008 LRT202526 Bearing 1
4009 HW1382917-A Speed reducer 1
4010 HR32017XJ Bearing 1
4011 AC3842-F1-FKM Oil seal 1
4012 HW1303780-1 Shaft 1
4013 HW0302261-A Shaft 1
4014 HW0302262-B Shaft C 1
4016 HW0100173-2 Housing 1
4018 HW1303381-1 Gear 1
4019 HW0401505-1 B nut 1
4020 HW0303951-1 Gear 1
4023 M4X6 Hexagon socket set screw 1
4033 GS210 O ring 1
4034 MSTM8-20 Pin 1
4035 HW0303948-1 Gear 1
4036 MSTH6-15 Pin 1
3012 HW1100592-1 Casing 1
11-9 HW1482308
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MS165 11 Parts List

11.5 Wrist Unit
11.5 Wrist Unit

Fig. 11-5: Wrist Unit
4013
4012
5014 5013
5013
5009
5012 5068
5010 5018
5015 5037 5042
5011 5088
5001 5025
5073 5026 5030
5032
5024 5023
5028
5008 5061 5033 5038
5021 5027 5032
5080 5023
5076 5029 5033
5075 5020 5031
5003 5019 5074 5023
5002 5022
5078 5036
5038
5079
5057
5077 5023
5089
5086 5085
5084 5043
5087 5086 5050
5095 5042
5017 5004
5005 5018 5034 5094
5035 5047
5090
5065 5091 5042
5016 5044
5039 5046
5093 5045
5092
5007
5006
5041
5040
5042
11-10 HW1482308
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MS165 11 Parts List
11.5 Wrist Unit
Table 11-5: Wrist Unit (Sheet 1 of 2)

5001 HW1100595-1 Wrist base 1
5004 HW1100594-1 Wrist 1
5005 HW9380961-G Speed reducer 1
5008 G110 O ring 1
5009 6908DB Bearing 1
5010 HW0401511-1 B holder 1
5011 HW0401509-1 Housing 1
5012 HW0401510-1 B nut 1
5015 6909 Bearing 1
5016 ARP568-263 O ring 1
5017 6009 Bearing 1
5019 HW1303384-1 Gear 1
5020 HW0301223-1 Gear 1
5021 HW9481236-A Bearing 1
5022 HW1404234-1 Cover 1
5024 6911 Bearing 1
5025 AE3290E3 Oil seal 1
5026 AR80 Circlip 1
5027 S60 O ring 1
5028 HW9403618-1 Housing 1
5030 HW0301224-1 Gear 1
5031 HW0301225-1 Gear 1
5032 HW0401514-1 B nut 2
5033 M5X7 Magic screw 4
5036 HW9403617-1 Housing 1
5037 HW0200615-1 Cover 1
5039 HW0300889-1 Cover 1
5043 HW0301227-1 Gear 1
5044 HW0389174-C Speed reducer 1
11-11 HW1482308
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MS165 11 Parts List

11.5 Wrist Unit
Table 11-5: Wrist Unit (Sheet 2 of 2)

5046 GT-SH M14 Conical spring washer 4
5047 HW1303903-1 Flange 1
5050 HW0406766-* Shim 1
5057 HW9403621-* Shim 1
5061 HW9403622-* Shim 1
5065 HW0401517-* Shim 1
5068 HW0401516-* Shim 1
5074 HW9405444-1 B nut 1
5075 HW9403610-1 B cover 1
5076 *HW1404864-1*G Housing 1
5080 HW9403623-* Shim 1
5087 HW0301231-1 Gear 1
5088 HW0301230-1 Gear 1
5089 HW0301226-1 Gear 1
5094 HW9482951-A Packing 1
5095 HW1405841-1 Collar 1
4012 HW1303780-1 Shaft 1
4013 HW0302261-A Shaft 1
11-12 HW1482308
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MOTOMAN-MS165
INSTRUCTIONS
HEAD OFFICE
2-1 Kurosakishiroishi, Yahatanishi-ku, Kitakyushu 806-0004, Japan
Phone +81-93-645-7703 Fax +81-93-645-7802
YASKAWA America Inc. (Motoman Robotics Division)

100 Automation Way, Miamisburg, OH 45342, U.S.A.
Phone +1-937-847-6200 Fax +1-937-847-6277
YASKAWA Europe GmbH Robotics Divsion )

Yaskawastrasse 1, 85391 Allershausen, Germany
Phone +49-8166-90-100 Fax +49-8166-90-103
YASKAWA Nordic AB
Verkstadsgatan 2, Box 504 ,SE-385 25 Torsas, Sweden
Phone +46-480-417-800 Fax +46-486-414-10
YASKAWA Electric (China) Co., Ltd.

22F, One Corporate Avenue, No.222, Hubin Road, Huangpu District, Shanghai 200021, China
Phone +86-21-5385-2200 Fax 㸩86-21-5385-3299
YASKAWA SHOUGANG ROBOT Co. Ltd.
No7 Yongchang North Road, Beijing E&T Development AreaChina 100176
Phone +86-10-6788-2858 Fax +86-10-6788-2878
YASKAWA India Private Ltd. (Robotics Division)

#426, Udyog Vihar, Phase- IV,Gurgaon, Haryana, India
Phone +91-124-475-8500 Fax +91-124-475-8542
YASKAWA Electric Korea Corporation

35F, Three IFC, 10 Gukjegeumyung-ro, Yeongdeungpo-gu, Seoul, Korea 07326
Phone +82-2-784-7844 Fax +82-2-784-8495
YASKAWA Electric Taiwan Corporation

12F, No.207, Sec. 3, Beishin Rd., Shindian District, New Taipei City 23143, Taiwan
Phone +886-2-8913-1333 Fax +886-2-8913-1513
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.

59,1st-5th Floor, Flourish Building, Soi Ratchadapisek 18,Ratchadapisek Road,
Huaykwang, Bangkok 10310, THAILAND
Phone +66-2-017-0099 Fax +66-2-017-0199
PT. YASKAWA Electric Indonesia

Secure Building-Gedung B Lantai Dasar & Lantai 1 JI. Raya Protokol Halim Perdanakusuma,
Jakarta 13610, Indonesia
Phone +62-21-2982-6470 Fax +62-21-2982-6741
Specifications are subject to change without notice

for ongoing product modifications and improvements.
MANUAL NO.
HW1482308 10
100 of 100

Motomanms 165

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MOTOMAN-MS165

Part Number: 167109-1CD

Copyright © 2018, 2017, 2016, 2015 Yaskawa America, Inc.

Terms of Use and Copyright Notice

Printed in the United States of America

First Printing, 2018

Yaskawa America, Inc.

• This instruction manual is intended to explain mainly on the

Notes for Safe Operation

Indicates an imminent hazardous

Indicates a potentially hazardous

Indicates a potentially hazardous

Always be sure to follow explicitly

Must never be performed.

Even items described as “CAUTION” may result in a serious accident in

To ensure safe and efficient operation at all times, be sure

• Observe the following precautions when performing teaching

• Perform the following inspection procedures prior to conducting

Definition of Terms Used Often in This Manual

Description of the Operation Procedure

Explanation of Warning Labels

Nameplate: WARNING Label A:

PAYLOAD MASS Moving parts

Mechanical Safety Devices

Programming, Operation, and Maintenance Safety

Summary of Warning Information

Customer Support Information

When using e-mail to contact Yaskawa Customer Support, please provide

Please use e-mail for routine inquiries only. If you have an

• Primary Application ___________________________

• Software Version Access this information on the

• Robot Serial Number Located on the robot data plate

• Robot Sales Order Number Located on the DX200 controller

1 Product Confirmation ...................................................................................................................... 1-1

1.1 Contents Confirmation ....................................................................................................... 1-1

1.2 Order Number Confirmation .............................................................................................. 1-2

2.1 Transport Method .............................................................................................................. 2-2

2.1.1 Using a Crane....................................................................................................... 2-2

2.2 Shipping Bolts and Brackets.............................................................................................. 2-3

2.3 Cushioning Material for Transport ..................................................................................... 2-3

3.1 Safeguarding Installation ................................................................................................... 3-2

3.2 Mounting Procedures for Manipulator Base ...................................................................... 3-2

3.2.1 Mounting Example................................................................................................ 3-4

3.3 Location ............................................................................................................................. 3-5

4.1 Grounding .......................................................................................................................... 4-1

4.2 Cable Connection .............................................................................................................. 4-2

4.2.1 Connection to the Manipulator.............................................................................. 4-2

4.2.2 Connection to the DX200 ..................................................................................... 4-2

5 Basic Specifications ........................................................................................................................ 5-1

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

5.5.1 Stop Category 0: Stopping Angles and Times...................................................... 5-4

5.5.2 Stop Category 1: Stopping Angles and Times...................................................... 5-7

5.6 Alterable Operating Range .............................................................................................. 5-10

5.6.1 Components for Altering Operating Range......................................................... 5-11

5.6.2 Notes on the Mechanical Stopper Installation .................................................... 5-12

5.6.3 Adjustment to the Pulse Limitation of S-Axis ...................................................... 5-12

6.1 Allowable Wrist Load ......................................................................................................... 6-1

6.2 Wrist Flange....................................................................................................................... 6-3

7 System Application.......................................................................................................................... 7-1

7.1 Peripheral Equipment Mounts............................................................................................ 7-1