motoman-es165d instructions · 2018-12-10 · mechanical part of the motoman-es165d for the...

MANUAL NO.

9HW0485249

Part Number: 155976-1CDRevision: 6

MOTOMAN-ES165DINSTRUCTIONS

TYPE:YR-ES0165D-A00 (STANDARD SPECIFICATION)YR-ES0165D-A01 (SLU-AXES WITH LIMIT SWITCHES)

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

MOTOMAN INSTRUCTIONS

MOTOVAN-ES165D INSTRUCTIONSDX100 INSTRUCTIONSDX100 OPERATOR’S MANUALDX100 MAINTENANCE MANUAL

The DX100 operator’s manual above corresponds to specific usage. Be sure to use the appropriate manual.

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Copyright © 2017, 2013 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, 2016

Yaskawa America, Inc. Motoman Robotics Division 100 Automation Way Miamisburg, OH 45342 Phone: 937-847-6200

www.motoman.com

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MANDATORY

• This instruction manual is intended to explain mainly on the mechanical part of the MOTOMAN-ES165D 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 DX100 Instructions. To ensure correct and safe operation, carefully read the DX100 Instructions before reading this manual.

CAUTION

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

• The drawings and photos in this manual are representative examples and differences may exist between them and the delivered product.

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

• If your copy of the manual is damaged or lost, contact a YASKAWA 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 Association900 Victors WayP.O. Box 3724

Ann Arbor, Michigan 48106TEL: (734) 994-6088FAX: (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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ES165D Notes for Safe Operation

Notes for Safe OperationRead this manual carefully before installation, operation, maintenance, or inspection of the MOTOMAN-ES165D.

In this manual, the Notes for Safe Operation are classified as “DANGER”, “WARNING”, “CAUTION”, “MANDATORY”, or “PROHIBITED”.

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

At any rate, be sure to follow these important items.

DANGERIndicates an imminent hazardous situation which, if not avoided, could result in death or serious injury to personnel.

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

CAUTIONIndicates 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.

MANDATORY Always be sure to follow explicitly the items listed under this heading.

PROHIBITED Must never be performed.

NOTETo 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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Notes for Safe Operation

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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 DX100 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.

Figure 1: 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.

Figure 2: Release of Emergency Stop

TURN

• 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 DX100.

– 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.

The emergency stop buttons are located on the right of front door of the DX100 and the programming pendant.

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ES165D Definition of Terms Used In this Manual

Definition of Terms Used In this ManualThe MOTOMAN is the YASKAWA industrial robot product.

The MOTOMAN usually consists of the manipulator, the controller, the programming pendant, and the manipulator cables.

In this manual, the equipment is designated as follows:

Description of the Operation ProcedureIn 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 TrademarkIn 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.

CAUTION

• 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 DX100 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 DX100 Instructions before operating the manipulator:

Equipment Manual Designation

DX100 controller DX100

DX100 programming pendant Programming pendant

Cable between the manipulator and the controller

Manipulator cable

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Explanation of Warning Labels

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Explanation of Warning LabelsThe 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.

Figure 3: Warning Label Locations

WARNING Label B

Nameplate

WARNING Label A

WARNING Label A WARNING Label B

WARNINGDo not enterrobot work area.

WARNINGMoving partsmay causeinjury

Nameplate:

WARNING Label B:

WARNING Label A:

MADE IN JAPAN

YASKAWA ELECTRIC CORPORATION

Kitakyushu 806-0004 Japan2-1 Kurosakishiroishi, Yahatanishi-ku,

SERIAL NO.

PAYLOADkg

TYPE

MASS

DATEORDER NO.kg

MOTOMAN-MODEL

NJ3878

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ES165D Safeguarding Tips

Safeguarding TipsAll 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 DevicesThe 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

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Programming, Operation, and Maintenance SafetyAll 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 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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ES165D Maintenance Safety

Maintenance SafetyTurn 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 InformationThis 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 Motoman Customer Support.

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Customer Support Information

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Customer Support InformationIf you need assistance with any aspect of your ES165D system, please contact YASKAWA Customer Support at the following 24-hour telephone number:

For routine technical inquiries, you can also contact YASKAWA Customer Support at the following e-mail address:

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 have the following information ready before you call Customer Support:

[email protected]

NOTEPlease 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.

• System ES165D

• Robots ___________________________

• Primary Application ___________________________

• Controller DX100

• 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 DX100 controller data plate

(937) 847-3200

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ES165D Table of 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 .............................................................................................................. 2-1

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

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

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

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 DX100 ..................................................................................... 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 Alterable Operating Range ................................................................................................ 5-4

5.5.1 Components for Altering Operating Range .......................................................... 5-5

5.5.2 Notes on the Mechanical Stopper Installation ...................................................... 5-6

5.5.3 Adjustment to the Pulse Limitation of S-Axis........................................................ 5-7

6 Allowable Load for Wrist Axis and Wrist Flange ............................................................................. 6-1

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

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

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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 Location 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 Notes on Maintenance Procedures....................................................................................9-6

9.2.1 Battery Pack Replacement ...................................................................................9-6

9.3 Notes on Grease Replenishment/Exchange Procedures ..................................................9-8

9.3.1 Grease Replenishment/Exchange for S-Axis Speed Reducer .............................9-8

9.3.1.1 Grease Replenishment............................................................................9-9

9.3.1.2 Grease Exchange....................................................................................9-9

9.3.2 Grease Replenishment/Exchange for L-Axis Speed Reducer............................ 9-10

9.3.2.1 Grease Exchange.................................................................................. 9-10

9.3.2.2 Grease Exchange.................................................................................. 9-11

9.3.3 Grease Replenishment/Exchange for U-Axis Speed Reducer ........................... 9-12

9.3.3.1 Grease Replenishment.......................................................................... 9-12

9.3.3.2 Grease Exchange.................................................................................. 9-13

9.3.4 Grease Replenishment/Exchange for U-Arm ..................................................... 9-14

9.3.4.1 Grease Replenishment for R-, B-, T-Axes Gears in the Casing ............ 9-14

9.3.4.2 Grease Replenishment for R-Axis Speed Reducer ............................... 9-15

9.3.4.3 Grease Replenishment for B-Axis Speed Reducer ............................... 9-16

9.3.4.4 Grease Replenishment for T-Axis Speed Reducer ............................... 9-16

9.3.4.5 Grease Exchange for R-, B-, T-Axes Gears in the Casing .................... 9-17

9.3.4.6 Grease Exchange for R-Axis Speed Reducer ....................................... 9-17

9.3.4.7 Grease Exchange for B-Axis Speed Reducer ....................................... 9-18

9.3.4.8 Grease Exchange for T-Axis Speed Reducer ....................................... 9-19

9.3.5 Grease Replenishment for Balancer Connection Part........................................ 9-20

9.3.6 Notes for Maintenance........................................................................................ 9-21

9.3.6.1 Battery Pack Connection....................................................................... 9-21

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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 ............................................................................................................ 11-5

11.4 U-Arm Unit ..................................................................................................................... 11-8

11.5 Wrist Unit ..................................................................................................................... 11-10

11.6 Balancer Unit ............................................................................................................... 11-13

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1 Product Confirmation1.1 Contents Confirmation

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1 Product Confirmation

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

• DX100

• Programming pendant

• Manipulator cables (3 cables between the DX100 and the Manipulator)

CAUTION

• Confirm that the manipulator and the DX100 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.

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ES165D 1 Product Confirmation1.2 Order Number Confirmation

1.2 Order Number Confirmation

Check that the order number of the manipulator corresponds to the DX100. The order number is located on a label as shown below.

Fig. 1-1: Location of Order Number Labels

X81PROGRAMMING PENDANT

YCEG N

OT P

ME

E

S

R

ON

TRIP

PEDRESET

OFF

AVERAGEPEAK kVA

kAINTERRUPT CURRENT

ERDR-POWER SUPPLY

TYPE

DX100kVA

3PHASE

NJ2960-1

60Hz

SERIAL No.

DATE

AC220V

MADE IN JAPAN

50/60HzAC200V

NJ1529

THE MANIPULATOR AND THE CONTROLLERSHOULD HAVE SAME ORDER NUMBER.

ORDER NO.

Check that the manipulator and the DX100 have the same order number.

Label (Enlarged View)

(b) Manipulator (Side View)(a) DX100 (Front View)

WARNING

Do not open the door

THE MANIPULATOR AND THE CONTROLLERSHOULD HAVE SAME ORDER NUMBER.

ORDER NO.

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2 Transport2.1 Transport Method

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2 Transport

2.1 Transport Method

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 performance.

NOTE

• The weight of the manipulator is approximately 1150 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 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. Failure to observe this instruction may result in injury.

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ES165D 2 Transport2.1 Transport Method

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

(1 piece)Shipping bolt

Electrical tapepainted in yellow

Rubber plate

Details of B part

Hook

AShipping bracket(4 pieces)

B

Details of A part

Axis

Angle

When equipped with external cablings, those settings are subject to change depending on the specifications.

Pulse

L RU B TS

0 -143518 -134502 0 -147520 0

0 -60 -63.9 0 -86.1 0

Factory setting for angle and pulse of each axis

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2 Transport2.2 Shipping Bolts and Brackets

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2.2 Shipping Bolts and Brackets

The manipulator is provided with shipping bolts and brackets at position A and with the hexagon socket head cap screws at point B. (Fig. 2-1 “Transporting Position”).

Fig. 2-2: Shipping Bolts and Brackets

• The A-shipping brackets are painted in yellow.

• The B-shipping bolt: hexagon socket head cap screw is taped in yellow.

Position Bolt Type Pcs

A Hexagon socket head cap screw M20 X 70 mm 12

B Hexagon socket head cap screw M16 X 20 mm 1

NOTEBefore turning ON the power, check to be sure that the shipping bolts and brackets are removed. The shipping bolts and brackets then must be stored for future use, in the event that the manipulator must be moved again.

Hook

Electrical tape paintedin yellow

Rubber plate

BA Shipping bracket Shipping bolt

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ES165D 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 explained in Fig. 2-2 “Shipping Bolts and Brackets” are removed.

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

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3 Installation3.1 Safeguarding Installation

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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 "Maximum Reaction Forces of the Manipulator at Emergency Stop" and Table 3-2 "Endurance Torque in Operation".

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 section 3.2.1 “Mounting Example”.

Table 3-1: Maximum Reaction Forces of the Manipulator at Emergency Stop

Maximum torque in horizontal rotation (S-axis moving direction)

32000 N•m(3265 kgf•m)

Maximum torque in vertical rotation (L-, U-axes moving direction)

78500 N•m(8000 kgf•m)

Table 3-2: Endurance Torque in Operation

Endurance torque in horizontal operation (S-axis moving direction)

9400 N•m(960 kgf•m)

Endurance torque in vertical operation (L-, U-axes moving direction)

23900 N•m(2434 kgf•m)

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ES165D 3 Installation3.3 Location

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 head bolts M20 (80 mm long is recommended).

Next, fix the manipulator base to the baseplate. Tighten the hexagon head bolts and anchor bolts firmly so that they will not work loose during the operation.

Refer to Fig. 3-1 “Mounting the Manipulator on Baseplate”.

Fig. 3-1: Mounting the Manipulator on Baseplate

3.3 Location

When the manipulator is installed, it is necessary to satisfy the following environmental conditions:

• Ambient temperature: 0° to + 45°C

• Humidity: 20 to 80%RH (at constant temperature)

• Free from dust, soot, or water

• Free from corrosive gases or liquids, or explosive gases

• Free from excessive vibration (Vibration acceleration: 4.9 m/s2 or less [0.5 G] or less)

• Free from large electrical noise (plasma)

• Flatness for installation: 0.5 mm or less

40

Baseplate

Manipulator base

Spring washer

Washer

Flatness: 0.5mm or less

Hexagon socket head cap screw M20 (8 screws)

Units: mm

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4 Wiring4.1 Grounding

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4 Wiring

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.

Fig. 4-1: Grounding Method

WARNING• Ground resistance must be 100 Ω or less.

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

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

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

CAUTION

• Wiring must be performed by authorized or certified personnel.

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

• 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.

NOTE

• Never use this wire sharing with other ground lines or grounding electrodes for other electric power, motor power, welding devices, etc.

• Where metal ducts, metallic conduits, or distributing racks are used for cable laying, ground in accordance with electrical installation standards.

A

5.5mm2 or more View A

Delivered with manipulatorBolt M8 (for grounding)

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ES165D 4 Wiring4.2 Cable Connection

4.2 Cable Connection

Three manipulator cables are delivered with the manipulator; an encoder cable for detection (1BC) and two power cables (2BC and 3BC). (Refer to Fig. 4-2 “Manipulator Cables”.)

Connect these cables to the manipulator base connectors and to the DX100. Refer to Fig. 4-3(a) “Manipulator Cable Connectors (Manipulator Side)” and Fig. 4-3(b) “Manipulator Cable Connection (DX100 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, 1 BC, then 3BC. After inserting the cables, depress the lever until it clicks.

4.2.2 Connection to the DX100

Before connecting cables to the DX100, verify the numbers on both manipulator cables and the connectors on the DX100. When connecting, insert the cables in the order of X21, X22, then X11, and depress each lever low until it clicks.

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4 Wiring4.2 Cable Connection

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Fig. 4-2: Manipulator Cables

X21

X22

3BC

3BC

2BC

1BC

X11

X11

1BC

1B

C

2BC

2BCX21

X22 3BC

The Manipulator SideThe DX100 Side



Encoder Cable

Power Cable

Power Cable

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ES165D 4 Wiring4.2 Cable Connection

Fig. 4-3(a): Manipulator Cable Connectors (Manipulator Side)

Fig. 4-3(b): Manipulator Cable Connection (DX100 Side)

1BC 3BC

S1AIRA

2BC

3BCmolexmolexmolex

1BC

2BC

Connector Details(Manipulator Side)

Key positions

X22X21

X11

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5 Basic Specifications5.1 Basic Specifications

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5 Basic Specifications

5.1 Basic SpecificationsTable 5-1: Basic Specifications1)

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

Item Model MOTOMAN-ES165D MOTOMAN-ES165D

with external cabling for SRBT-axes

Structure Vertically Articulated

Degree of Freedom 6

Payload 165 kg

Repeatability2)

2 Conformed to ISO9283

±0.2 mm

Range of Motion S-Axis (turning) -180° - +180°

L-Axis (lower arm) -60° - +76°

U-Axis (upper arm) -142.5° - +230°

R-Axis (wrist roll) -360° - +360° -205° - +205°

B-Axis (wrist pitch/yaw) -130° - +130° -120° - +120°

T-Axis (wrist twist) -360° - +360° -200° - +200°

Maximum Speed S-Axis 1.92 rad/s, 110°/s

L-Axis 1.92 rad/s, 110°/s

U-Axis 1.92 rad/s, 110°/s

R-Axis 3.05 rad/s, 175°/s

B-Axis 2.62 rad/s, 150°/s

T-Axis 4.19 rad/s, 240°/s

Allowable Moment3)

3 Refer to chapter 6.1 “Allowable Wrist Load” for details on the permissible moment of inertia.

R-Axis 921 N•m (94 kgf•m)

B-Axis 921 N•m (94 kgf•m)

T-Axis 490 N•m (50 kgf•m)

Allowable Inertia (GD2/4) R-Axis 85 kg•m2

B-Axis 85 kg•m2

T-Axis 45 kg•m2

Approx. Mass 1100 kg

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 gassesFree from exposure to water, oil, or dustFree from excessive electrical noise (plasma)

Power Requirements 5.0 kVA

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ES165D 5 Basic Specifications5.2 Part Names and Working Axes

5.2 Part Names and Working Axes

Fig. 5-1: Part Names and Working Axes

5.3 Manipulator Base Dimensions

Fig. 5-2: Manipulator Base Dimensions

T+

T-B-

B+R+

R-U-

U+

L- L+

S-

S+

350

0.1

290

0.1

290

0.1

640

290 0.1

893

290 0.1

540

290 0.1290 0.1

540

640

735

353 0.1

40

A

View A

22 dia. (8 holes)(For fixing the manipulator)

Units: mm

Fitting surface

Fitting surface

20 dia. (2 holes)(Pin hole for manipulator positioning)

+0.021 0

16 dia. (2 holes)(Pin hole for manipulator positioning)

+0.018 0

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5 Basic Specifications5.4 Dimensions and P-Point Maximum Envelope

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5.4 Dimensions and P-Point Maximum Envelope

Fig. 5-3: Dimensions and P-Point Maximum Envelope

491 294

180

180

3050

142.

5

495348

1024

650

0

322

16

R729

R2651

2651

491

19614612

2251225

76

285

25

42

153

250

50

650

1150

60

729

727

582

701

524

0

A

945

40

2203

126

687

0

1307

R608R608

18

P-point

P-point maximumenvelope

View A

Note: This figure shows the standard specification manipulator in the home position.

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ES165D 5 Basic Specifications5.5 Alterable Operating Range

5.5 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.

* The interval between stoppers must be 60° or more.

Table 5-2: S-Axis Operating Range

Item Specifications

S-Axis Operating Range

-180° - +180° (standard) *(-165° - +165°) -150° - +150°-135° - +135°-120° - +120°-105° - +105°-90° - +90°-75° - +75°-60° - +60°-45° - +45°-30° - +30°

*(-15° - +15°)

NOTE When altering the operating range to ±15° or ±165°, please contact your YASKAWA representative.

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5 Basic Specifications5.5 Alterable Operating Range

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5.5.1 Components for Altering Operating Range

Arrange the components listed in Fig. 5-4 “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. HW0302424-2, 1 stopper)

(3) Hexagon socket head cap screw M20 (length: 45 mm) (3 screws) (tightening torque: 402 N•m)

(4) Flat washer M20 (3 flat washers)

Fig. 5-4: The Components of the S-Axis Stopper

A A

HW0302424-2

HW0402104-1

Section A-A

Pin

Flat washer M20

Hexagon socket head cap screws M20 (3 screws)(length: 45) (tightening torque: 12.9)

Stopper

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5.5.2 Notes on the Mechanical Stopper Installation

• For S-Axis mechanical stopper, install the stopper (drawing No. HW0302424-2) with the pin which is used bottom up (drawing No. HW0402104-1) as in Fig. 5-4 “The Components of the S-Axis Stopper”.

• DO NOT forget to apply the locktite 242 to the thread part of pin before inserting it into the stopper.

• Mount the stopper to the S-head with three hexagon head screws M20 (length: 45 mm) and tighten the screws to the tightening torque of 402 N•m (tensile strength: 1200 N/mm2 or more). The stopper is to be installed as shown in the Fig. 5-4 “The Components of the S-Axis Stopper” 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".

• Confirm to stabilize both sides of the protrusion with the hexagon socket head cap screws as in Fig. 5-5 “Properly-Mounted Image” on account of the limitation of strength to the unit.

• Refer to the figures: Fig. 5-6(a) to Fig. 5-6(g) as adjusting the setting angle of the S-Axis mechanical stopper. When mounting the S-Axis mechanical stopper by inverse angle to the examples in the figures: Fig. 5-6(a) to Fig. 5-6(g) , settle the machinery symmetrical to those models.

• As in the figures: Fig. 5-6(a) to Fig. 5-6(g) , the component is reversible that both sides of the machinery can be attached to the stopper, except for the angles of ±30, ±60, ±120, ±150 degrees. Flip side and retry installing the S-Axis mechanical stopper if finding any difficulty to set the machinery to the stopper based on Fig. 5-4 “The Components of the S-Axis Stopper”.

Fig. 5-5: Properly-Mounted Image

Improperly-mounted Properly-mounted

Hexagon socket head cap scerws

Hexagon socket head cap scerws

NOTE1. Apply the specified components when mounting the

S-Axis mechanical stopper.

2. TURN OFF the electric power supply before mounting.

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5.5.3 Adjustment to the Pulse Limitation of S-Axis

To limit the operating range of the S-axis, refer to DX100 Instructions section 8.17 “Changing the Parameter Setting (162536-1CD)” and change the following parameters with the programming pendant.

The limitation to the pulse (Pulse Soft Limit + 1st Axis ) : SICxG400

The limitation to the pulse (Pulse Soft Limit - 1st Axis ) : SICxG408

* Refer to section 5.5 “Alterable Operating Range”.

Degree ±0° ∗(±15°) ±30° ±45° ±60° ±75° ±90°

Number of Pulse

±0 ±35840 ±71680 ±107520 ±143360 ±179200 ±215040

Degree ±105° ±120° ±135° ±150° ∗(±165°) ±180° (Standard)

Number of Pulse

±250880 ±286720 ±322560 ±358400 ±394240 ±430080

NOTEAdjust both of the pulse limitation and the angle of S-Axis mechanical stopper as modifying the range of motion for machinery.

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Table 5-3: The settable angle for S-Axis Stopper

180

165

150

135

120

105

9075

6045

3015

0-1

5-3

0-4

5-6

0-7

5-9

0-1

05-1

20-1

35-1

50-1

65-1

80-1

80-1

65-1

50-1

35-1

20-1

05 -90

-75

-60

-45

-30

-15 0 15 30 45 60 75 90 105

120

135

150

165

180

�S

etta

ble

angl

e�

Non

set

tabl

e an

gle

The

Ang

le o

f S-A

xis

Sto

pper

for +

Dire

ctio

n

The Angle of S-Axis Stopper for - Direction

"Tab

le 5

-3 T

he S

etta

ble

Ang

le fo

r S-A

xis

Sto

pper

" ind

icat

es th

e an

gle

rang

ew

hich

allo

ws

S-a

xis

to b

e se

t for

+ d

irect

ion

and

- dire

ctio

n an

gles

.

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Fig. 5-6(a): The Properly-Mounted Models for S-Axis Stopper

The stopper is reversible.Either side of the stopper can be used.

Installation at + 180°

Hexagon head screws



Hexagon head screws

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Fig. 5-6(b): The Properly-Mounted Models for S-Axis Stopper


Hexagon head screws

Hexagon head screws



The stopper is irreversible.Only this side of the stopper can be used at this angle.

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Fig. 5-6(c): The Properly-Mounted Models for S-Axis Stopper


Hexagon head screws



Installation at + 105

Hexagon head screws

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Fig. 5-6(d): The Properly-Mounted Models for S-Axis Stopper


Hexagon head screws



Hexagon head screws


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Fig. 5-6(e): The Properly-Mounted Models for S-Axis Stopper


Hexagon head screws




Hexagon head screws

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Fig. 5-6(f): The Properly-Mounted Models for S-Axis Stopper

Fig. 5-6(g): The Properly-Mounted Models for S-Axis Stopper



The stopper is irreversible.Only this side of the stopper can be used at this angle.Hexagon head screws


Hexagon head screws


Installation at 0°

Hexagon head screws

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6 Allowable Load for Wrist Axis and Wrist Flange6.1 Allowable Wrist Load

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6 Allowable Load for Wrist Axis and Wrist Flange

6.1 Allowable Wrist Load

The allowable wrist load including the weight of the mount/gripper is:

• YR-ES0165D-A00, -A01: 165kg maximumIf force is applied to the wrist instead of the load, force on R-, B-, and T-axes should be within the value shown in Table 6-1 "Allowable Wrist Load". Contact your YASKAWA representative for further information or assistance.

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.

Table 6-1: Allowable Wrist Load

Axis Moment N•m (kgf•m)1)

1 ( ): Gravitational unit

GD2/4 Total Moment of Inertia kg•m2

R-Axis 921 (94) 85

B-Axis 921 (94) 85

T-Axis 490 (50) 45

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ES165D 6 Allowable Load for Wrist Axis and Wrist Flange6.1 Allowable Wrist Load

Fig. 6-1: Moment Arm Rating

14001200

1000

800

800

1000 40kg

60kg

80kg

1000600

130kg

400

100kg

800 LB(mm)

600

400

LT(mm)

200

200

400

600

LT(mm)

165kgP-point

T-, R-axiscenter of rotation

B-axis center of rotation

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6 Allowable Load for Wrist Axis and Wrist Flange6.2 Wrist Flange

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6.2 Wrist Flange

The wrist flange dimensions are shown in Fig. 6-2 “Wrist Flange”. It is recommended that the attachment be mounted inside the fitting in order to identify the alignment marks. Fitting depth of inside and outside must be 8 mm or less.

Fig. 6-2: Wrist Flange

8

8

P.C.D.125

P.C.D.92

Units: mm

9 dia.(2 holes) (depth: 8 mm)10 dia.

(2 holes) (depth: 8 mm)Alignment mark

63

dia.

+0.0

30

0

160

dia

.

0

-0.0

25

+0.018 0

+0.015 0

Tapped hole M10 (6 holes) (depth: 12 mm)

Tapped hole M10(6 holes) (depth: 12 mm)

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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ES165D 7 System Application7.1 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

120

40 255

133

120

255

153

40

25540

30

117 73

50

120

13312

0

255 40

137.5

85

75

5

855

75 137.5 153

B

5030

73117

B

A1

A2

Tapped hole M12(4 holes) (depth: 24mm)




Table 7-1: Conditions for Installation

Application Note

A1, A2 Cable Processing and Valve Load

30 kg max.49 N•m (5 kgf•m) max. for moment increase amount of upper arm

B Others 250 kg max.

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7 System Application7.2 Internal User I/O Wiring Harness and Air Line

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7.2 Internal User I/O Wiring Harness and Air Line

6 cables for valves (0.75 mm2), 18 internal user I/O wires (0.5 mm2 x 6 wires, 0.75 mm2 x 12 wires), the cables for the external axis (1.25 mm2 x 7 cables, 0.75 mm2 x 2 cables, 0.2 mm2 x 4 cables), and an air line are used in the manipulator for the drives of 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 “Connectors for Internal User I/O Wiring Harness and Air Line” and Fig. 7-3 “Details of the Connector Pin Numbers”. Wiring must be performed by users.

The allowable current for internal user I/O wiring harness

8.0A or less / wire. (1.25 mm2)5.0A or less / wire. (0.75 mm2)3.5A or less / wire. (0.5 mm2)2.8A or less / wire. (0.3 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: 8.0 mm )

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ES165D 7 System Application7.2 Internal User I/O Wiring Harness and Air Line

Fig. 7-2: Connectors for Internal User I/O Wiring Harness and Air Line

3BC

AIR S1

1BC

2BC

Tapped holes PT3/8 with pipe plug

Exhaust port (air flow)

Connector for the external axis (Power cable):JL05-2A18-1SC (socket connector with cap).Prepare pin connector: JL05-6A18-1P.

Connector for internal user I/O wiring harness (Casing):JL05-2A22-14SC (socket connector with cap).Prepare pin connector: JL05-6A22-14P.

JL05-2A20-29SC(socket connector with cap).Prepare pin connector: JL05-6A20-29P.

Connector for the external axis (Encoder cable):

Key position

Key position

Tapped holes PT3/8 with pipe plugAir inlet (air flow)

JL05-2A28-21PC (pin connector with cap).Prepare socket connector: JL05-6A28-21S.

Connector for internal user I/O wiring harness (Base):

View A

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7 System Application7.2 Internal User I/O Wiring Harness and Air Line

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Fig. 7-3: Details of the Connector Pin Numbers

43

22

14

21

13

20

2726

32 33

15

28

98

21

1211

18

2524

30

35

10

16

23

29

34

17

5 6 7

36

31

19

321

6

45

P

P

P

78

1011

9

1314

1617

15

192021

18

12

7611

3

121615

549

1

81413

17 18

10

2

12

543

P

P

87

11109

P 6

131415161718

12

6

10

3

85

12

74

9

1416

121115

13

12P

P 1015

9 214

7

5

8

3

96

21

54

6

3

0.3mm2 (12 pins)

0.75mm2 (6 pins)

0.2mm2 (4 pins)

1.25mm2 (4 pins)

0.75mm2 (2 pins)

0.5mm2 (6 pins)

0.3mm2 (12 pins)

222324

87

9

1.25mm2 (3 pins)

0.5mm2 (6 pins)

Pins used Pins used

Pins used

Pins used

Shielded wire

Pin details for internal user I/O wiring harness (Base side)

Pin details for internal user I/O wiring harness (Casing side)

Pin details for external axis encoder cable

Pin details for external axis power cable

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ES165D 8 Electrical Equipment Specification8.1 Position of Limit Switch

8 Electrical Equipment Specification

8.1 Position of Limit Switch

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 section 8.9 “Overrun/Tool Shock Sensor Releasing” in “DX100 INSTRUCTIONS” 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.

8.1.2 Location of Limit Switch

The limit switch is optional. For the S-, L-, and U-axes with limit switch specifications, the limit switch is located on S-, L-, and U-axis respectively. For their locations, refer to Fig. 8-1 “Location of Limit Switch”.

Fig. 8-1: Location of Limit Switch

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

L- and U-axes interferencelimit switch

L-axis overrun limit switch

S-axis overrun limit switch

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8 Electrical Equipment Specification8.1 Position of 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

61 77

L-axis center of rotation

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ES165D 8 Electrical Equipment Specification8.1 Position of Limit Switch

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 -8° to +280° as the interference angle with L-axis.

Fig. 8-3: LU-Axes Interference Angle

280

U-axis center of rotation

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8 Electrical Equipment Specification8.2 Internal Connections

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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

Table 8-1: List of Connector Types

Name Type of Connector

Connector Base Connector for internal user I/O wiring harness

JL05-2A28-21PC(JL05-6A28-21S: Optional)

U-arm Connector for internal user I/O wiring harness

JL05-2A22-14SC(JL05-6A22-14P: Optional)

Connector for external axis(Encoder cable)


Connector for external axis(Power cable)


2BC 3BC1BC Connector for

Internal user I/O wiring harness (Base)

Connector for external axis(Power cable)

Connector for external axis(Encoder cable)

Connector for internal user I/O wiring harness (Casing)

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Fig. 8-5(a): Internal Connection Diagram

T-AXIS

B-AXIS

R-AXIS

U-AXIS

L-AXIS

E E E E

LD1+24

B3

B2

B1

A3

A2

A1

E E E E E E E

LD1+24

0V

LC1 LD1

LB2LB1

LD1LD2

LA3LB3

LD3LC3

CN4-10CN4-10 0V

2324

22 SP22SP23SP24

P

P

P

P

P

P

0BAT6BAT6

PG5V6

T-1-2-3

No.21CN

-4 PG0V6

0BAT5BAT5

PG5V5

B-1-2-3

No.20CN

-4 PG0V5

R

0BAT4

PG0V4PG5V4

BAT4

-4-3-2-1No.19CN

U

0BAT3

PG0V3PG5V3

BAT3

-4-3-2-1No.18CN

L

0BAT2

PG0V2PG5V2

BAT2

-4-3-2-1No.17CN

S

0BAT1BAT1

PG5V1PG0V1

-1-2-3-4

No.16CN

X

0V+24V

0V+24V

No.22CN

-2-4

-1-3

-6-5-4-9

-6-5-4-9

-6-5-4-9

-6-5-4-9

-6-5-4-9

-9-4-5-6

LA1

E

E

S-AXISPG

DATA-1DATA+1

-2

0V

BATOBT+5V

1CN-1No.1CN

0BAT2

0BAT3BAT2

BAT3

BAT11819

2122

20

0BAT4

0BAT5

0BAT6BAT5

BAT4

2425

2829

2726

23

17 0BAT1BAT0BTBAT

P

P 4

23

BAT110BAT12BAT12

0BT

0BTBATP

BATP 6

87

5 0BAT21

BAT220BAT22BAT21

0BAT1110BT

BAT6

PG0V2PG5V1PG0V1

3031

32132

PG0V3

PG0V5

PG0V4PG5V4

PG5V35

9

78

6

4 PG5V2

P

P

P

PG5V6PG0V6

1211

16151413

10 PG5V5

12

543

876

1BC(10P 4)

31

42

0V+24V

0V+24V

SPG-1SPG+1

CN1-5

CN1-2CN1-1

CN1-9CN1-10

CN1-4

PG

PG

DATA+2

FG1

BATOBT

-10

2CN-1No.2CN

-10

BAT

0VFG2

+5VOBT

-2 DATA-2

DATA-3DATA+3

-2BAT

BAT

3CN-1No.3CN

-10

OBT

0VFG3OBT

+5V

OBT

PG

PG

DATA+4DATA-4-2

OBTBAT

4CN-1No.4CN

-10OBTBAT

FG40V+5V

DATA+5DATA-5-2

0V

BATOBT+5V

5CN-1

DATA+6

-10OBTBAT

FG5

6CN-1No.6CN

No.5CN

BAT

P

P

P

P

P

P

FG1

SPG+2

FG2

SPG-2CN1-7CN1-6

CN1-8

SPG-3SPG+3

FG3CN2-3

CN2-2CN2-1

P

P

P

P

P

P

SPG+4SPG-4

FG4

CN2-7CN2-6

CN2-8

SPG-5SPG+5

SPG+6

FG5

CN3-6

CN3-3

CN3-2CN3-1

PG

No.7CN(20-29)1

-10

BAT

0V

OBT+5V

FG6

BATOBT

LA2LB2

BC1BC2

LD2LC2

15

109 0V

5V

SPG-7

FG7P

E

SP19

2 SPG+7P

P

P

LB1

SS1

LB1LB2

SS2LD2LD1

FG6

LB1+24V

CN3-8

CN4-6CN4-1

SS2

SPG+7

BC2

CN4-4

CN4-8CN4-3

CN4-7CN4-2

E

E

FG7

0V

0V5V

5V

CN2-10CN2-9CN2-5CN2-4CN4-9

CN3-5CN3-9CN3-10

CN3-4

19

S1(28-21)

CN4-5 SPG-7

MANIPULATOR

PSPG-6CN3-7 -2 DATA-6

CN1-3

CN1-5CN1-4

CN1-10CN1-9

0V

0V+24V

+24V

CN1-1CN1-2 SPG-1

SPG+1

DX100

CN1-3

CN1-6

FG1

SPG+2CN1-7

CN1-8 FG2

SPG-2

CN2-1CN2-2 SPG-3

SPG+3

CN2-3 FG3

CN2-6CN2-7

SPG+4SPG-4

CN2-8 FG4

CN3-1CN3-2

SPG+5SPG-5

CN3-6

CN3-3

SPG+6

FG5

CN3-7

CN3-8 FG6

CN4-1CN4-6

+24VLB1

CN4-2CN4-7

SS2AL1

CN4-8CN4-3 BC2

AL2

SPG+7

FG7CN4-5CN4-9CN2-4CN2-5CN2-9CN2-10 0V

CN3-10CN3-9CN3-5 0V

5V

5VCN3-4

SPG-7CN4-4

SPG-6

No.8CN(22-14)

321 SP1

SP2SP3

SP6

789

SP7SP8

65 SP5

SP44

13141516

1211

SP12SP13SP14SP15

SP11SP10

18 SP18SP1717 SP16

10 SP9

SP20SP21

P

P

P

12

21

6

87

45

3

20

1213

1514

1011

181716

9

B3A3

B2A2

B1

A1

LA3LB3

LB2LB1

LB1

LA1

LC3LD3

LD2LD1

LD1

LC1LD1

LC2LD2LD2

LD1LC1

LB1

LA2LB2LB2

LB1LA1

Base Casing

SLU-axes with Limit Switch Specification

Connected to

L AND U-AXIS INTERFERENCE L.S.

L-AXIS OVERRUN L.S.

S-AXIS OVERRUN L.S.

L AND U-AXIS INTERFERENCE L.S.

L-AXIS OVERRUN L.S.

S-AXIS OVERRUN L.S.

Connected to

Connected to

Connected to

Connected to

Connected to

1. For the limit switch specification, the connection of the section Notes

A B parts are changed as follows:and

FOR LAMP (OPTION)

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Fig. 8-5(b): Internal Connection Diagram

T-AXIS

B-AXIS

R-AXIS

U-AXIS

L-AXIS

S-AXIS

1

8

72

4

9

3

EE

CN5-1

CN5-4

CN6-1CN6-4

CN6-6

CN6-5

CN5-5

CN5-2

E

MU1MU1

MW1

MV1MV1MV1

MU1

2BC(8PX5+12PX1)

CN1-7CN1-6CN1-5

CN2-1

CN1-3CN1-2CN1-1

MW1

ME1ME1ME1

BB1

MU2MU2

BA1CN6-2

CN2-6CN2-5

CN2-3

CN2-4

CN1-4CN1-8

CN6-1

CN2-2 MW1

MW2

MV2MV2MV2

ME2ME2ME2

MW2MW2

CN3-8CN3-4CN2-8

CN3-7CN3-6CN3-5

CN3-3CN3-2CN3-1

BB2

MU3MU3

MW3

MV3MV3MV3

MU3CN4-2CN4-1

CN6-4

CN5-1

CN4-7CN4-6CN4-5

CN4-3

CN6-3 BA2

MW3

ME3ME3ME3

BB3

BA4BB4

BA5

BA3CN6-6

CN5-3

CN6-5

CN5-4CN4-8CN4-4

CN6-7CN6-8

CN6-9

BA6BB6

MW4MV4

MW4

MU4

MV4MU4

3BC(6PX6)

CN2-2CN2-1CN1-5CN1-4CN1-2CN1-1

CN6-11CN6-12

CN6-10 BB5

CN5-2 MW3

CN2-7 MU2

ENo.15CN

56

ME4ME4

MW5

ME5MW5

MV5MU5

MV5

MU5

CN1-6CN1-3

CN3-1

CN3-3CN3-2

CN2-6CN2-3CN2-5CN2-4

MU6MU6

ME6ME6

MW6MW6

MV6MV6

CN4-6CN4-5CN4-3CN4-2CN4-4CN4-1CN3-5CN3-4

CN3-6 ME5

MU7

MU7

MW7

MW7

MV7MV7

CN6-5

CN6-6

CN6-4CN6-1

CN5-4

CN5-1

BA7BB7

ME7

CN5-3CN5-6

CN5-5

CN5-2 ME7

CN1-1CN1-2

E

MU1MU1

CN1-7CN1-6CN1-5

CN2-1

MV1MV1MV1

MW1

MU1CN1-3

CN2-3

CN1-8CN1-4

CN2-4

MW1

ME1ME1ME1

CN6-2

CN2-6CN2-5

BB1

MU2MU2

BA1CN6-1

MW1CN2-2

CN3-3

CN3-1CN3-2

CN3-5

MV2MV2MV2

MW2

CN3-7

CN2-8CN3-4CN3-8

MW2

ME2ME2ME2

MW2CN3-6

CN4-1CN4-2

CN6-4

MU3MU3

BB2

CN4-7

CN4-5CN4-6

CN5-1

MV3MV3MV3

MW3

MU3CN4-3

BA2CN6-3

CN5-3

CN4-4CN4-8CN5-4

MW3

ME3ME3ME3

CN6-9

CN6-7CN6-8

CN6-6

BA5

BB4BA4

BB3BA3CN6-5

CN6-11CN6-12

BA6BB6

CN2-2

CN1-5CN2-1

CN1-2CN1-4

CN1-1

MW4

MV4

MU4

MW4

MV4

MU4

CN6-10 BB5

MW3CN5-2

MU2CN2-7

CN1-3CN1-6

ME4ME4

CN3-1CN3-2CN3-3

CN2-6

CN2-5CN2-3

MW5

MV5

MU5MV5

MW5

ME5

MU5CN2-4

CN3-5CN3-4

MU6MU6

CN4-5

CN4-4

CN4-3CN4-2

CN4-6

MV6

MW6MW6

ME6ME6

MV6CN4-1

ME5CN3-6

MU7

MU7

MW7

MW7

MV7MV7

CN5-6CN5-3

BB7BA7

ME7

PE

ME7

LB1

LA1

LD1

LC1LD1

LC2LD2LD2

LD1LC1

LB1

LA2LB2LB2

LB1LA1

LA1

LC1LD1 LD1

LC1

LB1 LB1LA1

SM

MU1MV1MW1

-B-C

9CN-ANo.9CN

YB

ME1

BB1BA1

-D

-2-1

SM

11CN-ANo.11CN

-C-B MV3

MW3

MU3

MV2MU2

YB

ME2

BB2BA2

MW2 SM-B

10CN-A

-D

-2-1

-C

No.10CN

YB

-D

-2-1

ME3

BB3BA3

SM

12CN-ANo.12CN

-B-C

MU4

MW4MV4

YB

SM

-2

-D

-1BB4BA4

ME4

13CN-ANo.13CN

-B-C-D

MV5

ME5MW5

MU5

YB

YB

SM

-2 BB5

14CN-A

-D

-1-2

-C-B

ME6

BB6BA6

MU6

MW6MV6

No.14CN

-1 BA5

B2

B1

A2

A1

SL-axes with Limit Switch Specification

Connected to

L-AXIS OVERRUN L.S.

S-AXIS OVERRUN L.S.

L-AXIS OVERRUN L.S.

S-AXIS OVERRUN L.S.

Connected to

Connected to

Connected to

S-axis with Limit Switch Specification

B1S-AXIS OVERRUN L.S. Connected to

A1Connected toS-AXIS OVERRUN L.S.

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ES165D 9 Maintenance and Inspection9.1 Inspection Schedule

9 Maintenance and Inspection

9.1 Inspection Schedule

Proper inspections are essential not only to assure that the mechanism will be able to function for a long period, but also to prevent malfunctions and assure safe operation. Inspection intervals are classified into six levels as shown in Table 9-1 "Inspection Items".

In Table 9-1 "Inspection Items", 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.

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.

NOTE

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

• For any different or special applications, the inspection process should be developed on an case-by-case basis.

• For axes which are used very frequently (in handling applications, etc.), it is recommended that inspections be conducted at shorter intervals. Contact your YASKAWA representative.

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Table 9-1: Inspection Items (Sheet 1 of 2)

Items1) Schedule Method Operation Inspection Charge

Dai

ly

100

0HC

ycle

600

0HC

ycle

120

00H

Cy

cle

240

00H

360

00H

Sp

ecif

ied

P

erso

nn

el

Lic

ense

e

Ser

vice

C

om

pan

y

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

WrenchTighten loose bolts. Replace if necessary. • • •

6 Cover mounting screws • Screwdriver, Wrench

Tighten loose bolts. Replace if necessary. • • •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 Balancer • Grease Gun Supply grease. See Chap. section 9.3.5. • •10 Wire harness in manipulator

(SLU-axis wires) (RBT-axis wires)

• Visual, Multimeter

Check for conduction between the main connector of base and intermediate connector with manually shaking the wires. Check for wear of protective spring.3)

• •

• 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.) Supply grease5). (6000H cycle) See section 9.3.1.Replace grease5). (12000H cycle) See section 9.3.1.

• •

13 L-axis speed reducer, • • Grease Gun Check for malfunction. (Replace if necessary.) Supply grease5). (6000H cycle) See section 9.3.2.Replace grease5). (12000H cycle) See section 9.3.2.

• •

14 U-axis speed reducer, • • Grease Gun Check for malfunction. (Replace if necessary.) Supply grease5) (6000H cycle). See section 9.3.3.Replace grease5) (12000H cycle). See section 9.3.3.

• •

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15 R-axis speed reducer • • Grease Gun Check for malfunction. (Replace if necessary.) Supply grease5). (6000H cycle) See section 9.3.4.Replace grease5). (12000H cycle) See section 9.3.4.

• •

16 B- and T-axes speed reducer,B- and T-axes gear

• • Grease Gun Check for malfunction. (Replace if necessary.) Supply grease5). (6000H cycle) See section 9.3.4.Replace grease5). (12000H cycle) See section 9.3.4.

• •

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 side for each axis from the motor. Otherwise, the home position may be lost. (Refer to section 9.3.6 “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 9-1: Inspection Items (Sheet 2 of 2)

Items1) Schedule Method Operation Inspection Charge

Da

ily

100

0HC

ycle

600

0HC

ycle

120

00H

Cyc

le

240

00H

360

00H

Sp

ecif

ied

P

erso

nn

el

Lic

ens

ee

Ser

vice

C

om

pa

ny

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Fig. 9-1: Inspection Items

U-AXIS

2

4

12

9

T-AXISB-AXISR-AXISS-AXIS 1 1

1516

5

1 1

1

14

13

7

10

811

2

L-AXIS1

7

2

4

7

Check that no greaseis leaked into the tube (2 tubes).

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The numbers in the above table correspond to the numbers in Table 9-1 "Inspection Items"

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 AxesR-, B-, and T-Axes gears

9 Alvania EP Grease 2 L-Axis Balancer

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9 Maintenance and Inspection9.2 Notes on Maintenance Procedures

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9.2 Notes on Maintenance Procedures

9.2.1 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 DX100, replace the battery in accordance with the following procedure:

Fig. 9-2(a): Battery Location (Back View)

Fig. 9-2(b): Battery Location (Top View)

S1

3BC

AIR

2BC

1BC

Plate fixing screw M4

Connector base

Plate

Base

Battery pack

Board

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Fig. 9-3: Battery Connection

1. Turn OFF the DX100 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 board.

6. Mount the new battery pack to the holder.

7. Reinstall the plate.

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

NOTE Do not allow plate to pinch the cables when reinstalling the plate.

See replacing step 5.

Board

Connector

See replacing step 4.

New battery pack

Battery pack before replacement

（Type：SGDR-EFBA02A）

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9.3 Notes on Grease Replenishment/Exchange Procedures

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

9.3.1 Grease Replenishment/Exchange for S-Axis Speed Reducer

Fig. 9-4: S-Axis Speed Reducer Diagram

NOTE

• If grease is added without removing the plug/screw from the grease exhaust port, the grease will leak inside a motor or an oil seal of a speed reducer will come off, which may result in damage to the motor. Make sure to remove the plug/screw.

• Do not install a joint, a hose, etc. to the grease exhaust port. Failure to observe this instruction may result in damage to the motor due to coming off of an oil seal.

• Make sure to use a grease pump to inject grease. Set air supply pressure to the grease pump at 0.3 MPa or less, and the grease injection rate at 8 g/s or less.

• Make sure to fill the hose on the grease inlet with grease beforehand to prevent air from leaking into the speed reducer.

S1

3BC

AIR

2BC

1BC

A

Grease inletHexagon socket head plug A-PT1/4

S-axis speed reducer

Grease exhaust portHexagon socket head plug PT3/8

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ES165D 9 Maintenance and Inspection9.3 Notes on Grease Replenishment/Exchange Procedures

9.3.1.1 Grease Replenishment

(Refer to Fig. 9-4 “S-Axis Speed Reducer Diagram”.)

Replenish the grease according to the following procedure:

1. Remove the hexagon socket head plugs PT3/8 from the grease exhaust port.

2. Install a grease zerk A-PT1/4 to the grease inlet. (The grease zerk is delivered with the manipulator.)

3. Inject the grease through the grease inlet using a grease gun

– Grease type: Molywhite RE No. 00

– Amount of grease: 1200 cc (2400 cc for 1st supply)

– Air supply pressure of grease pump: 0.3 MPa or less

– Grease injection rate: 8 g/s or less

4. Move the S-axis for a few minutes to discharge excess grease.

5. Wipe the discharged grease with a cloth, and reinstall the plug. Before installing the plug, apply Three Bond 1206C on the thread part of the plug, then tighten the plug with a tightening torque of 5 N•m (0.51 kgf•m).

9.3.1.2 Grease Exchange

(Refer to Fig. 9-4 “S-Axis Speed Reducer Diagram”.)

1. Remove the hexagon socket head plugs PT3/8 from the exhaust port.


3. Inject the grease through the grease inlet using a grease gun.


– Amount of grease: approx. 7000 cc



4. The grease exchange is completed when new grease appears in the grease exhaust port. (The new grease can be distinguished from the old grease by color.)

5. Move the S-axis for a few minutes to discharge excess grease.

NOTEIf grease is injected with the plug on, the grease will leak inside the motor and may cause a damage. Make sure to remove the plug before the grease injection.


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9.3.2 Grease Replenishment/Exchange for L-Axis Speed Reducer

Fig. 9-5: L-Axis Speed Reducer Diagram


(Refer to Fig. 9-5 “L-Axis Speed Reducer Diagram”.)

1. Make the L-arm vertical to the ground.

2. Remove the hexagon socket head plug PT3/8 from the grease exhaust port.


4. Inject grease through the grease inlet using a grease gun.





5. Move the L-axis for a few minutes to discharge excess grease.


NOTE If the plug is installed when the grease is being exhausted, the grease will go inside the motor and may damage it.

Hexagon socket head plug PT3/8Grease exhaust portGrease Inlet

Hexagon socket head plug PT1/8


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(Refer to Table 9-5 "L-Axis Speed Reducer Diagram".)

1. Make the L-arm vertical to the ground.









6. Move the L-axis for a few minutes to discharge excess grease.



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9.3.3 Grease Replenishment/Exchange for U-Axis Speed Reducer

Fig. 9-6: U-Axis Speed Reducer Diagram

9.3.3.1 Grease Replenishment

(Refer to Fig. 9-6 “U-Axis Speed Reducer Diagram”.)

1. Make the U-arm horizontal to the ground.

2. Remove the hexagon socket head plug PT1/8 from grease exhaust port.







5. Move the U-axis for a few minutes to discharge excess grease.


Hexagon socket head plug A-PT1/8

Grease exhaust port

Grease inlet



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(Refer to Fig. 9-6 “U-Axis Speed Reducer Diagram”.)

1. Make the U-arm horizontal to the ground.








5. The grease exchange is complete when new grease appears in the grease exhaust port. (The new grease can be distinguished from the old grease by color.)

6. Move the U-axis for a few minutes to discharge excess grease.



NOTE If the plug is installed when the grease is being exhausted, the grease will go inside the motor and may damage it.

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9.3.4 Grease Replenishment/Exchange for U-Arm

Fig. 9-7: U-Arm Diagram

9.3.4.1 Grease Replenishment for R-, B-, T-Axes Gears in the Casing

(Refer to Fig. 9-7 “U-Arm Diagram”.)



Grease exhaust port (R-, and B-axes speed reducer)Hexagon socket head plug PT1/8

A

R-axis speed reducer

B-axis speed reducer

Grease Inlet (B-, and T-axes speed reducer)Hexagon socket head plug PT1/8

T-axis speed reducer

Grease exhaust port(T-axis speed reducer)Hexagon socket headplug PT1/16

Hexagon socket head plug A-PT1/8 Grease inlet (R-,B-, and T-gears in the casing)

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


Grease exhaust port(R-,B-,and T-gears in the casing)

View A


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4. Move the R-, B-, T-Axes for a few minutes to discharge excess grease.


6. Remove the grease zerk from the grease inlet, and reinstall the plug. Before installing the plug, apply Three Bond 1206C on the thread part of the plug, then tighten the plug with a tightening torque of 5 N•m (0.51 kgf•m).

9.3.4.2 Grease Replenishment for R-Axis Speed Reducer









4. Move the R-Axis for a few minutes to discharge excess grease.


6. Remove the grease zerk from the grease inlet, and reinstall the plug. Before installing the plug, apply Three Bond 1206C on the thread part of the screw, then tighten the plug with a tightening torque of 5 N•m (0.51 kgf•m).


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9.3.4.3 Grease Replenishment for B-Axis Speed Reducer









4. Move the B-Axis for a few minutes to discharge excess grease.



9.3.4.4 Grease Replenishment for T-Axis Speed Reducer









4. Move the T-Axis for a few minutes to discharge excess grease.



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6. Remove the grease zerk from the grease inlet, and reinstall the plug Before installing the plug, apply Three Bond 1206C on the thread part of the plug, then tighten the plug with a tightening torque of 5 N•m (0.51 kgf•m).

9.3.4.5 Grease Exchange for R-, B-, T-Axes Gears in the Casing










5. Move the R-, B-, T-Axes for a few minutes to discharge excess grease.



9.3.4.6 Grease Exchange for R-Axis Speed Reducer






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5. Move the R-Axis for a few minutes to discharge excess grease.



9.3.4.7 Grease Exchange for B-Axis Speed Reducer










5. Move the B-Axis for a few minutes to discharge excess grease.




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9.3.4.8 Grease Exchange for T-Axis Speed Reducer










5. Move the T-Axis for a few minutes to discharge excess grease.




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9.3.5 Grease Replenishment for Balancer Connection Part

Fig. 9-8: Balancer Connection Part

1. Remove the hexagon socket head plugs of connection and . (Refer to Fig. 9-8 “Balancer Connection Part”.)

– Grease type: Alvania EP grease 2


2. Inject grease through grease inlets of connection and using a grease gun.

3. Reinstall the plugs PT1/8 of connection and . Before installing the plug, apply Three Bond 1206C on the thread part of the plug, then tighten the plug with a tightening torque of 5 N•m (0.51 kgf•m).


Hexagon socket head plug PT1/8 Exhaust port 1

Exhaust port 2

Grease zerk A-PT1/8

Connection 1 Tapered roller bearing(2 bearings)

Grease zerk A-PT1/8 (2 grease zerks)Connection 1 Grease inlet

Connection 2 Needle bearing

Connection 2 Grease inlet

NOTEThe exhaust port is used only for air flow.

Do not inject excessive grease through the gear grease inlet.

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9.3.6 Notes for Maintenance

9.3.6.1 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.

Fig. 9-9: Battery Pack Connection

NOTE

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 connect the battery pack to the battery backup connector before removing the encoder connector.

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. 9-9 “Battery Pack Connection”.

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

b

aab0BT

BAT BAT*0BT*

Motor

Connector for the battery backup

Battery Pack: HW9470932-A

Motor power connector

Connector for the encoder

b:Insertion-type pin terminal (Socket)a:Insertion-type pin terminal (Pin)

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10 Recommended Spare Parts

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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-ES165D. 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 YASKAWA representative.

Table 10-1: Spare Parts for the YR-ES0165D-A00, -A01 (Sheet 1 of 2)

Rank PartsNo.

Name Type Manufacturer Qty Qty per Unit

Remarks

A 1 Grease Molywhite RE No. 00 YASKAWA 16 kg - for all axes 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 Seal Three Bond 1206C Three Bond Co., Ltd. 1 1

A 4 Battery Pack HW0470360-A YASKAWA 1 1

A 5 Battery Pack HW9470932-A YASKAWA 1 - for wire harness in manipulator replacing

B 6 S-Axis Speed Reducer

HW0388208-A YASKAWA 1 1

B 7 S-Axis Input Gear HW0314016-1 YASKAWA 1 1

B 8 L-Axis Speed Reducer


B 9 L-Axis Input Gear HW0303271-1 YASKAWA 1 1

B 10 U-Axis Speed Reducer


B 11 U-Axis Input Gear HW9482451-A YASKAWA 1 1

B 12 R-Axis Speed Reducer


B 13 B-Axis Speed Reducer

HW9380961-D YASKAWA 1 1

B 14 T-Axis Speed Reducer


B 15 Wrist Unit HW0174234-A YASKAWA 1 1

C 16 AC Servo Motor for S-, L-, and U-Axes

SGMRV-37ANA-YR1*HW0388670-A

YASKAWA 1 3

C 17 AC Servo Motor for R-Axis


YASKAWA 1 1

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C 18 AC Servo Motor for B-and T-Axes


YASKAWA 1 2

C 19 Internal Wire Harness


C 20 Connector Base Set


C 21 Board SGDR-EFBA02A YASKAWA 1 1

C 22 Limit switch setfor S-axis

HW0371747-A YASKAWA 1 1 Treatment of -A01 lead terminal is done

C 23 Limit switch setfor L-axis

HW0374590-A YASKAWA 1 1 Treatment of -A01 lead terminal is done

C 24 Limit switch setfor U-axis

HW0374590-B YASKAWA 1 1 Treatment of　-A01 lead terminal is done

Table 10-1: Spare Parts for the YR-ES0165D-A00, -A01 (Sheet 2 of 2)

Rank PartsNo.

Name Type Manufacturer Qty Qty per Unit

Remarks

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11 Parts List11.1 S-Axis Unit

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11 Parts List

11.1 S-Axis Unit

Fig. 11-1: S-Axis Unit

1001

1002

1003

1004

1005

1006

1007

1008

1009

1010

1011

1013

1014

1015

1016

1017

1020

1021

10231024

1018

1019

10251026

10271028

10291030

1031

1032

1036

10371038

1035

1039

1012

1022

10331034

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ES165D 11 Parts List11.1 S-Axis Unit

Table 11-1: S-Axis Unit

No. DWG No. Name Pcs

1001 HW0388208-A Speed reducer 1

1002 SGMRV-37ANA-YR1* Motor 1

1003 TC12015014 Oil seal 1

1004 STW-50 Retaining rings 1

1005 6310 Bearing 1

1006 HW0314016-1 Gear 1

1007 HW0100193-2 Base 1

1008 HW0100471-1 S head 1

1009 HW0402102-1 Stopper 1

1010 HW0302424-2 Stopper 1

1011 HW0402104-1 Pin 1

1012 HW0306181-1 Pipe 1

1013 HW0403903-1 Plate 1

1014 HW9404486-1 Shaft 1

1015 MSTH12-30 Pin 1

1016 MSTH12-40 Pin 2

1017 MSTH6-20 Pin 2

1018 KQ2L10-01S Union 1

1019 NB-1075 Tube 1

1020 PT3/8 Plug 1

1021 G415 O ring 1

1022 G105 O ring 1

1023 M6X16 Socket screw 1

1024 2L-6 Spring washer 1


1026 SW2H-12 Spring washer 16

1027 M8X40 Socket Screw 1



1030 2H-12 Spring washer 3





1035 M20X45(12.9) Bolt 3

1036 M20 Spring washer 3


1038 GT-SH-16 Spring washer 12

1039 EZ5002A0 Cap 1

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11 Parts List11.2 L-Axis Unit

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11.2 L-Axis Unit

Fig. 11-2: L-Axis Unit

2001

2002

2003

2005

2006

2009

2019

2019

2009 2010

2011

2012

2012

2017

20172018

2018

2019

2019

2005

2007

2020-26

2020-26

20312032

20372038

2045

6004

2046

1008

20312032

20342033

20332034

2047

2019

20392040

20432044

20412042

20352036

2027

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Table 11-2: L-Axis Unit


2001 HW9381442-B Speed reducer 1


2003 Y507212.5 Oil seal 1

2005 HR32916J Bearing 2

2006 HW0100472-1 L arm 1

2007 HW0303271-1 Gear 1

2009 HW9405055-1 Shaft 2

2010 EZ0094-A0 Air breather 1

2011 G300 O ring 1

2012 S105 O ring 2

2017 KE901107 Oil seal 2

2018 HW9405699-1 B Cover 2

2019 PT1/8 (Stainless) Plug 5

2020 HW9405195-1 Shim 1

2021 HW9405195-2 Shim 2

2022 HW9405195-3 Shim 1

2023 HW9405195-4 Shim 1

2024 HW9405195-5 Shim 1

2025 HW9405195-6 Shim 1

2026 HW9405195-7 Shim 1

2027 GT-SA-M12X35 Socket screw 4










2040 SW-2H-12 Spring washer 24





2045 62PP050BG14 Plug 6

2046 CP-30-BC-12 Cap 6


1008 HW0100471-1 S head 1

6004 HW0100477-1 Case 1

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11 Parts List11.3 URBT-Axes Unit

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11.3 URBT-Axes Unit

Fig. 11-3: URBT-Axes Unit

3002

3004

3003

3005

30053005

3006

3007

3008

3011

3012

30133014

3015

3016

3019

3020

3021

3022

3023

3024

3024

302430253026

3027

30283027

3028

3035

4009

3036

30413042

30453046

3009

30273028

30303029

30393040

30103037

3038

3047

30483049

3001

3017

3024

30433044

30333034

3031

3032

2006

3050

R-axis

30413042

3050

30413042

3018

3018

3018

B-axis

T-axis

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Table 11-3: URBT-Axes Unit (Sheet 1 of 2)





3004 TAFI405520 Needle bearing 1

3005 Y507212.5 Oil seal 3

3006 Y507212.5 Oil seal 1

3007 HW0303963-1 Gear 1

3008 HW0303949-1 Gear 1

3009 HW0303947-1 Gear 1

3010 HW9482306-C Shaft 1

3011 HW0100196-3 Casing 1

3012 HW9405703-1 Flange 1

3013 HW0402391-1 Collar 1

3014 HW0402390-1 Collar 1

3015 HW0402406-1 Collar 1

3016 GS210 O ring 1

3017 G270 O ring 1

3018 HW0401506-1 Plate 3

3019 HW0401507-1 Plate 1

3020 ISTW-36 Stopper 1

3021 IRTW-55 Stopper 1

3022 HW0402885-1 Cover 1

3023 MSTM8-20 Pin 1

3024 PT1/8 Plug 5

3025 TSH6-01M Union 2

3026 UB-0640-0.1C Tube 2











3037 HW9482316-A Bolt 1

3038 HW0408806-1 Washer 1





3044 SW-2H-12 Spring washer 16


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11 Parts List11.3 URBT-Axes Unit

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3047 HW9481343-A Shaft 1

3048 HW9482451-A Gear 1



2006 HW0100472-1 L arm 1

4009 HW0100172-2 U arm 1

Table 11-3: URBT-Axes Unit (Sheet 2 of 2)


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11.4 U-Arm Unit

Fig. 11-4: U-Arm Unit

40014030

4003

4004

4006

4006

4005

4007

4008

4009

4010

4011

4012

4013

4014

4015

4016

40174018

4019 4020

4021

40224023

40244025

40244025

4026

4028

4002

3011

4026

4029

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11 Parts List11.4 U-Arm Unit

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Table 11-4: U-Arm Unit


4001 NK25/20R Bearing 1


4003 6810DDU Bearing 1

4004 HR32017XJ Bearing 1



4007 AC2847-F3-FKM Oil seal 1

4008 AC3842-F1-FKM Oil seal 1

4009 HW0100172-2 U arm 1

4010 HW0312106-1 Shaft 1

4011 HW0302261-A Shaft 1

4012 HW0302262-B Shaft 1

4013 HW0303948-1 Gear 1

4014 HW0303950-1 Gear 1

4015 HW0303951-1 Gear 1

4016 HW0100173-1 Housing 1

4017 HW0401508-1 Plate 1

4018 HW0401505-1 B nut 1

4019 WR50 Sir clip 1

4020 MSTH6-15 Pin 1

4021 M4X6 H set screw 1






4028 PT1/8 Plug 1

4029 WR20 Retaining rings 1

4030 LRT202526 Bearing 1

3011 HW0100196-3 Casing 1

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11.5 Wrist Unit

Fig. 11-5: Wrist Unit

50025010

5020

5002A5095

5099

50865087

5075

5032

5033

5050-53 5049

5003

5004

5006

5014

5015

5022

50235041

5045

5046

5090

5089

5024-28

5090

5005

5011

5063-66

4010

50735074

5100

50715072

5078

5094

5035

50685067

5007

5007

5012

5016

5017

5018

5019

5062

50395040

5045

5054-57

5038

5040

5036

5007

50075008

5048

5047

5047

5088

5088

5058-615037

5001

50135021

5073

5074

5076

5048

5077

5034

5029-31

50695070

5096

5046

5098

5097

5091

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11 Parts List11.5 Wrist Unit

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Table 11-5: Wrist Unit (Sheet 1 of 2)


5001 HW9380961-D Speed reducer 1


5002A FU00SC Fine U nut 1

5003 6908DB Bearing 1

5004 6909 Bearing 1

5005 6009 Bearing 1

5006 6907 Bearing 1


5008 6911 Bearing 1

5010 HW0100475-1 Wrist 1

5011 HW0100476-1 Wrist base 1

5012 HW0200615-1 Cover 1

5013 HW0300889-1 Cover 1

5014 HW0301230-1 Gear 1

5015 HW0309164-1 Gear 1

5016 HW0301223-1 Gear 1

5017 HW0301224-1 Gear 1

5018 HW0301225-1 Gear 1

5019 HW0301226-1 Gear 1

5020 HW0301227-1 Gear 1

5021 HW0301231-1 Gear 1

5022 HW0401509-1 Housing 1

5023 HW0401510-1 B nut 1

5024 HW0401516-1 Shim 1

5025 HW0401516-2 Shim 1

5026 HW0401516-3 Shim 1

5027 HW0401516-4 Shim 1

5028 HW0401516-5 Shim 1

5029 HW0401517-1 Shim 1

5030 HW0401517-2 Shim 1

5031 HW0401517-3 Shim 1

5032 HW0304688-1 Flange 1

5033 HW9482951-A Packing 1

5034 ARP568-263 O ring 1

5035 G110 O ring 1

5036 S60 O ring 1

5037 HW9403618-1 Housing 1

5038 HW9403617-1 Housing 1

5039 AE3290E3 Oil seal 1

5040 HW0401514-1 B nut 2

5041 HW0401511-1 B cover 1

5045 STW-45 C stopper 2



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5048 PT1/8 Plug 2

5049 PT1/16 Plug 1

5050 HW0406766-1 Shim 1

5051 HW0406766-2 Shim 1

5052 HW0406766-6 Shim 1

5053 HW0406766-7 Shim 1

5054 HW9403621-1 Shim 1

5055 HW9403621-2 Shim 1

5056 HW9403621-5 Shim 1

5057 HW9403621-6 Shim 1

5058 HW9403622-1 Shim 1

5059 HW9403622-2 Shim 1

5060 HW9403622-4 Shim 1

5061 HW9403622-6 Shim 1

5062 HW0404270-1 Shim 1

5063 HW0410868-1 Shim 1

5064 HW0410868-2 Shim 1

5065 HW0410868-3 Shim 1

5066 HW0410868-4 Shim 1














5087 GT-SH-M14 Spring washer 4





5094 HW0411720-1 Cover 1

5095 HW0413886-3 Washer 1

5096 HW0411718-1 Collar 1

5097 HW0411721-1 B nut 1

5098 M5X7 Magic screw 2

5099 HW0406765-1 Collar 1


4010 HW0312106-1 Shaft 1

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


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11 Parts List11.6 Balancer Unit

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11.6 Balancer Unit

Fig. 11-6: Balancer Unit

2004

2008

2014

20152016

2013

20292030

6001

6002

6003

6004

6005

6006

6007

6008

6009

6010

6011

6017

6012

6012

6013

6014

60156016

6003

2006

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Table 11-6: Balancer Unit


6001 HW0481740-A Coil spring 1

6002 HW0481741-A Coil spring 1

6003 SOB607440 Oiless 2

6004 HW0100477-1 Case 1

6005 HW0306033-1 Flange 1

6006 HW0200420-1 Flange 1

6007 HW0401112-1 Flange 1

6008 HW0303581-1 Rod 1

6009 HW9405057-1 Clevis 1

6010 FD3187A0 Dust seal 1

6011 EZ2228B0 Cap 1

6012 IRTW-75 Stopper 2

6013 M6X8 Magic screw 2





2004 NA6912 Needle bearing 1

2006 HW0100472-1 L arm 1

2008 HW9302054-1 Shaft 1

2013 AR-85 Clip 1

2014 WR60 Sir clip 1

2015 VB75X95X6 Oil seal 1

2016 VB60X78X7 Oil seal 1

2029 12X50 Socket screw 12


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HEAD OFFICE2-1 Kurosakishiroishi, Yahatanishi-ku, Kitakyushu 806-0004, JapanPhone +81-93-645-7703 Fax +81-93-645-7802

100 Automation Way, Miamisburg, OH 45342, U.S.A. Phone +1-937-847-6200 Fax +1-937-847-6277

YASKAWA America Inc. (Motoman Robotics Division)

Yaskawastrasse 1, 85391 Allershausen, GermanyPhone +49-8166-90-100 Fax +49-8166-90-103

YASKAWA Europe GmbH Robotics Divsion )

Phone +82-2-784-7844 Fax +82-2-784-8495

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

YASKAWA Electric (Singapore) PTE Ltd.

No7 Yongchang North Road, Beijing E&T Development Area China 100176Phone +86-10-6788-2858 Fax +86-10-6788-2878

YASKAWA SHOUGANG ROBOT Co. Ltd.

#426, Udyog Vihar, Phase- IV, Gurgaon, Haryana, IndiaFax +91-124-475-8542Phone +91-124-475-8500

YASKAWA India Private Ltd. (Robotics Division)

YASKAWA Electric (China) Co., Ltd.22F, One Corporate Avenue, No.222, Hubin Road, Huangpu District, Shanghai 200021, ChinaPhone +86-21-5385-2200 Fax 86-21-5385-3299

YASKAWA Electric (Thailand) Co., Ltd.59,1st-5th Floor, Flourish Building, Soi Ratchadapisek 18,Ratchadapisek Road, Huaykwang, Bangkok 10310, THAILANDPhone +66-2-017-0099 Fax +66-2-017-0199

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

YASKAWA Electric Taiwan Corporation

Secure Building-Gedung B Lantai Dasar & Lantai 1 JI. Raya Protokol Halim Perdanakusuma, Jakarta 13610, Indonesia

Fax +62-21-2982-6741Phone +62-21-2982-6470

PT. YASKAWA Electric Indonesia

Phone +46-480-417-800 Fax +46-486-414-10

YASKAWA Nordic ABVerkstadsgatan 2, Box 504 ,SE-385 25 Torsas, Sweden

35F, Three IFC, 10 Gukjegeumyung-ro, Yeongdeungpo-gu, Seoul, Korea　07326YASKAWA Electric Korea Corporation

Specifications are subject to change without noticefor ongoing product modifications and improvements.

MANUAL NO.

9HW0485249

MOTOMAN-ES165DINSTRUCTIONS

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