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MOTOMAN-MH12

INSTRUCTIONS
TYPE:
YR-MA1440/MH12-A00 (STANDARD SPECIFICATION)
Upon receipt of the product and prior to initial operation, read these instructions thoroughly, and retain
for future reference.
MOTOMAN INSTRUCTIONS
MOTOMAN-MH12 INSTRUCTIONS
DX200 INSTRUCTIONS
DX200 OPERATORS MANUAL (for each purpose)
DX200 MAINTENANCE MANUAL
FS100 INSTRUCTIONS
FS100 OPERATORS MANUAL
FS100 MAINTENANCE MANUAL
The DX200/ FS100 operators manual above corresponds to specific usage. Be sure to use the appropriate manual.

Part Number:
Revision:

167105-1CD
2

MANUAL NO.

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Copyright 2016, 2015, 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-MH12 for the application to the
actual operation and for proper maintenance and inspection. It
describes on safety and handling, details on specifications,
necessary items on maintenance and inspection, to explain
operating instructions and maintenance procedures. Be sure to
read and understand this instruction manual thoroughly before
installing and operating the manipulator.

General items related to safety are listed in Chapter 1: Safety of the


DX200/FS100 Instructions. To ensure correct and safe operation,
carefully read the DX200/FS100 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 Association
900 Victors Way
P.O. Box 3724
Ann Arbor, Michigan 48106
TEL: (734) 994-6088
FAX: (734) 994-3338
www.roboticsonline.com
Ultimately, well-trained personnel are the best safeguard against
accidents and damage that can result from improper operation of the
equipment. The customer is responsible for providing adequately trained
personnel to operate, program, and maintain the equipment. NEVER
ALLOW UNTRAINED PERSONNEL TO OPERATE, PROGRAM, OR
REPAIR THE EQUIPMENT!
We recommend approved Yaskawa training courses for all personnel
involved with the operation, programming, or repair of the equipment.
This equipment has been tested and found to comply with the limits for a
Class A digital device, pursuant to part 15 of the FCC rules. These limits
are designed to provide reasonable protection against harmful
interference when the equipment is operated in a commercial
environment. This equipment generates, uses, and can radiate radio
frequency energy and, if not installed and used in accordance with the
instruction manual, may cause harmful interference to radio
communications.

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Notes for Safe Operation

Notes for Safe Operation


Read this manual carefully before installation, operation, maintenance, or
inspection of the MOTOMAN-MH12.
In this manual, the Notes for Safe Operation are classified as DANGER,
WARNING, CAUTION, MANDATORY, or PROHIBITED.

DANGER

Indicates an imminent hazardous


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

WARNING

Indicates a potentially hazardous


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

CAUTION

Indicates a potentially hazardous


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

MANDATORY items listed under this heading.

PROHIBITED

Must never be performed.

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


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

NOTE

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


to follow all instructions, even if not designated as
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

<DX200>

WARNING

Before operating the manipulator, check that servo power is turned


OFF pressing the emergency stop buttons on the front door of the
DX200 and the programming pendant.
When the servo power is turned OFF, the SERVO ON LED on the
programming pendant is turned OFF.

Injury or damage to machinery may result if the emergency stop circuit


cannot stop the manipulator during an emergency. The manipulator
should not be used if the emergency stop buttons do not function.
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
manipulators unexpected motion toward you.
Ensure that you have a safe place to retreat in case of
emergency.

Improper or unintended manipulator operation may result in injury.

Confirm that no person is present in the P-point maximum envelope


of the manipulator and that you are in a safe location before:
Turning ON the power for the DX200.
Moving the manipulator with the programming pendant.
Running the system in the check mode.
Performing automatic operations.

Injury may result if anyone enters the P-point maximum envelope of the
manipulator during operation. Always press an emergency stop button
immediately if there is a problem.
The emergency stop buttons are located on the right of front door of the
DX200 and the programming pendant.

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Notes for Safe Operation

<FS100>

WARNING

Before operating the manipulator, check that servo power is turned


OFF when the emergency stop button on the programming pendant
is pressed.
When the servo power is turned OFF, the SERVO ON LED on the
programing 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 button does not function.
Figure 3: Emergency Stop Button

In the case of not using the programming pendant, be sure to


supply the emergency stop button on the equipment. Then before
operating the manipulator, check to be sure that the servo power is
turned OFF by pressing the emergency stop button.
Connect the external emergency stop button to the 5-6 pin and
16-17 pin of the robot system signal connector (CN2).

Upon shipment of the FS100, this signal is connected by a jumper


cable in the dummy connector. To use the signal, make sure to
supply a new connector, and then input it.

If the signal is input with the jumper cable connected, it does not
function, which may result in personal injury or equipment damage.

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 4: Release of Emergency Stop Button
TURN

Observe the following precautions when performing teaching


operations within the manipulators operating range:
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.
Ensure that you have a safe place to retreat in case of
emergency.

Improper or unintended manipulator operation may result in injury.

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Notes for Safe Operation

WARNING

Confirm that no person is present in the manipulators operating


range and that you are in a safe location before:
Turning ON the power for the FS100.
Moving the manipulator with the programming pendant.
Running the system in the check mode.
Performing automatic operations.

Injury may result if anyone enters the manipulators operating range


during operation. Always press an emergency stop button immediately
if there are problems.
The emergency stop button is located on the programing pendant.

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 DX200/FS100 after use.

The programming pendant can be damaged if it is left in the


manipulator's work area, on the floor, or near fixtures.

Read and understand the Explanation of Warning Labels in the


DX200/FS100 Instructions before operating the manipulator:

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Definition of Terms Used In this Manual (DX200)

Definition of Terms Used In this Manual (DX200)


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

Manual Designation

DX200 controller

DX200

DX200 programming pendant

Programming pendant

Cable between the manipulator and the


controller

Manipulator cable

Definition of Terms Used In this Manual (FS100)


The MOTOMAN is the YASKAWA industrial robot product.
The MOTOMAN usually consists of the manipulator, the FS100 controller,
manipulator cables, the FS100 programming pendant (optional), and the
FS100 programming pendant dummy connector (optional).
In this manual, the equipment is designated as follows:
Equipment

Manual Designation

FS100 controller

FS100

FS100 programming pendant

Programming pendant

Cable between the manipulator and


the controller

Manipulator Cable

FS100 programming pendant


dummy connector

Programming pendant
dummy connector

Registered Trademark
In this manual, names of companies, corporations, or products are
trademarks, registered trademarks, or bland names for each company or
corporation. The indications of (R) and TM are omitted.

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Explanation of Warning Labels

Explanation of Warning Labels


The following warning labels are attached to the manipulator.
Always follow the warnings on the labels.
Also, an identification label with important information is placed on the
body of the manipulator. Prior to operating the manipulator, confirm the
contents.
Note: Taking the maintenance-relevant trainings offered by Yaskawa is
indispensable for replacing the L-axis of the balancer-equipped
manipulator.
Figure 5: Warning Label Locations

WARNING Label B
WARNING Label A

WARNING Label A

Nameplate

Nameplate:

WARNING Label A:

WARNING
Moving parts
may cause
injury

WARNING Label B:

WARNING
Do not enter
robot
work area.

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Customer Support Information

Customer Support Information


If you need assistance with any aspect of your MH12 system, please
contact Motoman Customer Support at the following 24-hour telephone
number:
(937) 847-3200

For routine technical inquiries, you can also contact Motoman Customer
Support at the following e-mail address:
techsupport@motoman.com

When using e-mail to contact Motoman 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.

NOTE

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


urgent or emergency need for service, replacement parts,
or information, you must contact Motoman Customer
Support at the telephone number shown above.

Please have the following information ready before you call Customer
Support:
System

MH12

Primary Application

___________________________

Controller

DX200/ FS100

Software Version

Access this information on the


Programming Pendants LCD
display screen by selecting {MAIN
MENU} - {SYSTEM INFO} {VERSION}

Robot Serial Number

Located on the robot data plate

Robot Sales Order Number

Located on the DX200/ FS100


controller data plate

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Customer Support Information

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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
2.1.2 Using a Forklift...................................................................................................... 2-2
2.2 Shipping Bolts and Brackets.............................................................................................. 2-3
2.3 Cushioning Material for Transport ..................................................................................... 2-4
3 Installation....................................................................................................................................... 3-1
3.1 Safeguarding Installation ................................................................................................... 3-2
3.2 Mounting Procedures for Manipulator Base ...................................................................... 3-2
3.2.1 Mounting Example................................................................................................ 3-4
3.3 Types of Mounting ............................................................................................................. 3-5
3.3.1 S-Axis Operating Range....................................................................................... 3-5
3.3.2 Fixing the Manipulator Base ................................................................................. 3-5
3.3.3 Precautions to Prevent the Manipulator from Falling............................................ 3-5
3.4 Location ............................................................................................................................. 3-6
4 Wiring.............................................................................................................................................. 4-1
4.1 Grounding .......................................................................................................................... 4-2
4.2 Cable Connection .............................................................................................................. 4-3
4.2.1 Connection to the Manipulator.............................................................................. 4-3
4.2.2 Connection to the DX200/FS100.......................................................................... 4-3
5 Basic Specifications ........................................................................................................................ 5-1
5.1 Basic Specifications........................................................................................................... 5-1
5.2 Part Names and Working Axes.......................................................................................... 5-2
5.3 Manipulator Base Dimensions ........................................................................................... 5-2
5.4 Dimensions and P-Point Maximum Envelope.................................................................... 5-3
5.5 Stopping Angles and Times for S-, L- and U-Axes (DX200).............................................. 5-4
5.5.1 Stop Category 0: Stopping Angles and Times...................................................... 5-4

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5.5.1.1 Position 100% ......................................................................................... 5-4


5.5.1.2 Position 66% ........................................................................................... 5-5
5.5.1.3 Position 33% ........................................................................................... 5-6
5.5.2 Stop Category 1: Stopping Angles and Times...................................................... 5-7
5.5.2.1 Position100% .......................................................................................... 5-7
5.5.2.2 Position 66% ........................................................................................... 5-8
5.5.2.3 Position 33% ........................................................................................... 5-9
5.6 Stopping Angles and Times for S-, L- and U-Axes (FS100) ............................................ 5-10
5.6.1 Stop Category 0: Stopping Angles and Times.................................................... 5-10
5.6.1.1 Position 100% ....................................................................................... 5-10
5.6.1.2 Position 66% ......................................................................................... 5-11
5.6.1.3 Position 33% ......................................................................................... 5-12
5.6.2 Stop Category 1: Stopping Angles and Times.................................................... 5-13
5.6.2.1 Position100% ........................................................................................ 5-13
5.6.2.2 Position 66% ......................................................................................... 5-14
5.6.2.3 Position 33% ......................................................................................... 5-15
5.7 Alterable Operating Range .............................................................................................. 5-16
5.7.1 Components for Altering Operating Range......................................................... 5-16
5.7.2 Notes on the Mechanical Stopper Installation .................................................... 5-17
5.7.3 Adjustment to the Pulse Limitation of S-Axis ...................................................... 5-17
6 Allowable Load for Wrist Axis and Wrist Flange ............................................................................. 6-1
6.1 Allowable Wrist Load ......................................................................................................... 6-1
6.2 Wrist Flange....................................................................................................................... 6-2
7 System Application.......................................................................................................................... 7-1
7.1 Peripheral Equipment Mounts............................................................................................ 7-1
7.1.1 Allowable Load ..................................................................................................... 7-1
7.1.2 Installation Position............................................................................................... 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
8.2 Position of Servo ON Lamp ............................................................................................... 8-2
8.3 Internal Connections .......................................................................................................... 8-3
9 Maintenance and Inspection ........................................................................................................... 9-1
9.1 Inspection Schedule........................................................................................................... 9-1
9.2 Notes on Maintenance Procedures.................................................................................... 9-5

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Table of Contents

9.2.1 Battery Pack Replacement ................................................................................... 9-5


9.3 Notes on Grease Replenishment/Exchange Procedures .................................................. 9-6
9.3.1 Grease Replenishment/Exchange for S-Axis Speed Reducer ............................. 9-7
9.3.1.1 Grease Replenishment............................................................................ 9-7
9.3.1.2 Grease Exchange ................................................................................... 9-8
9.3.2 Grease Replenishment/Exchange for L-Axis Speed Reducer.............................. 9-9
9.3.2.1 Grease Exchange ................................................................................... 9-9
9.3.2.2 Grease Exchange ................................................................................. 9-10
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 ................................................................................. 9-14
9.3.4 Grease Replenishment for R-Axis Speed Reducer ............................................ 9-15
9.3.5 Grease Replenishment for B-Axis Speed Reducer ............................................ 9-16
9.3.6 Grease Replenishment for T-Axis Gear ............................................................. 9-17
9.3.7 Grease Replenishment for R-Axis Gear ............................................................. 9-19
9.3.8 Notes for Maintenance ....................................................................................... 9-21
9.3.8.1 Wrist Unit............................................................................................... 9-21
9.3.8.2 Battery Pack Connection....................................................................... 9-21
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 U-Axis Unit..................................................................................................................... 11-5
11.4 R-Axis Unit (Shipped in or After August 2014) .............................................................. 11-7
11.5 Wrist Unit ....................................................................................................................... 11-9
11.6 Gear Unit (No. 5040) ................................................................................................... 11-12

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1 Product Confirmation
1.1 Contents Confirmation

Product Confirmation

CAUTION

Confirm that the manipulator and the DX200/FS100 have the same
order number. Special care must be taken when more than one
manipulator is to be installed.

If the numbers do not match, manipulators may not perform as


expected and cause injury or damage.

1.1

Contents Confirmation
Confirm the contents of the delivery when the product arrives.
Standard delivery includes the following four items (information for the
content of optional goods are given separately):
Manipulator
DX200/FS100
Programming pendant
Manipulator cables (between the DX200/FS100 and the Manipulator)

1-1

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1 Product Confirmation
1.2 Order Number Confirmation

1.2

Order Number Confirmation


Check that the order number of the manipulator corresponds to the
DX200/FS100. The order number is located on a label as shown below.

Fig. 1-1: Location of Order Number Labels

Label (Enlarged View)


THE MANIPULATOR AND THE CONTROLLER
SHOULD HAVE SAME ORDER NUMBER.

ORDER NO.

Check that the manipulator


and the DX200/FS100 have the
same order number.

US

PROGRAMMING PENDANT

X81

CN

FBB
CN210 CN211

(c) FS100 (Front View)

(a) DX200 (Front View)

(b) Manipulator (Top View)

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2 Transport
2.1 Transport Method

Transport

CAUTION

Sling applications and crane or forklift operations must be


performed by authorized personnel only.

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

Avoid excessive vibration or shock during transport.

The system consists of precision components. Failure to observe this


caution may adversely affect performance.

2.1

Transport Method

The weight of the manipulator is approximately 135 kg


including the shipping bolts and brackets. Use a wire rope
strong enough to withstand the weight.

NOTE

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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2 Transport
2.1 Transport Method
2.1.1

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

View A

Shipping bolts and bracket


#
#
$

GT-SA bolt M10X25


(2 eyebolts)

2.1.2

Using a Forklift
When using a forklift, the manipulator should be fixed on a pallet with
shipping bolts as shown in Fig. 2-2 Using a Forklift. Insert claws under
the pallet and lift it. The pallet must be strong enough to support the
manipulator. Transport the manipulator slowly with due caution in order to
avoid overturning or slippage.
Fig. 2-2: Using a Forklift

Pallet

Bolt M16 (4 places)

Forklift claw entries

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2 Transport
2.2 Shipping Bolts and Brackets

2.2

Shipping Bolts and Brackets


The manipulator is provided with two shipping bolts and a shipping
bracket. (See Fig. 2-4 Cushioning Materials for Transport.)
Fig. 2-3: Shipping Bolts and Brackets
Shipping bolts and bracket

GT-SA bolt M10X25


(2 eyebolts)

Front View

Side View

The shipping bolts and bracket are painted yellow.


The shipping bracket is to be fixed with the GT-SA bolt M10
(length: 25mm) (2 screws).

NOTE

Before 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.

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2 Transport
2.3 Cushioning Material for Transport

2.3

Cushioning Material for Transport


The manipulator is provided with the cushioning materials for transport at
sections A and B. (See Fig. 2-4 Cushioning Materials for Transport.)
Fig. 2-4: Cushioning Materials for Transport

A rubber cushion is respectively wedged at the sections A and B.

NOTE

Before turning ON the power, check to be sure that the


cushioning materials for transport are removed.
In the event that the manipulator must be moved again, to
avoid its main body from being damaged, the cushioning
materials such as rubber plate, etc. must be used.

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Installation

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.

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

Failure to observe these warnings may result in 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. 2-4 Cushioning Materials for
Transport on page 2-4 are removed.

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


parts.

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3 Installation
3.1 Safeguarding Installation

3.1

Safeguarding Installation
To insure safety, be sure to install safeguarding. It prevents unforeseen
accidents with personnel and damage to equipment. Refer to the quoted
clause for your information and guidance.
Responsibility for Safeguarding (ISO10218)
The user of a manipulator or robot system shall ensure that safeguards
are provided and used in accordance with Sections 6, 7, and 8 of this
standard. The means and degree of safeguarding, including any
redundancies, shall correspond directly to the type and level of hazard
presented by the robot system consistent with the robot application.
Safeguarding may include but not be limited to safeguarding devices,
barriers, interlock barriers, perimeter guarding, awareness barriers, and
awareness signals.

3.2

Mounting Procedures for Manipulator Base


The manipulator should be firmly mounted on a base plate or foundation
strong enough to support the manipulator and withstand repulsion forces
during acceleration and deceleration.
Construct a solid foundation with the appropriate thickness to withstand
maximum repulsion forces of the manipulator referring to Table 3-1
"Manipulator Repulsion Force and Torque".
A base plate 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: Manipulator Repulsion Force and Torque


Horizontal rotation

Vertical rotation

Repulsion force FH Torque MH

Repulsion force FH Torque MV

Emergency stop

9025 N
(920 kgf)

4120 Nm
(420 kgfm)

5885 N
(600 kgf)

4120 Nm
(420 kgfm)

Acceleration/
deceleration

3140 Nm
(320 kgf)

1275 Nm
(130 kgfm)

2355 Nm
(240 kgf)

1670 Nm
(170 kgfm)

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3 Installation
3.2 Mounting Procedures for Manipulator Base
Fig. 3-1: Manipulator Repulsion Force and Torque

/8

(8

/*
(*

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3.2 Mounting Procedures for Manipulator Base
Mounting Example
For the first process, anchor the base plate firmly to the ground. The base
plate should be rugged and durable to prevent shifting of the manipulator
or the mounting fixture. It is recommend to prepare a base plate of 40 mm
or more thick, and anchor bolts of M16 or larger size.
The manipulator base is tapped for four mounting holes; securely fix the
manipulator base to the base plate with four hexagon head bolts M16
(50 mm long is recommended).
Next, fix the manipulator base to the base plate. Tighten the hexagon
head bolts and anchor bolts firmly so that they will not work loose during
the operation.
Refer to Fig. 3-2 Mounting the Manipulator on Base Plate.
Fig. 3-2: Mounting the Manipulator on Base Plate
Hexagon head bolt M16 (4 bolts)
Spring washer
Washer

20

Manipulator base
Baseplate

40 mm
or more
Manipulator base

Anchor bolt (M16 or larger)


Baseplate

300
240

Baseplate

260
60

12 dia.

292

260

60

18 dia. (4 holes)

300

3.2.1

+0.018
0

16 dia.

1000.1

+0.018
0

(2 holes)

View A

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3 Installation
3.3 Types of Mounting

3.3

Types of Mounting
The MOTOMAN-MH12 is available in three types: floor-mounted type
(standard), wall-mounted type, and ceiling-mounted type. For wallmounted and ceiling-mounted types, the three points listed below are
different from the floor-mounted type.
S-Axis Operating Range
Fixing the Manipulator Base
Precautions to Prevent the Manipulator from Falling

3.3.1

S-Axis Operating Range


For wall-mounted type, the S-axis operating range is 30.
(The range is adjusted prior to the shipment.)

3.3.2

Fixing the Manipulator Base


For wall- and ceiling-mounted types, be sure to use four hexagon socket
head cap screws M16 (tensile strength: 1200 N/mm2 or more) when fixing
the manipulator base. Use a torque of 206 Nm when tightening the
screws.

3.3.3

Precautions to Prevent the Manipulator from Falling


For the wall- or ceiling-mounted types, take appropriate measures to avoid
the falling of the manipulator in case of emergency. Refer to Fig. 3-3
Precaution Against Falling for details.
Fig. 3-3: Precaution Against Falling

Support for fall prevention


Manipulator base
Hexagon socket head cap
screw M16 (4 places)
(Tensile strength: 1200 N/mm2 or more)

NOTE

In case of using the wall/ceiling-mounted type, inform


Yaskawa of the matter when placing an order. Be sure to
contact your Yaskawa representative (listed on the back
cover of this instruction manual) to perform a wall/ceiling
installation on site.

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3.4 Location

3.4

Location
When installing a manipulator, it is necessary to satisfy the following
environmental conditions:
Ambient temperature: 0 to + 45 C
Humidity: 20 to 80 %RH (no-condensing)
Free from dust, soot, oil, or water
Free from corrosive gas or liquid, or explosive gas or liquid.
Free from excessive vibration (Vibration acceleration: 4.9 m/s2
[0.5 G] or less)
Free from large electrical noise (plasma)
Flatness for installation: 0.5 mm or less

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Wiring

Wiring

WARNING

Ground resistance must be 100 or less.

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

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

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

CAUTION

Wiring must be performed by authorized or certified personnel.

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

Do not cover the cable or allow it to tangle. Keep the cable as


straight as possible.

Failure to observe this caution may result in preventing heat of the


cable from being discharged.

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4.1 Grounding

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.

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.

Fig. 4-1: Grounding Method

Section A

Bolt M8 (For grounding)


Delivered with the manipulator

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4.2 Cable Connection

4.2

Cable Connection
Two manipulator cables are delivered with the manipulator; an encoder
cable (1BC) and a power cable (2BC).
(Refer to Fig. 4-2(a) Manipulator Cables (DX200),Fig. 4-2(b)
Manipulator Cables (FS100).)
Connect these cables to the manipulator base connectors and to the
DX200/FS100. Refer to Fig. 4-3 Manipulator Cable Connectors
(Manipulator Side) ,Fig. 4-4(a) Manipulator Cable Connection (DX200
Side) and Fig. 4-4(b) Manipulator Cable Connection (FS100 Side).

4.2.1

Connection to the Manipulator


Before connecting 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, then 1BC. After inserting the cables, depress the lever until it clicks.

4.2.2

Connection to the DX200/FS100


Before connecting two cables to the DX200/FS100, verify the numbers on
both manipulator cables and the connectors on the DX200/FS100. When
connecting, insert the cables in the order of X21, then X11, and depress
each lever low until it clicks.

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4.2 Cable Connection
Fig. 4-2(a): Manipulator Cables (DX200)

Manipulator Side

DX200 Side

X11

1BC

X11

1BC

1BC

Encoder Cable

DX200 Side

Manipulator Side

2BC

X21

MH12

2BC
X21

2BC

Power Cable

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4.2 Cable Connection
Fig. 4-2(b): Manipulator Cables (FS100)

Manipulator Side

FS100 Side

X11

1BC

1BC
X11

1BC
molex

Encoder Cable
Manipulator Side

FS100 Side

2BC

X21

MH12

2BC

X21

2BC

Power Cable

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

Connector Details
(Manipulator Side)

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4.2 Cable Connection
Fig. 4-4(a): Manipulator Cable Connection (DX200 Side)

X11

X21

Fig. 4-4(b): Manipulator Cable Connection (FS100 Side)

X21

X11

Back View

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5 Basic Specifications
5.1 Basic Specifications

Basic Specifications
5.1

Basic Specifications

Table 5-1: Basic Specifications1)


Item

Model

MOTOMAN-MH12

Structure

Vertically Articulated

Degree of Freedom

Payload

12 kg

Repeatability2)

0.08 mm

Range of Motion

Maximum Speed

3)

Allowable Moment

S-Axis (turning)

-170 - +170

L-Axis (lower arm)

-90 - +155

U-Axis (upper arm)

-175 - +240

R-Axis (wrist roll)

-180 - +180

B-Axis (wrist pitch/yaw)

-135 - +135

T-Axis (wrist twist)

-360 - +360

S-Axis

3.84 rad/s, 220/s

L-Axis

3.49 rad/s, 200/s

U-Axis

3.84 rad/s, 220/s

R-Axis

7.16 rad/s, 410/s

B-Axis

7.16 rad/s, 410/s

T-Axis

10.6 rad/s, 610/s

R-Axis

22 Nm (2.2 kgfm)

B-Axis

22 Nm (2.2 kgfm)

T-Axis

9.8 Nm (1.0 kgfm)

Allowable Inertia (GD2/4) R-Axis

0.65 kgm2

B-Axis

0.65 kgm2

T-Axis

0.17 kgm2

Approx. mass
Ambient Conditions

Power Requirements
Noise

4)

130 kg
Temperature

0C to 45 C

Humidity

20 to 80% RH (non-condensing)

Vibration Acceleration

4.9 m/s2 or less (0.5 G)

Others

Free from corrosive gasses or liquids, or explosive gasses


Free from exposure to water, oil, or dust
Free from excessive electrical noise (plasma)
1.5 kVA
Less than 78.8 dB

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


).
2 Conformed to ISO9283
3 Refer to section 6.1 Allowable Wrist Load on page 6-1
for details on the permissible moment of inertia.
4 Conformed to ISO6926
1, Measurement is carried out when the maximum load is mounted to the manipulator and
operated in the maximum speed.
2, Measurement is carried out:
- between 1.2 m and 1.5 m above the ground.
- 400 mm away from the P-point maximum envelope.

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5 Basic Specifications
5.2 Part Names and Working Axes

5.2

Part Names and Working Axes


Fig. 5-1: Part Names and Working Axes
U+

U-arm

R+

B+

T+
Wrist flange

U-

L-

R-

B-

T-

L+
L-arm

S-head
S+

S-

5.3

Manipulator base

Manipulator Base Dimensions

Fig. 5-2: Manipulator Base Dimensions

300
240

60
60

260

292

300

18 dia.
(4 holes)

20

Baseplate

260

+0.018
0

12 dia.

+0.018

16 dia. 0
(2 holes)

View A

Units: mm

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5 Basic Specifications
5.4 Dimensions and P-Point Maximum Envelope

5.4

Dimensions and P-Point Maximum Envelope

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

13

26

R4
10

170

45

R4

10

170

R14

40

P-point maximum
envelope
195
100

2
640

100

90

614

84

85

200

155

94.5

1734

198.5

705

450

2511

155

240

299
0

361
17

5-3

1440

410

206

606

848

1129

777

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5 Basic Specifications
5.5 Stopping Angles and Times for S-, L- and U-Axes (DX200)

5.5

Stopping Angles and Times for S-, L- and U-Axes (DX200)


Following data on stopping angle and time for each axis measured under
the standard of ISO10218.

5.5.1
5.5.1.1

Stop Category 0: Stopping Angles and Times

Position 100%

Fig. 5-4: Stop Category 0, Position 100% : Stopping Angle and Time for each Axis
(a)S-Axis

(b)L-Axis

(c)U-Axis

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5.5.1.2

5 Basic Specifications
5.5 Stopping Angles and Times for S-, L- and U-Axes (DX200)
Position 66%

Fig. 5-5: Stop Category 0, Position 66% : Stopping Angle and Time for each Axis
(a)S-Axis

(b)L-Axis

(c)U-Axis

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5.5.1.3

5 Basic Specifications
5.5 Stopping Angles and Times for S-, L- and U-Axes (DX200)
Position 33%

Fig. 5-6: Stop Category 0, Position 33% : Stopping Angle and Time for each Axis
(a)S-Axis

(b)L-Axis

(c)U-Axis

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5 Basic Specifications
5.5 Stopping Angles and Times for S-, L- and U-Axes (DX200)
5.5.2

Stop Category 1: Stopping Angles and Times

NOTE

5.5.2.1

Stopping angles and times at Stop category 1 are not


subjected to the load of the manipulator.

Position100%

Fig. 5-7: Stop Category 1: Position 100% Stopping Angle and Time for each Axis
(a)S-Axis

Notes) Not depends on the load


(b)L-Axis

Notes) Not depends on the load


(c)U-Axis

Notes) Not depends on the load

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5.5.2.2

5 Basic Specifications
5.5 Stopping Angles and Times for S-, L- and U-Axes (DX200)
Position 66%

Fig. 5-8: Stop Category 1: Position 66% Stopping Angle and Time for each Axis
(a)S-Axis

Notes) Not depends on the load


(b)L-Axis

Notes) Not depends on the load


(c)U-Axis

Notes) Not depends on the load

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5.5.2.3

5 Basic Specifications
5.5 Stopping Angles and Times for S-, L- and U-Axes (DX200)
Position 33%

Fig. 5-9: Stop Category 1: Position 33% Stopping Angle and Time for each Axis
(a)S-Axis

Notes) Not depends on the load


(b)L-Axis

Notes) Not depends on the load


(c)U-Axis

Notes) Not depends on the load

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5 Basic Specifications
5.6 Stopping Angles and Times for S-, L- and U-Axes (FS100)

5.6

Stopping Angles and Times for S-, L- and U-Axes (FS100)


Following data on stopping angle and time for each axis measured under
the standard of ISO10218.

5.6.1
5.6.1.1

Stop Category 0: Stopping Angles and Times

Position 100%

Fig. 5-10: Stop Category 0, Position 100% : Stopping Angle and Time for each Axis
(a)S-Axis

(b)L-Axis

(c)U-Axis

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5.6.1.2

5 Basic Specifications
5.6 Stopping Angles and Times for S-, L- and U-Axes (FS100)
Position 66%

Fig. 5-11: Stop Category 0, Position 66% : Stopping Angle and Time for each Axis
(a)S-Axis

(b)L-Axis

(c)U-Axis

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5.6.1.3

5 Basic Specifications
5.6 Stopping Angles and Times for S-, L- and U-Axes (FS100)
Position 33%

Fig. 5-12: Stop Category 0, Position 33% : Stopping Angle and Time for each Axis
(a)S-Axis

(b)L-Axis

(c)U-Axis

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5 Basic Specifications
5.6 Stopping Angles and Times for S-, L- and U-Axes (FS100)
5.6.2

Stop Category 1: Stopping Angles and Times

NOTE

5.6.2.1

Stopping angles and times at Stop category 1 are not


subjected to the load of the manipulator.

Position100%

Fig. 5-13: Stop Category 1: Position 100% Stopping Angle and Time for each Axis
(a)S-Axis

Notes) Not depends on the load


(b)L-Axis

Notes) Not depends on the load


(c)U-Axis

Notes) Not depends on the load

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5.6.2.2

5 Basic Specifications
5.6 Stopping Angles and Times for S-, L- and U-Axes (FS100)
Position 66%

Fig. 5-14: Stop Category 1: Position 66% Stopping Angle and Time for each Axis
(a)S-Axis

Notes) Not depends on the load


(b)L-Axis

Notes) Not depends on the load


(c)U-Axis

Notes) Not depends on the load

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5.6.2.3

5 Basic Specifications
5.6 Stopping Angles and Times for S-, L- and U-Axes (FS100)
Position 33%

Fig. 5-15: Stop Category 1: Position 33% Stopping Angle and Time for each Axis
(a)S-Axis

Notes) Not depends on the load


(b)L-Axis

Notes) Not depends on the load


(c)U-Axis

Notes) Not depends on the load

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5 Basic Specifications
5.7 Alterable Operating Range

5.7

Alterable Operating Range


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

5.7.1

Item

Specifications

S-Axis Operating
Range

-170 - +170 (standard)


-150 - +150
-135 - +135
-120 - +120
-105 - +105
-90 - +90
-75 - +75
-60 - +60
-45 - +45
-30 - +30

Components for Altering Operating Range


Arrange the components listed in Fig. 5-16 The Components of the SAxis Stopper and Stopper Mounting Position, when modifying the angle
of S-axis.
(1) Dog (drawing No. HW0414041-2) (2 dogs)
(2) Hexagon socket head cap screw M12
(length: 30 mm) (2 screws)
(Tensile strength: 1200 N/mm2 or more)
(3) Conical spring washer M12 (2 washers)

Fig. 5-16: The Components of the S-Axis Stopper and Stopper Mounting Position

S-axis Operating Range

Stopper position

-135 VQ+135

-120 VQ+120

-105 VQ+105

-90 VQ+90

-75 VQ+75
-60 VQ+60

f
g

-45 VQ+45

-30 VQ+30

c
b
a

a
b

it)

al Lim

-150 VQ+150

hanic
(Mec

-170 VQ+170

c
i

d
g

(Mechanical Limit)

HW0414041-2dog(2 dogs)

M12 tap (18 places)


Hexagon socket head cap screw M12
(length: 30 mm) (2 screws)
( Tensile strength: 1200 N/mm2 or more)
Conical spring washer M12 (2 washers)
Tightening torque: 84N m(8.6kgf m)

Section A-A
Dog Mouting Position

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5 Basic Specifications
5.7 Alterable Operating Range
5.7.2

Notes on the Mechanical Stopper Installation


As shown in Fig. 5-16 The Components of the S-Axis Stopper and
Stopper Mounting Position on page 5-16, as a mechanical stopper, mount
a dog (HW0414041-2) on the S-head by using one hexagon socket head
cap screw M12 (length: 30 mm) (2 places) (tensile strength: 1200 N/mm2
or more). The mechanical stopper is not necessary when the operating
range is set to 170 (Standard specification).
The mechanical stopper can be set at 15 pitch intervals from 30 to 150
range.
For the settable angles, refer to Table 5-3 "The Settable Angle for S-Axis
Stopper"

NOTE

1. Apply the specified components when mounting the


S-Axis mechanical stopper.
2. TURN OFF the electric power supply before mounting.

5.7.3

Adjustment to the Pulse Limitation of S-Axis


Apply the Instruction for DX200 Instructions section 8.17 Changing the
Parameter Setting (165292-1CD) as part of reference materials for
adjusting the programming pendant when modifying the range of motion
of S-Axis.
The limitation to the pulse (Pulse Soft Limit + 1st Axis) : SICxG400
The limitation to the pulse (Pulse Soft Limit - 1st Axis) : SICxG408

Degree
Number
of Pulse

Degree
Number
of Pulse

NOTE

30
43061

45
64591

60
86121

75
107651

90
129182

105
150712

120
172242

135
193772

150
215303

170
244010

Adjust 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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The Angle of S-Axis Stopper for - Direction

Settable angle
Non settable angle

"Table 5-3 The Settable Angle for S-Axis Stopper" indicates the angle range which
allows S-axis to be set for + direction and - direction angles.
(Ex. -150 to +150 is settable, however 0 to +135 is not settable)

The Angle of S-Axis Stopper for + Direction



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5 Basic Specifications
5.7 Alterable Operating Range

Table 5-3: The Settable Angle for S-Axis Stopper

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Allowable Load for Wrist Axis and Wrist Flange


Allowable Wrist Load
The allowable wrist load is 12 kg maximum. If force is applied to the wrist
instead of the load, force on R-, B-, and T-axes should be within the value
shown in Table 6-1 "Allowable Wrist Load". Contact your Yaskawa
representative for further information or assistance.
Table 6-1: Allowable Wrist Load
Axis

Moment Nm (kgfm)1)

GD2/4 Total Moment of Inertia


kgm2

R-Axis

22 (2.2)

0.65

B-Axis

22 (2.2)

0.65

T-Axis

9.8 (1.0)

0.17

1 ( ): Gravitational unit

When the volume load is small, refer to the moment arm rating shown in
Fig. 6-1 Moment Arm Rating.
The allowable total moment of inertia is calculated when the moment is at
the maximum. Contact your Yaskawa representative beforehand when
only moment of inertia, or load moment is small and moment of inertia is
large. Also, when the load mass is combined with an outside force,
contact your Yaskawa representative beforehand.
Fig. 6-1: Moment Arm Rating
LB

100

LT

Load gravity position

LT

6.1

R-, T-axis
rotation center

300
238

LT [mm]

6 Allowable Load for Wrist Axis and Wrist Flange


6.1 Allowable Wrist Load

W=3Kg

200
167

W=6Kg
100
83

W=12Kg
100

187

200

300

329

400

465

500

LB [mm]

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6 Allowable Load for Wrist Axis and Wrist Flange


6.2 Wrist Flange

6.2

Wrist Flange
The wrist flange dimensions are shown in Fig. 6-2 Wrist Flange.
It is recommended that the attachment be mounted outside the fitting in
order to identify the alignment marks. Fitting depth shall be 5 mm or less.
The attachment should be mounted inside the range shown in the figure
below.
Fig. 6-2: Wrist Flange
Tapped holes M4 (8 holes)
(Pitch: 0.7)(Depth: 8)
+0.012

4 dia. 0
(Depth: 6)

22.5

Dia.100

5
Attachments should be
mounted within this
range.

NOTE

0
62 dia. -0.019 (Depth: 6)

Dia.100

Dia.50

62 dia. -0.019

56

Wash off anti-corrosive paint (yellow) on the wrist flange


surface with thinner or light oil before mounting the tools.

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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 on page 7-1 for easier installation of the userss system
applications. The following conditions shall be observed to attach or
install peripheral equipment.

7.1.1

Allowable Load
The maximum allowable load on the U-axis is 22 kg, including the wrist
load.
For instance, when the mass installed on the wrist point is 12 kg, the mass
which can be installed on the upper arm is 10 kg.
The maximum allowable load on the S-axis is 20 kg. Install the peripheral
equipment on the S-axis so that the moment of inertia (GD2/4) from the
S-axis rotation center is 1.25 kgm2 or less.
Installation Position
There is a limitation on where to install the peripheral equipment as shown
in Fig. 7-1 Installing Peripheral Equipment on the following page.

70

Tapped hole M8 (4 holes)


(Depth: 18) (Pitch: 1.25)

130

Fig. 7-1: Installing Peripheral Equipment

48
78

24

165

15

Tapped hole M6 (2 holes)


(Depth: 12) (Pitch: 1.0)

28.5

50

View B

Mount the peripheral


equipment within this range
300

Mount the peripheral


equipment so that the
center of gravity of
the peripheral equipment
on the U-arm should be
within this range

Tapped hole M6 (2 holes)


(Depth: 12) (Pitch: 1.0)

60
130

26

Tapped hole M6 (4 holes)


(Depth: 14) (Pitch: 1.0)

60

13

206

7.1.2

50

7 System Application
7.1 Peripheral Equipment Mounts

45

110 90
Tapped hole M10 (4 holes)
(Depth: 18) (Pitch: 1.5)

7-1

475

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7 System Application
7.2 Internal User I/O Wiring Harness and Air Line

7.2

Internal User I/O Wiring Harness and Air Line


Internal user I/O wiring harness (14 wires: 0.2 mm2 x 8 wires, 0.75 mm2 x
2 wires and 1.25 mm2 x 4 wires), and an air line are incorporated in the
manipulator for the drive 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 1 to 16 are assigned as shown in Fig. 7-3 Details of
the Connector Pin Numbers on page 7-4 on the following page. Wiring
must be performed by users.
The following optional can be incorporated in the manipulator.
A. Cables for the power for arc welding and an air line
B. An air line

The allowable current for internal user


I/O wiring harness

3 A or less for each wire


(The total current value for pins 1 to 16 must be 40 A or less.)

The maximum pressure for the air line 490 kPa (5 kgf/cm2) or less
(The air line inside diameter: 8.0mm and 6.5 mm (With optional A and
B))
The allowable current for arc welding
power cable (With optional A)

Rated current of 350 A or less and the rated operational ratio should be
60% or lower.
The allowable operational ratio when it is operated with less current
than the allowable current is calculated by the following formula.
Allowable operational ratio = 60% x (350A/operating current )2

7-2

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7 System Application
7.2 Internal User I/O Wiring Harness and Air Line

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

Air Inlet A
PT3/8
with a pipe plug

Air Inlet B
PT3/8
with a pipe plug
Usable to optional A or B only

Connector for the internal user I/O wiring harness:


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

Power cable terminal block for arc welding


TS200CHM (with a cover)
9KVJoptional A
#

Air Inlet B
PT3/8
with a pipe plug

Air Inlet A
PT3/8
with a pipe plug

Power cable terminal block for arc welding


Recomennded crimpted terminal: R100-10
Cover (TCV-2001-04) is packed.

With optional A
Air Inlet B
PT3/8
with a pipe plug

Connector for the internal user I/O


wiring harness: JL05-2A20-29PC (with a cap)
Prepare connector JL05-6A20-29

View A
Standard specification

With optional B

7-3

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7 System Application
7.2 Internal User I/O Wiring Harness and Air Line
Fig. 7-3: Details of the Connector Pin Numbers
Connector for Internal User I/O Wiring Harness
on the Connector Base

Pins used

1
2
3
4
5
6
7Open
8Open
9
10
11(0.75mm2 )
12(0.75mm2)
13(1.25mm2 )
14(1.25mm2 )
15(1.25mm2 )
16(1.25mm2 )

1
2

3
5

11

12

10
14

13
16

15

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


: 0.75 mm2, 2 wires
: 1.25 mm2, 4 wires
Details of the Connector Pin Numbers

Connector for Internal User I/O Wiring Harness


on the U-arm

Pins used

1
2
3
4
5
6
7 (+24V: for shock sensor)
8 (Shock sensor signal input)
9
10
11(0.75mm2 )
12(0.75mm2 )
13(1.25mm2 )
14(1.25mm2 )
15(1.25mm2 )
16(1.25mm2 )

1
2

3
5

11

12

10

14

13
15

16

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


: 0.75 mm2, 2 wires
Details of the Connector Pin Numbers
: 1.25 mm2, 4 wires

For the standard specification, the pins No.7 and No.8 of


3BC connector on the U-arm are respectively connected
with the shock sensor power supply and shock sensor
signal input port of the DX200/FS100 controller.

NOTE

The pins No.7 and No.8 of respective 3BC connectors on


the connector base side and the U-arm side are not
connected with each other.
For wiring, refer to Fig. 8-4(a) Internal Connection
Diagram DX200)and Fig. 8-4(c) Internal Connection
Diagram (FS100).

The same pin-number connectors (1 to 16) at both connector base part


and arm part are connected with the single wire lead of 0.2 mm2,
0.75 mm2 or 1.25 mm2.

7-4

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8 Electrical Equipment Specification


8.1 Position of Limit Switch

Electrical Equipment Specification


8.1

Position of Limit Switch


The limit switches are optional. See Fig. 8-1 Location of Limit Switches.
Fig. 8-1: Location of Limit Switches

LU-axis interference
limit switch (optional)

S-axis overrun
limit switch (optional)

8-1

L-axis overrun
limit switch (optional)

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8 Electrical Equipment Specification


8.2 Position of Servo ON Lamp

8.2

Position of Servo ON Lamp


The limit switches are optional. See Fig. 8-2 Location of Servo On Lamp
Fig. 8-2: Location of Servo On Lamp
Servo ON lamp
(Optional)

8-2

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8 Electrical Equipment Specification


8.3 Internal Connections

8.3

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. 8-3
Locations and Numbers of Connectors.
Diagrams for Internal connections of the manipulator are shown in Fig.
8-4(a) Internal Connection Diagram DX200) , Fig. 8-4(a) Internal
Connection Diagram DX200), Fig. 8-4(c) Internal Connection Diagram
(FS100)and Fig. 8-4(d) Internal Connection Diagram (FS100).
Fig. 8-3: Locations and Numbers of Connectors
3BC (for internal user I/O wiring harness)
on the U-arm

3BC (for internal user I/O wiring harness)


on the connector base

Table 8-1: List of Connector Types


Name

Type of Connector

Connector for the internal user I/O


wiring harness on the connector
base

JL05-2A20-29PC
(JL05-6A20-29S: Optional)

Connector for the internal user I/O


wiring harness on the U-arm

JL05-2A20-29SC
(JL05-6A20-29P: Optional)

8-3

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8 Electrical Equipment Specification


8.3 Internal Connections
Fig. 8-4(a): Internal Connection Diagram DX200)
Internal Cable

Power Cable

Note
1.For the limit switch specification, the connection of the section A B is changed as follows:
LC1
LD1 LD1

LC1
LD1

S-AXIS OVERRUN L.S.

LC2
LD2

LD1

LC3
LD3

0BT
P BAT
0BT
P BAT

0BT
P BAT
0BT
P BAT

1
2
3
4

5
6
7
8

0BAT11
BAT11
0BAT12
BAT12

0BAT21
BAT21
0BAT22
BAT22

1
2
3
4
5
6
7
8
1BC(10X4)

DX200
CN1-5
CN1-4

CN1-5
CN1-4

+24V
0V

1
3

CN1-10
CN1-9

CN1-10
CN1-9

+24V
0V

2
4

CN1-1
CN1-2

SPG+1
SPG-1

CN1-1
CN1-2

17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16

LA1
LB1 LB1

0BAT1
BAT1
0BAT2
BAT2
0BAT3
BAT3

LA1
LB1

CN1-6
CN1-7

CN1-6
CN1-7

PG0V1
PG5V1
PG0V2
PG5V2
PG0V3
PG5V3
PG0V4
PG5V4
PG0V5
PG5V5
PG0V6
PG5V6

LA2
LB2

A2

LC2
LD2

B2

LD1

CN4-1
CN4-6

No.22CN
22CN-1

+24V
LB1

CN4-1
CN4-6

CN4-2
CN4-7

CN4-2
CN4-7

CN2-1
CN2-2

CN2-1
CN2-2

1BC(10X4)

CN2-6
CN2-7

SPG+3
SPG-3

FG3

CN2-6
CN2-7

SPG+4
SPG-4

-2
-6
-5
-4
-9
-7

DATA+1
DATA-1
BAT
OBT
+5V
0V
FG1

No.23CN
23CN-1
-2
-6
-5
-4
-9
-7

DATA+2
DATA-2
BAT
OBT
+5V
0V
FG2

P
P
P

P
P
P

No.16CN
16CN-1
-2
-6
-5
-4
-9
-10

DATA+3
DATA-3
BAT
OBT
+5V
0V
FG3

CN2-8
CN2-10

LC1
LD1
LD1
LD2
LD2
LD1

LC2
LD2

LA1
LB1
LB1
LB2
LB2
LB1

LA2
LB2

S-AXIS OVERRUN L.S.

Connected to B1

LC3
LD3
S-AXIS OVERRUN L.S.Connected to A1

LA3
LB3

No.18CN
18CN-1
-2
-6
-5
-4
-9
-10

DATA+1
DATA-1
BAT
OBT
+5V
0V
FG1

PG

No.19CN
19CN-1
-2
-6
-5
-4
-9
-10

DATA+2
DATA-2
BAT
OBT
+5V
0V
FG2

PG

S-axis

L-axis

PG

U-axis

No.9CN
9CN-1
-2
-3
-4
10CN-1
-2
-3

P
P

CN2-8

A3

SS2

CN2-3

CN2-10

Connected to

AL1

P
CN2-3

A2

S-axis with Limit Switch Specification

SPG+2
SPG-2

FG2

Connected to

L AND U-AXIS INTERFERENCE L.S.

LA1
LB1

LB1

FG1

CN1-8

B3

A1

L-AXIS OVERRUN L.S.

LC1
LD1

P
CN1-8

Connected to

Connected to

SLU-axes with Limit Switch Specification

0BAT4
BAT4

P
CN1-3

S-AXIS OVERRUN L.S.

LA3
LB3

P
CN1-3

B2

Connected to

L AND U-AXIS INTERFERENCE L.S.

LA2
LB2

LB1

B1

Connected to

L-AXIS OVERRUN L.S.

FG4

+24V
P

DATA+4
DATA-4
BAT
OBT
+5V
0V
FG4
OBT
BAT

PGLAMP(OPTION)
FOR

Internal Cable in BT-axes

CN3-1
CN3-2

CN3-3

CN3-1
CN3-2
CN3-3

CN2-4
CN2-5

CN2-4
CN2-5
CN2-9

CN2-9
CN3-6
CN3-7

CN3-8

CN3-6
CN3-7
CN3-8

CN4-3
CN4-8

CN4-3
CN4-8

CN4-10

CN4-10

CN3-4
CN3-5

CN3-4
CN3-5

CN3-9
CN3-10

CN3-9
CN3-10

CN4-4
CN4-5
CN4-9

SPG+5
SPG-5

No.13CN
-1
DATA+5
-7
DATA-5
-2
BAT
-8
OBT
-3
+5V
-9
0V

-4
-10

DATA+6
DATA-6

-5
-11
-6

+5V
0V
FG6

FG5
SPG+7
SPG-7

P
P

FG7
SPG+6
SPG-6

FG6

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

BC2
AL2
0V
P

CN4-4
CN4-5
CN4-9

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

U
V

DATA+5
DATA-5
BAT
OBT
+5V
0V
FG5
OBT
BAT
DATA+6
DATA-6
BAT
OBT
+5V
0V
FG6
OBT
BAT

PG

B-axis

PG

T-axis

R-axis

0V
+5V

0V
+5V

A1

LB1

LA1

LC1

+24V
LD1
FG8

LD1

LB2

LB2
LB1

LD2

LD2
LD1

LA3
LB3

LC3
LD3

A3
B3

B1
E

8-4

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8 Electrical Equipment Specification


8.3 Internal Connections
Fig. 8-4(b): Internal Connection Diagram (DX200)

3BC-1
-2
-3
-4
-5
-6
-7
-8
-9
-10
-11
-12
-13
-14
-15
-16

Casing

Base

3BC(20-29)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16

3BC(20-29)

7
8

1
2
3
4
5
6
SS1
SS2

1
2
3
4
5
6
SS1
SS2

E
1
2
3
4

P
P

1
2
3
4

P
P

P
SS1
SS2

SS1
SS2

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16

3BC-1
-2
-3
-4
-5
-6
-7
-8
-9
-10
-11
-12
-13
-14
-15
-16

For Spare Cable

2BC(6X6)

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

2BC(6X6)

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

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

ME1
ME2
ME2
MU1
MV1
MW1

No.20CN
MU1
20CN-3
MV1
-2
MW1
-1
ME1
-PE
BA1
-4
BB1
-5

MU2
MV2
MW2
MU2
MV2
MW2

No.21CN
MU2
21CN-3
MV2
-2
MW2
-1
ME2
-PE
BA2
-4
BB2
-5

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

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

MU3
MV3
MW3
MU4
MV4
MW4

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

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

MU5
MV5
MW5
MU6
MV6
MW6

SM

S-axis

YB

SM

L-axis

YB
No.17CN
MU3
17CN-3
MV3
-2
MW3
-1
ME3
-PE
BA3
-4
BB3
-5

SM

U-axis

YB
No.11CN
MU4
11CN-1
MV4
-2
MW4
-3
ME4
-4
BA4
-1
BB4
-2

SM

R-axis

YB

No.12CN

Internal Cable in BT-axes


No.5CN

No.14CN
CN5-1
CN5-2
CN5-3
CN5-4
CN5-5
CN5-6

CN5-1
CN5-2
CN5-3
CN5-4
CN5-5
CN5-6

ME3
ME4
ME5
ME6
BA1
BB1

14CN-1
-2
-3
-4

MU5
MV5
MW5
ME5

CN6-1
CN6-2
CN6-3
CN6-4
CN6-5
CN6-6

CN6-1
CN6-2
CN6-3
CN6-4
CN6-5
CN6-6

BA2
BA3
BA4
BB4
BA5
BA6

-5
-6
-7
-8

MU6
MV6
MW6
ME6

5CN-1
-2
-3
-4
-1
-2

MU5
MV5
MW5
ME5
BA5
BB5

No.6CN

15CN-1
BA5
-2
BB5
-3
BA6
-4
BB6
No.15CN

PE

E-WRCT(60sq)

No.7CN
MU6
7CN-1
MV6
-2
MW6
-3
ME6
-4
BA6
-1
BB6
-2
No.8CN

SM

B-axis

YB
SM

T-axis

YB

Power cable for arc welding (optional)

8-5

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8 Electrical Equipment Specification


8.3 Internal Connections
Fig. 8-4(c): Internal Connection Diagram (FS100)

3BC-1
-2
-3
-4
-5
-6
-7
-8
-9
-10
-11
-12
-13
-14
-15
-16

Casing

Base

3BC(20-29)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16

3BC(20-29)

7
8

1
2
3
4
5
6
SS1
SS2

1
2
3
4
5
6
SS1
SS2

E
1
2
3
4

P
P

1
2
3
4

P
P

P
SS1
SS2

SS1
SS2

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16

3BC-1
-2
-3
-4
-5
-6
-7
-8
-9
-10
-11
-12
-13
-14
-15
-16

For Spare Cable

2BC(6X6)

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

2BC(6X6)

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

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

ME1
ME2
ME2
MU1
MV1
MW1

No.20CN
MU1
20CN-3
MV1
-2
MW1
-1
ME1
-PE
BA1
-4
BB1
-5

MU2
MV2
MW2
MU2
MV2
MW2

No.21CN
MU2
21CN-3
MV2
-2
MW2
-1
ME2
-PE
BA2
-4
BB2
-5

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

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

MU3
MV3
MW3
MU4
MV4
MW4

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

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

MU5
MV5
MW5
MU6
MV6
MW6

SM

S-axis

YB

SM

L-axis

YB
No.17CN
MU3
17CN-3
MV3
-2
MW3
-1
ME3
-PE
BA3
-4
BB3
-5

SM

U-axis

YB
No.11CN
MU4
11CN-1
MV4
-2
MW4
-3
ME4
-4
BA4
-1
BB4
-2

SM

R-axis

YB

No.12CN

Internal Cable in BT-axes


No.5CN

No.14CN
CN5-1
CN5-2
CN5-3
CN5-4
CN5-5
CN5-6

CN5-1
CN5-2
CN5-3
CN5-4
CN5-5
CN5-6

ME3
ME4
ME5
ME6
BA1
BB1

14CN-1
-2
-3
-4

MU5
MV5
MW5
ME5

CN6-1
CN6-2
CN6-3
CN6-4
CN6-5
CN6-6

CN6-1
CN6-2
CN6-3
CN6-4
CN6-5
CN6-6

BA2
BA3
BA4
BB4
BA5
BA6

-5
-6
-7
-8

MU6
MV6
MW6
ME6

MU5
MV5
MW5
ME5
BA5
BB5

No.6CN

15CN-1
BA5
-2
BB5
-3
BA6
-4
BB6
No.15CN

PE

E-WRCT(60sq)

8-6

5CN-1
-2
-3
-4
-1
-2

No.7CN
MU6
7CN-1
MV6
-2
MW6
-3
ME6
-4
BA6
-1
BB6
-2
No.8CN

SM

B-axis

YB
SM

T-axis

YB

Power cable for arc welding (optional)

64 of 102

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8 Electrical Equipment Specification


8.3 Internal Connections
Fig. 8-4(d): Internal Connection Diagram (FS100)

3BC-1
-2
-3
-4
-5
-6
-7
-8
-9
-10
-11
-12
-13
-14
-15
-16

Casing

Base

3BC(20-29)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16

3BC(20-29)

7
8

1
2
3
4
5
6
SS1
SS2

1
2
3
4
5
6
SS1
SS2

E
1
2
3
4

P
P

1
2
3
4

P
P

P
SS1
SS2

SS1
SS2

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16

3BC-1
-2
-3
-4
-5
-6
-7
-8
-9
-10
-11
-12
-13
-14
-15
-16

For Spare Cable

2BC(6X6)

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

2BC(6X6)

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

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

ME1
ME2
ME2
MU1
MV1
MW1

No.20CN
MU1
20CN-3
MV1
-2
MW1
-1
ME1
-PE
BA1
-4
BB1
-5

MU2
MV2
MW2
MU2
MV2
MW2

No.21CN
MU2
21CN-3
MV2
-2
MW2
-1
ME2
-PE
BA2
-4
BB2
-5

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

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

MU3
MV3
MW3
MU4
MV4
MW4

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

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

MU5
MV5
MW5
MU6
MV6
MW6

SM

S-axis

YB

SM

L-axis

YB
No.17CN
MU3
17CN-3
MV3
-2
MW3
-1
ME3
-PE
BA3
-4
BB3
-5

SM

U-axis

YB
No.11CN
MU4
11CN-1
MV4
-2
MW4
-3
ME4
-4
BA4
-1
BB4
-2

SM

R-axis

YB

No.12CN

Internal Cable in BT-axes


No.5CN

No.14CN
CN5-1
CN5-2
CN5-3
CN5-4
CN5-5
CN5-6

CN5-1
CN5-2
CN5-3
CN5-4
CN5-5
CN5-6

ME3
ME4
ME5
ME6
BA1
BB1

14CN-1
-2
-3
-4

MU5
MV5
MW5
ME5

CN6-1
CN6-2
CN6-3
CN6-4
CN6-5
CN6-6

CN6-1
CN6-2
CN6-3
CN6-4
CN6-5
CN6-6

BA2
BA3
BA4
BB4
BA5
BA6

-5
-6
-7
-8

MU6
MV6
MW6
ME6

5CN-1
-2
-3
-4
-1
-2

MU5
MV5
MW5
ME5
BA5
BB5

No.6CN

15CN-1
BA5
-2
BB5
-3
BA6
-4
BB6
No.15CN

PE

E-WRCT(60sq)

No.7CN
MU6
7CN-1
MV6
-2
MW6
-3
ME6
-4
BA6
-1
BB6
-2
No.8CN

SM

B-axis

YB
SM

T-axis

YB

Power cable for arc welding (optional)

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9 Maintenance and Inspection


9.1 Inspection Schedule

Maintenance and Inspection

DANGER

Maintenance and inspection must be performed by specified


personnel.

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

For disassembly or repair, contact your Yaskawa representative.

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

Failure to observe these safety precautions may result in death or


serious injury from unexpected turning of the manipulator's arm.

WARNING

Before maintenance or inspection, be sure to turn the main power


supply OFF, and put up a warning sign. (ex. DO NOT TURN THE
POWER ON.)

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

CAUTION

The battery pack must be connected before removing detection


connector when maintenance and inspection.

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

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 9-2 "Inspection Items" on page 9-2.
In Table 9-2, the inspection items are categorized by three types of
operations: operations which can be performed by personnel authorized
by the user, operations to be performed by trained personnel, and
operations to be performed by service company personnel. Only specified
personnel shall perform the inspection work.

The inspection interval depends on the total servo


operation time.

NOTE

The following inspection schedule is based on the case


where the manipulator is used for arc welding application.
If the manipulator is used for other application or if it is
used under special conditions, a case-by-case
examination is required.
The inspection may be conducted at shorter intervals if the
manipulator is used very frequently for the application
such as handling; in this case, contact your Yaskawa
representative.

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

Alignment mark

2
3
4
5

External lead
Working area and
manipulator
Motors for S-, L-, U-axes
Baseplate mounting bolts

Cover mounting screws

7
8

Connector base
Timing belts for B- and
T-axes
Wire harness in manipulator
(SLU-axes wires)
(RBT-axes wires)

Visual
Spanner
Wrench
Screwdriver,
Wrench
Manual
Manual
Visual,
Multimeter

Visual,
Multimeter

Visual

Tighten loose bolts. Replace if necessary.


Check for loose connectors.
Check for belt tension and wear.

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)
Check for conduction between terminals and wear of protective spring.3)
Replace4)
Check for holes or tears, and adhesion of spatters. Replace it if any.
Refer to MOTOMAN MA1440/MH12 OPTIONS FOR PROTECTIVE
TUBING (VELCRO TYPE) REPLACING PROCEDURES, for replacing the
protective tubing (velcro type).
Replace the battery pack when the battery alarm occurs or the manipulator
drove for 36000H.

Service
Company

Licensee

Specified
Personnel
Check alignment mark accordance at the home position.
Check for damage.
Check for damage and deterioration of leads.
Clean the work area if dust or spatter is present. Check for damage and
outside cracks.
Check for grease leakage.2)
Tighten loose bolts. Replace if necessary.

36000H

24000H

12000HCycle

6000HCycle

Visual

Inspection
Charge

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12 Battery pack in manipulator

Operation

Visual
Visual

10 Wire harness in manipulator


(BT-axis wires)
11 Protective tubing
(velcro type)

Method

9 Maintenance and Inspection


9.1 Inspection Schedule

9-2

1000HCycle

Schedule

Daily

Items1)

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13 S-axis speed reducer

Grease Gun

14 Speed reducers for L- and


U-axes

Grease Gun

15 R-axis speed reducer

Grease Gun

16 B-axis speed reducer


17 T-axis gear

Grease Gun
Grease Gun

18 Overhaul

Service
Company

Licensee

Check for malfunction. (Replace if necessary.)


Supply grease5) (6000H cycle). See section 9.3.1 on page 9-7.
Replace grease(12000H cycle). See section 9.3.1 on page 9-7.
Check for malfunction. (Replace if necessary.)
Supply grease5) (6000H cycle).
See section 9.3.2 on page 9-9 and section 9.3.3 on page 9-12.
Replace grease5) (12000H cycle).
See section 9.3.2 on page 9-9 and section 9.3.3 on page 9-12.
Check for malfunction. (Replace if necessary.)
Supply grease5) (6000H cycle). See section 9.3.4 on page 9-15.
Check for malfunction. (Replace if necessary.)
Supply grease5) (6000H cycle). See section 9.3.5 on page 9-16.
Check for malfunction. (Replace if necessary.)
Supply grease5) (6000H cycle). See section 9.3.6 on page 9-17

Inspection
Charge
Specified
Personnel

Operation

9 Maintenance and Inspection


9.1 Inspection Schedule

9-3

Method

36000H

24000H

12000HCycle

6000HCycle

1000HCycle

Daily

Schedule

HW1482347

1 Inspection No. correspond to the numbers in Fig. 9-5 Inspection Items on page 9-4.
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 9.3.8 Notes for Maintenance on page 9-21)
4 Wire harness in manipulator to be replaced at 24000H inspection.
5 For the grease, refer to Table 9-3 "Inspection Parts and Grease Used".

Table 9-3: Inspection Parts and Grease Used


No.
12, 13
14,15
16

Grease Used
VIGO Grease RE No. 0
Harmonic Grease SK-1A
Alvania EP Grease 2

Inspected Parts
Speed reducers for S-, L- and U-axes
Speed reducers for R- and B-axes, R-axis gear
T-axis gear

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

MH12

The numbers in the above table correspond to the numbers in Table 9-2 "Inspection Items"
Fig. 9-5: Inspection Items
4

15

9-4

17
11
14
4

9 Maintenance and Inspection


9.1 Inspection Schedule

11
4

12
13
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9 Maintenance and Inspection


9.2 Notes on Maintenance Procedures

9.2
9.2.1

Notes on Maintenance Procedures


Battery Pack Replacement
The battery packs are installed in the position shown in Fig. 9-6 Battery
Location. If the battery alarm occurs in the DX200/FS100, replace the
battery in accordance with the following procedure:
Fig. 9-6: Battery Location

Support
Connector base

Battery pack

Plate fixing screw

Fig. 9-7: Battery Connection


Battery pack
before replacement

See step 5 below


Connector

Board
(type: SGDR-EFBA02A)

See step 4 below


New battery pack

1. Turn OFF the DX200/FS100 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.

NOTE

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

6. Mount the new battery pack to the holder.


7. Reinstall the plate.

NOTE

Do not allow plate to pinch the cables when reinstalling the


plate.

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9 Maintenance and Inspection


9.3 Notes on Grease Replenishment/Exchange Procedures

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.
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.

NOTE

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 hoses, which are joined to the grease
inlet, with grease beforehand to prevent air from intruding
into the speed reducer.

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9 Maintenance and Inspection


9.3 Notes on Grease Replenishment/Exchange Procedures
9.3.1

Grease Replenishment/Exchange for S-Axis Speed Reducer


Fig. 9-8: S-Axis Speed Reducer Diagram
Grease exhaust port
Hexagon socket head plug PT3/8
(Grease inlet: when mounted on the ceiling)

Grease inlet
S-axis speed reducer
Hexagon socket head plug PT3/8
(Grease exhaust port: when mounted on the ceiling)

9.3.1.1

Grease Replenishment
(Refer to Fig. 9-8 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 inlet
and grease exhaust port.
Note that the function of grease inlet and grease exhaust
port exchanges when the manipulator is mounted on the
ceiling.

NOTE

If 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.
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.

2. Install a grease zerk A-PT3/8 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:

VIGO Grease RE No. 0

Amount of grease:

70 cc (140 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. 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 screw with a tightening torque of 23 Nm
(2.34 kgfm).
6. 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
plugs. Then tighten the plug with a tightening torque of 23 Nm
(2.34 kgfm).

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9.3.1.2

9 Maintenance and Inspection


9.3 Notes on Grease Replenishment/Exchange Procedures
Grease Exchange
(Refer to Fig. 9-8 S-Axis Speed Reducer Diagram on page 9-7.)
1. Remove the hexagon socket head plugs PT3/8 from the grease inlet
and grease exhaust port.
Note that the function of grease inlet and grease exhaust
port exchanges when the manipulator is mounted on the
ceiling.

NOTE

If 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.
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.

2. Install a grease zerk A-PT3/8 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:

VIGO Grease RE No. 0

Amount of grease:

approx. 450 cc

Air supply pressure of grease pump:

0.3 MPa or less

Grease injection rate:

8 g/s or less

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.
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 screw with a tightening torque of 23 Nm
(2.34 kgfm).
7. 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
plugs. Then tighten the plug with a tightening torque of 23 Nm
(2.34 kgfm).

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9 Maintenance and Inspection


9.3 Notes on Grease Replenishment/Exchange Procedures
9.3.2

Grease Replenishment/Exchange for L-Axis Speed Reducer


Fig. 9-9: L-Axis Speed Reducer Diagram
Grease exhaust port
Hexagon socket head plug PT3/8
(Grease exhaust inlet: when mounted on the ceiling)

L-arm

Grease inlet
Hexagon socket head tapered pipe plug
(NPTF type) NPTF3/8
(Grease exhaust port: when mounted on the ceiling)

9.3.2.1

Grease Exchange
(Refer to Fig. 9-9 L-Axis Speed Reducer Diagram.)
1. Make the L-arm vertical to the ground.
2. Remove the hexagon socket head tapered pipe plug (NPTF type)
NPTF3/8 from the grease inlet and remove the hexagon socket head
plug PT3/8 from the grease exhaust port.
Note that the function of grease inlet and grease exhaust
port exchanges when the manipulator is mounted on the
ceiling.

NOTE

If 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.
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.

3. Install a grease zerk A-PT3/8 to the grease inlet.


(The grease zerk is delivered with the manipulator.)
4. Inject grease through the grease inlet using a grease gun.
Grease type:

VIGO Grease RE No. 0

Amount of grease:

65 cc (130 cc for 1st supply)

Air supply pressure of grease pump:

0.3 MPa or less

Grease injection rate:

8 g/s or less

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


6. Remove the grease zerk from the grease inlet, and reinstall the
hexagon socket head tapered pipe plug (NPTF type) NPTF3/8. Before
installing the plug, apply Three Bond 1206C on the thread part of it.
Then tighten it with a tightening torque of 23 Nm (2.34 kgfm).

9-9

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9 Maintenance and Inspection


9.3 Notes on Grease Replenishment/Exchange Procedures
The hexagon socket head tapered pipe plug (NPTF type) protrudes
from the L-arm mounting surface. Be careful not to tighten it too much.
7. Wipe the discharged grease with a cloth, and reinstall the hexagon
socket head plug PT3/8. Before installing the plug 3/8, apply Three
Bond 1206C on the thread part of it. Then tighten it with a tightening
torque of 23 Nm (2.34 kgfm).

NOTE

9.3.2.2

When installing a plug to the grease inlet or the grease


exhaust port, please be careful not to install the wrong plug.
For the corresponding plugs and their installing positions,
refer to Fig. 9-9 L-Axis Speed Reducer Diagram on page
9-9. Should wrong plug is installed, the tapped hole may
damage or the plug may fall inside the L-axis driving part.

Grease Exchange
(Refer to Fig. 9-9 L-Axis Speed Reducer Diagram on page 9-9.)
1. Make the L-arm vertical to the ground.
2. Remove the hexagon socket head tapered pipe plug (NPTF type)
NPTF3/8 from the grease inlet and remove the hexagon socket head
plug PT3/8 from the grease exhaust port..
Note that the function of grease inlet and exhaust port
exchanges when the manipulator is mounted on the
ceiling.

NOTE

If 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.
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.

3. Install a grease zerk A-PT3/8 to the grease inlet.


(The grease zerk is delivered with the manipulator.)
4. Inject grease through the grease inlet using a grease gun.
Grease type:

VIGO Grease RE No. 0

Amount of grease:

approx. 420 cc

Air supply pressure of grease pump:

0.3 MPa or less

Grease injection rate:

8 g/s or less

5. The grease exchange is completed when new grease appears in the


grease exhaust port. (The new grease can be distinguished from the
old grease by color.)
6. Move the L-axis for a few minutes to discharge excess grease.
7. Remove the grease zerk from the grease inlet, and reinstall the
hexagon socket head tapered pipe plug (NPTF type) NPTF3/8. Before
installing the plug, apply Three Bond 1206C on the thread part of it.
Then tighten it with a tightening torque of 23 Nm (2.34 kgfm).
The hexagon socket head tapered pipe plug (NPTF type) protrudes
from the L-arm mounting surface. Be careful not to tighten it too much.

9-10

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9 Maintenance and Inspection


9.3 Notes on Grease Replenishment/Exchange Procedures
8. Wipe the discharged grease with a cloth, and reinstall the hexagon
socket head tapered pipe plug (NPTF type) NPTF3/8. Before installing
the hexagon socket head tapered pipe plug (NPTF type), apply Three
Bond 1206C on the thread part of it. Then tighten it with a tightening
torque of 23 Nm (2.34 kgfm).

NOTE

When installing a plug to the grease inlet or the grease


exhaust port, please be careful not to install the wrong plug.
For the corresponding plugs and their installing positions,
refer to Fig. 9-9 L-Axis Speed Reducer Diagram on page
9-9. Should wrong plug is installed, the tapped hole may
damage or the plug may fall inside the L-axis driving part.

9-11

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9 Maintenance and Inspection


9.3 Notes on Grease Replenishment/Exchange Procedures
9.3.3

Grease Replenishment/Exchange for U-Axis Speed Reducer


Fig. 9-10: U-Axis Speed Reducer Diagram
U-axis
speed reducer
U-arm
Casing
Grease exhaust port
Hexagon socket head tapered pipe plug
(NPTF type)NPTF3/8
(Grease inlet: when mounted on the ceiling)

Grease inlet
Hexagon socket head plug PT3/8
(Grease exhaust port: when mounted on the ceiling)

Casing

9.3.3.1

Grease Replenishment
(Refer to Fig. 9-10 U-Axis Speed Reducer Diagram.)
1. Make the U-arm horizontal to the ground.
2. Remove the hexagon socket head plug PT3/8 from the grease inlet
and the hexagon socket head tapered pipe plug (NPTF type)
NPTF3/8 from the grease exhaust port.
Note that the function of grease inlet and exhaust port
exchanges when the manipulator is mounted on the
ceiling.

NOTE

f 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.
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.

3. Install a grease zerk A-PT3/8 to the grease inlet.


(The grease zerk is delivered with the manipulator.)
4. Inject grease through the grease inlet using a grease gun.
Grease type:

VIGO Grease RE No. 0

Amount of grease:

40 cc (80 cc for 1st supply)

Air supply pressure of grease pump:

0.3 MPa or less

Grease injection rate:

8 g/s or less

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


6. Remove the grease zerk from the grease inlet, and reinstall the
hexagon socket head plug PT3/8. Before installing the plug, apply
Three Bond 1206C on the thread part of the plug, then tighten the plug
with a tightening torque of 23 Nm (2.3 kgfm).

9-12

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9 Maintenance and Inspection


9.3 Notes on Grease Replenishment/Exchange Procedures
7. Wipe the discharged grease with a cloth, and reinstall the hexagon
socket head tapered pipe plug (NPTF type) NPTF3/8 to the grease
exhaust port. Before installing the plug, apply Three Bond 1206C on
the thread part of it, then tighten it with a tightening torque of 23 Nm
(2.34 kgfm).
The hexagon socket head tapered pipe plug (NPTF type) NPTF3/8
protrudes from the L-arm mounting surface. Be careful not to tighten it
too much.

NOTE

When installing a plug to the grease inlet or the grease


exhaust port, please be careful not to install the wrong plug.
For the corresponding plugs and their installing positions,
refer to Fig. 9-10 U-Axis Speed Reducer Diagram on page
9-12. Should wrong plug is installed, the tapped hole may
damage or the plug may fall inside the U-axis driving part.

9-13

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9.3.3.2

9 Maintenance and Inspection


9.3 Notes on Grease Replenishment/Exchange Procedures
Grease Exchange
(Refer to Fig. 9-10 U-Axis Speed Reducer Diagram on page 9-12.)
1. Make the U-arm horizontal to the ground.
2. Remove the hexagon socket head plug PT3/8 from the grease inlet
and the hexagon socket head tapered pipe plug (NPTF type)
NPTF3/8 from the grease exhaust port.
Note that the function of grease inlet and exhaust port
exchanges when the manipulator is mounted on the
ceiling.

NOTE

If 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.
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.

3. Install a grease zerk A-PT3/8 to the grease inlet.


(The grease zerk is delivered with the manipulator.)
4. Inject grease through the grease inlet using a grease gun.
Grease type:

VIGO Grease RE No. 0

Amount of grease:

approx. 250 cc

Air supply pressure of grease pump:

0.3 MPa or less

Grease injection rate:

8 g/s or less

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.
7. Remove the grease zerk from the grease inlet, and reinstall the
hexagon socket head plug PT3/8. Before installing the plug, apply
Three Bond 1206C on the thread part of it, then tighten it with a
tightening torque of 23 Nm (2.34 kgfm).
8. Wipe the discharged grease with a cloth, and reinstall the hexagon
socket head tapered pipe plug (NPTF type) NPTF3/8 to the grease
exhaust port. Before installing the plug, apply Three Bond 1206C on
the thread part of it, then tighten it with a tightening torque of 23 Nm
(2.34 kgfm).
The hexagon socket head tapered pipe plug (NPTF type) NPTF3/8
protrudes from the L-arm mounting surface. Be careful not to tighten it
too much.

NOTE

When installing a plug to the grease inlet or the grease


exhaust port, please be careful not to install the wrong plug.
For the corresponding plugs and their installing positions,
refer to Fig. 9-10 U-Axis Speed Reducer Diagram on page
9-12. Should wrong plug is installed, the tapped hole may
damage or the plug may fall inside the U-axis driving part.

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9 Maintenance and Inspection


9.3 Notes on Grease Replenishment/Exchange Procedures
9.3.4

Grease Replenishment for R-Axis Speed Reducer


Fig. 9-11: R-Axis Speed Reducer Diagram
R-axis speed reducer
Exhaust port
Hexagon socket head plug PT1/8
(Grease inlet: when mounted on the ceiling)

Grease inlet
Hexagon socket head plug PT1/8
(Exhaust port: when mounted on the ceiling)

1. Remove the hexagon socket head plugs PT1/8 from the grease inlet
and exhaust port.

NOTE

Note that the function of grease inlet and exhaust port


exchanges when the manipulator is mounted on the ceiling.

2. Install a grease zerk A-PT1/8 to the grease inlet.


(The grease zerk is delivered with the manipulator.)
3. Inject grease through the grease inlet using a grease gun.
(Refer to Fig. 9-11 R-Axis Speed Reducer Diagram.)
Grease type:

Harmonic grease SK-1A

Amount of grease:

6 cc (12cc for the first supply)

NOTE

The exhaust port is used for air exhaust, and the grease is
not exhausted from the exhaust port. Do not inject
excessive grease through the grease inlet.

4. 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 4.9 Nm
(0.49 kgfm).
5. Reinstall the plug to the exhaust port. Before installing the plug, apply
Three Bond 1206C on the thread part of the plug, then tighten the plug
with a tightening torque of 4.9 Nm (0.49 kgfm).

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9 Maintenance and Inspection


9.3 Notes on Grease Replenishment/Exchange Procedures
9.3.5

Grease Replenishment for B-Axis Speed Reducer


Fig. 9-12: B-Axis Speed Reducers Diagram
Exhaust port
Hexagon socket head
cap screw M6

B-axis speed
reducer

Grease inlet
Hexagon socket head
cap screw M6

1. Remove the hexagon socket head cap screws M6 from the grease
inlet and exhaust port.
2. Install a grease zerk A-MT6X1 to the grease inlet.
(The grease zerk is delivered with the manipulator.)
3. Inject grease through the grease inlet using a grease gun
(Refer to Fig. 9-12 B-Axis Speed Reducers Diagram.)
Grease type:

Harmonic grease SK-1A

Amount of grease:

6 cc (12 cc for the 1st supply)

NOTE

The exhaust port is used for air exhaust, and the grease is
not exhausted from the exhaust port. Do not inject
excessive grease through the grease inlet.

4. Remove the grease zerk from the grease inlet, and reinstall the screw.
Before installing the screw, apply Three Bond 1206C on the thread
part of the screw, then tighten the screw with a tightening torque of
6 Nm (0.6 kgfm).
5. Reinstall the screw to the exhaust port. Before installing the screw,
apply Three Bond 1206C on the thread part of the screw, then tighten
the screw with a tightening torque of 6 Nm (0.6 kgfm).

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9 Maintenance and Inspection


9.3 Notes on Grease Replenishment/Exchange Procedures
9.3.6

Grease Replenishment for T-Axis Gear


Fig. 9-13: T-Axis Gear Diagram
T-axis Gear

Grease exhaust port


Hexagon socket
set screw M6
Grease inlet 1
Hexagon socket
head cap screw M6

Grease inlet 2
Hexagon socket
head cap screw M6

1. Remove the hexagon socket head cap screws M6 from the grease
inlet 1 and exhaust port.
2. Install a grease zerk A-MT6X1 to the grease inlet 1.
(The grease zerk is delivered with the manipulator.)
3. Inject grease through the grease inlet 1 using a grease gun.
Grease type:

Alvania EP Grease 2

Amount of grease:

5 cc

NOTE

The exhaust port is used for air exhaust, and the grease is
not exhausted from the exhaust port. Do not inject
excessive grease through the grease inlet.

4. Remove the grease zerk from the grease inlet 1, and reinstall the
screw. Before installing the screw, apply Three Bond 1206C on the
thread part of the screw, then tighten the screw with a tightening
torque of 6 Nm (0.6 kgfm).
5. Remove the hexagon socket head cap screw M6 from the grease
inlet 2.
6. Install a grease zerk A-MT6X1 to the grease inlet 2.
(The grease zerk is delivered with the manipulator.)

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9 Maintenance and Inspection


9.3 Notes on Grease Replenishment/Exchange Procedures
7. Inject grease through the grease inlet 2 using a grease gun.
Grease type:

Alvania EP Grease 2

Amount of grease:

5 cc

NOTE

The exhaust port is used for air exhaust, and the grease is
not exhausted from the exhaust port. Do not inject
excessive grease through the grease inlet.

8. Remove the grease zerk from the grease inlet 2, and reinstall the
screw. Before installing the screw, apply Three Bond 1206C on the
thread part of the screw, then tighten the screw with a tightening
torque of 6 Nm (0.6 kgfm).
9. Reinstall the set screw to the exhaust port. Before installing the set
screw, apply Three Bond 1206C on the thread part of the screw, then
tighten the screw with a tightening torque of 6 Nm (0.6 kgfm).

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9 Maintenance and Inspection


9.3 Notes on Grease Replenishment/Exchange Procedures
9.3.7

Grease Replenishment for R-Axis Gear


Fig. 9-14: R-Axis Gear Diagram
R-axis gear

Grease exhaust port


Hexagon socket head plug PT1/8
(Grease inlet: when mounted on the ceiling)

Grease inlet
Hexagon socket head plug PT1/8
(Grease exhaust port: when mounted on the ceiling)

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


2. Remove the hexagon socket head plugs PT1/8 from the grease inlet
and exhaust port.
Note that the function of grease inlet and exhaust port
exchanges when the manipulator is mounted on the
ceiling.

NOTE

If 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.
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.

3. Install a grease zerk A-PT1/8 to the grease inlet.


(The grease zerk is delivered with the manipulator.)
4. Inject grease through the grease inlet using a grease gun.
(Refer to Fig. 9-14 R-Axis Gear Diagram.)
Grease type:

Harmonic grease SK-1A

Amount of grease:

10 cc

Air supply pressure of grease pump:

0.3 MPa or less

Grease injection rate:

8 g/s or less

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

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9 Maintenance and Inspection


9.3 Notes on Grease Replenishment/Exchange Procedures
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 4.9 Nm
(0.5 kgfm).
7. 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 4.9 Nm
(0.5 kgfm).

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9 Maintenance and Inspection


9.3 Notes on Grease Replenishment/Exchange Procedures
9.3.8

9.3.8.1

Notes for Maintenance

Wrist Unit
The motor and encoder units are provided with the wrist unit. To prevent
fumes from penetrating into the wrist unit, the matched parts are sealed
with sealing bond. If the wrist cover is disassembled, make sure to reseal
with sealing bond (Three Bond 1206C, refer to Table 10-1 "Spare Parts for
the YR-MA1440/MH12-A00" on page 10-1.)
Fig. 9-15: Sealing Part of Wrist Unit
Cover
Cover jointing face

Cover jointing face


Cover

9.3.8.2

Battery Pack Connection

When performing maintenance such as replacement of a


wire harness in the manipulator, the encoder connector
(with CAUTION label) will be removed. In this case, be sure
to connect the battery pack to the battery backup connector
before removing the encoder connector.

NOTE

Removing the encoder connector without connecting the


battery pack leads to disappearance of the encoder
absolute data.
For the battery pack connection, refer to Fig. 9-16(a)
"Encoder connector Diagram (for S-, L- and U-Axes)" on
page 9-22 and Fig. 9-16(b) "Encoder Connector Diagram
(for R-, B-, and T-Axes)" on page 9-22.

Before removing the encoder connector (with CAUTION label), connect


the battery pack referring to the following figures.

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9 Maintenance and Inspection


9.3 Notes on Grease Replenishment/Exchange Procedures

Fig. 9-16(a): Encoder connector Diagram (for S-, L- and U-Axes)


Motor

Motor power connector


Encoder connector
0BT

0BT*

BAT

BAT*

Battery pack HW9470932-A


Connector for battery back-up

Fig. 9-16(b): Encoder Connector Diagram (for R-, B-, and T-Axes)
Encoder
Motor

Motor cable, etc.


Wire harness
in manipulator

Power connector
Connection
OBT
BAT

CAUTION

Connect battery to encoder


to save the data before
removing connector.

CAUTION label

a OBT4
b BAT4

b
a

Encoder connector

Battery pack

Connection Diagram
0BT

BAT

a
b

0BT4
BAT4

CAUTION Label (Enlarged View)

CAUTION

a: Crimped contact-pin (Pin)


b: Crimped contact-pin (Socket)

Connect battery to encoder


to save the data before
removing connector.

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10

Recommended Spare Parts

10 Recommended Spare Parts


It is recommended to keep the parts and components in the following table
in stock as spare parts for the MOTOMAN-MH12. 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-MA1440/MH12-A00 (Sheet 1 of 2)


Rank Parts Name
No.

Type

Grease

Manufacturer

Qty

Qty
per
Unit

VIGO Grease RE No. 0 YASKAWA

16 kg

Grease

Harmonic Grease SK1A

Harmonic Drive Systems


Co., Ltd.

2.5 kg -

Grease

Alvania EP Grease 2

Showa Shell Sekiyu K.K.

16 kg

Liquid Seal

Three Bond 1206C

Three Bond Co., Ltd.

Battery Pack

HW0470360-A

YASKAWA

Battery Pack

HW9470932-A

YASKAWA

Protective Tubing
(velcro type)

MTK-50FR

YASKAWA
(0.5 m+ 0.6 m)

1.1 m

B-Axis Timing Belt 60S3M642

Mitsuboshi Belting Limited 1

T-Axis Timing Belt 80S3M819

Mitsuboshi Belting Limited 1

10

S-Axis Speed
Reducer

HW0386621-B

YASKAWA

11

S-Axis Input Gear

HW0312734-2

YASKAWA

12

L-Axis Speed
Reducer

HW0387809-A

YASKAWA

13

L-Axis Input Gear

HW0312735-2

YASKAWA

14

U-Axis Speed
Reducer

HW1380153-A

YASKAWA

15

U-Axis Input Gear

HW1303245-1

YASKAWA

16

R-Axis Speed
Reducer

HW1382521-A

YASKAWA

17

B-Axis Speed
Reducer

HW1382522-A

YASKAWA

18

R-Axis Gear

HW1303246-1
HW1303247-1

YASKAWA

1 each 1 each

19

T-Axis Gear
(Output Side)

HW1371294-A

YASKAWA

20

T-Axis Gear
(Input Side)

HW1303250-1

YASKAWA

10-1

Remarks

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Recommended Spare Parts

Table 10-1: Spare Parts for the YR-MA1440/MH12-A00 (Sheet 2 of 2)


Rank Parts Name
No.

Type

Manufacturer

Qty

Qty
per
Unit

21

Internal Wire
Harness

HW1171418-A

YASKAWA

22

Internal Cable for


B- and T-Axes

HW1270926-A

YASKAWA

23

AC Servomotor for SGMRV-05ANA-YR2*


S- and U-Axes
HW0388664-A

YASKAWA

24

L-Axis AC
Servomotor

SGMRV-09ANA-YR1*
HW0388665-A

YASKAWA

25

R-, B- and T-Axis


AC Servomotors

SGMAV-01ANA-YR1*
HW0389294-A

YASKAWA

26

Board

SGDR-EFBA02A

YASKAWA

Remarks

10-2

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11.1 S-Axis Unit

11 Parts List
11.1

S-Axis Unit

Fig. 11-1: S-Axis Unit

1010
1015

1003
1027
1005

1025

1010

1004

1014

1010

1006
1028
1012

1029
1025
1009

1011

1020
1021
1032
1019
1031
1025

1030

1023

1008
1024
1002
1025
1033

1006
1007
1001

1026

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11.1 S-Axis Unit

Table 11-1: S-Axis Unit


No.

DWG No.

Name

Pcs

1001

HW1100498-1

Base

1002

HW0386621-B

Speed reducer

1003

HW0312734-2

Gear

1004

2H-5

Conical spring washer

1005

M585

Hexagon socket head cap


screw

1006

TSH8-03

Union

1007

NB-0860-0.3

Tube

1008

M635

GT-SA bolt

16

1009

HW1303263-1

M base

1010

M825

GT-SA bolt

28

1011

HW1100499-1

S head

1012

PT3/8

Hexagon socket head


plug

1014

NB-0860-0.2

Tube

1015

SGMRV-05ANA-YR2*

Motor

1019

CD31

Saddle

1020

M58

Hexagon socket head cap 2


screw

1021

2H-5

Conical spring washer

1023

HW0414670-2

Support

1024

HW1303253-1

Cover

1025

M615

GT-SA bolt

21

1026

M510 (STAINLESS)

APS bolt

1027

HW1303254-1

Cover

1028

C-30-SG-30A

Gromet

1029

HW1303255-1

Cover

1030

TA1-S10

Clamp

1031

M58 (STAINLESS)

Pan-head sems screw

1032

T50R

Cable tie

1033

EZ5036A0

Cap

11-2

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11.2 L-Axis Unit

11.2

L-Axis Unit

Fig. 11-2: L-Axis Unit

2007

2008

2011

2005
2004
2003

2009
1011

2006

2008

2012

2013
2010
2014
2002
2001

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11.2 L-Axis Unit

Table 11-2: L-Axis Unit


No.

DWG No.

Name

Pcs

2001

M660

GT-SA bolt

16

2002

NPTF3/8 (STAINLESS)

Hexagon socket head


tapered pipe plug
(NPTF type)

2003

M675

Hexagon socket head cap 1


screw

2004

2H-6

Conical spring washer

2005

HW0312735-2

Gear

2006

M615

GT-SA bolt

2007

SGMRV-09ANA-YR1*

Motor

2008

M825

GT-SA bolt

22

2009

PT3/8

Hexagon socket head


plug

2010

HW0387809-A

Speed reducer

2011

HW1100500-1

L-arm

2012

HW1304187-1

Cover

2013

HW1405226-1

Support

2014

M510

GT-SA bolt

1011

HW1100499-1

S head

11-4

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11.3 U-Axis Unit

11.3

U-Axis Unit

Fig. 11-3: U-Axis Unit


3029
3011

3001

3003

3012

3022
3023

3028

3023

3020
3021
3006
3019
3005
3004 3013
3018

3024

3017

3025
3016

3003

3026

3009

3010
3014

3002

3003
3027

3002

3015
3008
3007

2011

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11.3 U-Axis Unit

Table 11-3: U-Axis Unit


No.

DWG No.

Name

Pcs

3001

HW1100617-1

Casing

3002

M1220

Hexagon socket head cap 2


screw

3003

M412

GT-SA bolt

3004

M575

Hexagon socket head cap 1


screw

3005

2H-5

Conical spring washer

3006

HW1303245-1

Gear

3007

NPTF3/8 (STAINLESS)

Hexagon socket head


tapered pipe plug
(NPTF type)

3008

HW1380153-A

Speed reducer

3009

M525

GT-SA bolt

16

3010

M1030

GT-SA bolt

3011

SGMRV-05ANA-YR2*

Motor

3012

M830

GT-SA bolt

3013

M625

GT-SA bolt

3014

HW1404044-1

Plate

3015

PT3/8

Hexagon socket head


plug

3016

HW1404041-1

Support

3017

HW0404554-2

N base

3018

M316 (STAINLESS)

Pan-head sems screw

3019

M3

Nut

3020

M412

GT-SA bolt

3021

KQE10-03

Union

3022

KQE12-03

Union

3023

PT3/8 (STAINLESS)

Hexagon socket head


plug

3024

HW1404786-1

Gasket

3025

TA1-58

Clamp

3026

M48 (STAINLESS)

Pan-head sems screw

3027

T50R

Cable tie

3028

HW1404517-1

Gasket

3029

HW1404057-1

Cover

2011

HW1100500-1

L-arm

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11.4 R-Axis Unit (Shipped in or After August 2014)

11.4

R-Axis Unit (Shipped in or After August 2014)

Fig. 11-4: R-Axis Unit


5063

4006
4004

3001

4021
4004
4001

4005
4030 4028
4026

4033

4027
4001

4010

4011

4029
4032

4028
4027

4003
4008
4001

4026

4001

4024

4023
4002
4001

4009

4014
4023

4014
4012
4013
4018
4019

4025

(shipped in or before July 2014)


4015
4016
4020
4007

4038

4041

4022

4037

4034

4017

4036

4001
4035

11-7

4039
4040

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11.4 R-Axis Unit (Shipped in or After August 2014)

Table 11-4: R-Axis Unit


No.

DWG No.

Name

Pcs

4001

M412

GT-SA bolt

10

4002

PT1/8

Hexagon socket head


plug

4003

HW1304069-1*1

Shaft

4004

M620

GT-SA bolt

13

4005

HW1304196-1*1

Shaft

4006

TC1151306

Oil seal

4007

AE0478G

Oil seal

4008

TC52647

Oil seal

4009

HW1303247-1

Gear

4010

HW1382521-A

Speed reducer

4011

M545

GT-SA bolt

4012

HW1303905-1

Housing

4013

HW1303257-1

Shaft

4014

M312

GT-SA bolt

11

4015

HW1303246-1

Gear

4016

HW1404045-1

M base

1
3

4017

M316

GT-SA bolt

4018

M416

Hexagon socket head cap 1


screw

4019

2H-4

Conical spring washer

4020

HW0404304-2

Gasket

4021

HW1404056-1

Cover

4022

SGMAV-01ANA-YR1*

Motor

4023

M412

GT-SA bolt

11

4024

HW9481319-D

Cable bushing

4025

HW1303904-1

Cover

4026

PZ1212

Saddle

4027

M46 (STAINLESS)

APS bolt

4028

PZ1208

Saddle

4029

HW1404042-1

Support

4030

HW1404043-1

Support

4032

HW1404499-1

Cover

4033

M640*1

GT-SA bolt

4034

HW1304053-1*2

Shaft

4035

HW1404986-1*2

Ring

4036

HW1405180-1*2

Ring

4037

HW1404958-1*2

Shaft

4038

M635*2

GT-SA bolt

4039

M425*2

Hexagon socket head cap 2


screw

4040

2H-4*2

Conical spring washer

4041

M615*2

GT-SA bolt

3001

HW1100617-1

Casing

5063

HW1100618-1

U-arm

*1 Use items shipped in or after August 2014


*2 Use items shipped in or before July 2014

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11 Parts List
11.5 Wrist Unit

11.5

Wrist Unit

Fig. 11-5: Wrist Unit


5043
5045

5008
5007
5001
5006
5047
5035

5041
5040
5005

5046

5042

5038
5036
5037

5009

5028
5001
5002

5026
5021

5003
5005

5005

5025
5019

5022

5044

5055

5039

5018
5020
5005
5027
5067

5029 5031
5030
5024

5016

5005
5033
5017
5066

5015

5032

5069

5011
5013
5014
5012

5028

5034
5023

5062
5065

5063

5054
5051
5050

5010
5058
3001

5058
5059

5064
5060

5010

5048

5005

5052
5049

5005

5061
5053

5065
5066 5015

5014
5056

5069

5057

5068

11-9

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11.5 Wrist Unit
Table 11-5: Wrist Unit (Sheet 1 of 2)
No.

DWG No.

Name

5001

M6X6

Hexagon socket head cap


5
screw

5002

HW0404371-1

Bolt

5003

HW1404058-1

Cover

5005

M310

GT-SA bolt

39

5006

HW1404060-1

Gasket

5007

HW1404069-1

Cover

5008

M4X10 (STAINLESS)

APS bolt

5009

M410

GT-SA bolt

23

5010

M410

GT-SA bolt

5011

HW1404053-1

Fly wheel

5012

HW1404038-A

Pulley

HW1404038-B
(For the manipulator assembled after Jun 21. 2015)

Pulley

5013

Pcs

M416

Hexagon socket head cap


1
screw

M420
(For the manipulator assembled after Jun 21. 2015)

Hexagon socket head cap


1
screw

5014

2H-4

Conical spring washer

5015

M416

GT-SA bolt

5016

HW1303244-1*1

Cover

HW1304180-1*2

Cover

5017

80S3M819

Belt

5018

WR20

Circlip

5019

HW1303260-1

Shaft

5020

HW1404049-1

Cover

5021

M840

Hexagon socket head cap


1
screw

5022

2H-8

Conical spring washer

5023

HW1481728-A

Bearing

5024

6809DDU

Bearing

5025

HW1404059-6

Spring

5026

HW1303248-1

Gear

5027

6804

Bearing

5028

M328

GT-SA bolt

18

5029

M820

Hexagon socket head cap


1
screw

5030

2H-8

Conical spring washer

5031

HW1404039-A

Pulley

5032

HW1303249-1

Gear

5033

HW1404048-1

B cover (holder)

5034

HW1404054-1

Shaft

5035

TC50606

Oil seal

5036

AR28

Circlip

5037

WR15

Circlip

5038

NA4902

Needle bearing

11-10

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11.5 Wrist Unit
Table 11-5: Wrist Unit (Sheet 2 of 2)
No.

DWG No.

Name

Pcs

5039

HW1303250-1

Gear

5040

HW1371294-A

Gear assy

5041

RA9008C0

Cross roller bearing

5042

TC1001105

Oil seal

5043

TC64746

Oil seal

5044

HW1303261-1

Flange

5045

HW1404055-1

Holder

5046

HW1303262-1

Flange

5047

HW1100619-1

Wrist

5048

HW1303259-1

Shaft

5049

M320

GT-SA bolt

12

5050

IRTW26

Retaining ring

5051

6803LLU

Bearing

5052

HW1404037-A

Pulley

5053

M316

GT-SA bolt

5054

HW1404047-1

Housing

5055

HW1382522-A

Speed reducer

5056

60S3M642

Belt

*1

Cover

*2

HW1304179-1

Cover

5058

SGMAV-01ANA-YR1*

Motor

5059

HW1404046-1*3

M base

*4

HW1406071-1

M base

5060

HW1404036-A

Pulley

5061

M412

Hexagon socket head cap


1
screw

5062

HW1404052-1*3

M base

*4

HW1406072-1

M base

5063

HW1100618-1

U-arm

5064

6902

Bearing

5065

HW1404516-1

Cover

5066

M48

5057

5067
5068

HW1303243-1

GT-SA bolt

*1

M412

GT-SA bolt

M410*2

GT-SA bolt

*1

GT-SA bolt

10

GT-SA bolt

10

M412

*2

M410

*4

5069

HW1482873

Seat

4054

HW1200341-1

Spacer

*1 Use items shipped in or before October 2014


*2 Use items shipped in or after November 2014
*3 Use items shipped in or before December 2014
*4 Use items shipped in or after January 2015

11-11

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MH12

11 Parts List
11.6 Gear Unit (No. 5040)

11.6

Gear Unit (No. 5040)


Fig. 11-6: Gear Unit (No. 5040)
6004

6002

6001

6005

6003
6006

Table 11-6: Gear Unit (No. 5040)


No.

DWG No.

Name

Pcs

6001

HW1304700-1

Gear

6002

HW1303252-1

Gear

6003

HW1405885-1

Collar

6004

HW1404050-1

Pin

6005

WB5-30

Coil spring

6006

M312

GT-SA bolt

11-12

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INSTRUCTIONS
HEAD OFFICE
2-1 Kurosakishiroishi, Yahatanishi-ku, Kitakyushu 806-0004, Japan
Phone +81-93-645-7703
Fax +81-93-645-7802
YASKAWA America Inc. (Motoman Robotics Division)
100 Automation Way, Miamisburg, OH 45342, U.S.A.
Phone +1-937-847-6200
Fax +1-937-847-6277
YASKAWA Europe GmbH Robotics Divsion )
Yaskawastrasse 1, 85391 Allershausen, Germany
Phone +49-8166-90-100
Fax +49-8166-90-103
YASKAWA Nordic AB
Bredbandet 1 vn. 3 varvsholmen 392 30 Kalmar, Sweden
Phone +46-480-417-800
Fax +46-480-417-999
YASKAWA Electric (China) Co., Ltd.
22/F One Corporate Avenue No.222, Hubin Road, Huangpu District, Shanghai 200021, China
Phone +86-21-5385-2200
Fax 86-21-5385-3299
YASKAWA SHOUGANG ROBOT Co. Ltd.
No7 Yongchang North Road, Beijing E&T Development AreaChina 100176
Phone +86-10-6788-2858
Fax +86-10-6788-2878
YASKAWA India Private Ltd. (Robotics Division)
#426, Udyog Vihar, Phase- IV,Gurgaon, Haryana, India
Phone +91-124-475-8500
Fax +91-124-475-8542
YASKAWA Electric Korea Co., Ltd
9F, KyoboSecuritiesBldg., 26-4, Yeouido-dong,Yeongdeungpo-gu, Seoul 150-737, Korea
Phone +82-2-784-7844
Fax +82-2-784-8495
YASKAWA Electric Taiwan Corporation
12F, No.207, Sec. 3, Beishin Rd., Shindian District, New Taipei City 23143, Taiwan
Phone +886-2-8913-1333
Fax +886-2-8913-1513
YASKAWA Electric (Singapore) PTE Ltd.
151 Lorong Chuan, #04-02A, New Tech Park, Singapore 556741
Phone +65-6282-3003
Fax +65-6289-3003
YASKAWA Electric (Thailand) Co., Ltd.
59,1st-5th Floor, Flourish Building, Soi Ratchadapisek 18,Ratchadapisek Road,
Huaykwang, Bangkok 10310, THAILAND
Phone +66-2-017-0099
Fax +66-2-017-0199
PT. YASKAWA Electric Indonesia
Secure Building-Gedung B Lantai Dasar & Lantai 1 JI. Raya Protokol Halim Perdanakusuma,
Jakarta 13610, Indonesia
Phone +62-21-2982-6470
Fax +62-21-2982-6741

Specifications are subject to change without notice


for ongoing product modifications and improvements.

MANUAL NO.

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