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Motoman, Incorporated

805 Liberty Lane

West Carrollton, OH 45449

TEL: (937) 847-6200

FAX: (937) 847-6277

24-Hour Service Hotline: (937) 847-3200

Part Number: 145074-1

Release Date: January 31, 2001

Document Version: 2

Document Status: Final

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The information contained within this document is the proprietary property of Motoman, Inc., and may not becopied, reproduced or transmitted to other parties without the expressed written authorization of Motoman,

Inc.

©2003 by MOTOMANAll Rights Reserved

Because we are constantly improving our products, we reserve the right to change specifications withoutnotice. MOTOMAN is a registered trademark of YASKAWA Electric Manufacturing.

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TABLE OF CONTENTS

MOTO

MAN i UP165-100 Manipulator Manual

Section Page

1 INTRODUCTION..........................................................................................................1-1

2 SAFETY.......................................................................................................................2-1

3 UP165-100 INSTRUCTIONS SUPPLEMENT................................................................3-1

4 UP165 INSTRUCTIONS...............................................................................................4-1

5 XRC INSTRUCTIONS — NORTH AMERICAN STANDARD (R1) ....................................5-1

6 XRC INSTRUCTIONS — GENERAL (R2).......................................................................6-1

7 XRC TROUBLESHOOTING ..........................................................................................7-1

8 UP165 ELEMENTARY DIAGRAMS ..............................................................................8-1

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UP165-100 Manipulator Manual ii

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NOTES

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MOTO MAN 1-1 UP165-100 Manipulator Manual

SECTION 1

INTRODUCTION

The Motoman UP165-100 and XRC controller represent state-of-the-arttechnology in robotics today. The Motoman UP165-100 has six individual axes:

Sweep, Lower arm, Upper arm, Rotate, Bend, and Twist.

The XRC controller coodinates the operation of the UP165-100 robot withexternal equipment such as power supply and positioning tables. The XRCprocesses input and output signals, maintains variable data, and performs numericprocessing to convert to and from different coordinate systems. Furthermore, itprovides main logic functions, servo control, program and constant data memory,and power distribution. Please read this manual thoroughly to familiarize yourself with the many aspects of the UP165-100 robot and XRC controller.

1.1 About this Document

This manual provides system information for UP165-100 robot and XRCcontroller and contains the following sections:

SECTION 1 — INTRODUCTION

Provides general information about the structure of this manual, a list of referencedocuments, and customer service information.

SECTION 2 — SAFETY

Provides information regarding the safe use and operation of the UP165-100 robot.

SECTION 3 — UP165-100 INSTRUCTIONS SUPPLEMENT

Provides detailed information about the UP165-100 where it differs from the basicUP165 robot.

SECTION 4 — UP165 INSTRUCTIONS

Provides basic detailed information about the UP165-type including installation,wiring, specifications, and maintenance.

SECTION 5 — XRC INSTRUCTIONS — NORTH AMERICAN STANDARD

Provides detailed information about the NAS XRC controller includingdescriptions, inspections, and parts replacement.

SECTION 6 — XRC INSTRUCTIONS — GENERAL

Provides general information about the XRC controller including system setup,inspections, diagnosis, and configuration, as well as specifications, maintenance,and alarm/error message lists.

SECTION 7 — XRC TROUBLESHOOTING

Provides logic trees for troubleshooting the XRC controller.

SECTION 8 — UP165 ELEMENTARY DIAGRAMS

Provides detailed information about XRC wiring and system configuration withregard to UP165-type robots.

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INTRODUCTION

UP165-100 Manipulator Manual 1-2

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1.2 Reference to Other Documentation

For additional information refer to the following:

• Concurrent I/O Parameters Manual (P/N 142102-1)

• Operator’s Manual for General Purpose (P/N 142099-1)

• Operator’s Manual for Handling (P/N 142100-1)

• Operator’s Manual for Spot Welding (P/N 142101-1)

• Operator’s Manual for Arc Welding (P/N 142098-1)

• Vendor manuals for system components not manufactured by Motoman.

1.3 Customer Service Information

If you are in need of technical assistance, contact the Motoman service staff at

(937) 847-3200. Please have the following information ready before you call:

• Robot Type (UP165-100)

• Application Type (Arc Welding, Handling, etc.)

• Software Version (5.101A, etc.)• Robot Serial Number (on the back side of the robot arm)

• Robot Sales Order Number (on front, lower right corner of the XRCcontroller and lower back of robot)

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MOTO MAN 2-1 UP165-100 Manipulator Manual

SECTION 2

SAFETY

2.1 Introduction

.

We suggest that you obtain and review a copy of the ANSI/RIA National SafetyStandard for Industrial Robots and Robot Systems. This information can beobtained from the Robotic Industries Association by requesting ANSI/RIAR15.06. The address is as follows:

Robotic Industries Association

900 Victors WayP.O. Box 3724

Ann Arbor, Michigan 48106TEL: (734) 994-6088FAX: (734) 994-3338

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

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

This safety section addresses the following:

• Standard Conventions (Section 2.2)

• General Safeguarding Tips (Section 2.3)

• Mechanical Safety Devices (Section 2.4)

• Installation Safety (Section 2.5)

• Programming Safety (Section 2.6)

• Operation Safety (Section 2.7)

• Maintenance Safety (Section 2.8)

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

state, and national codes, regulations, rules, or laws relating to

safety and safe operating conditions for each installation are met

and followed.

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SAFETY


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2.2 Standard Conventions

This manual includes information essential to the safety of personnel andequipment. As you read through this manual, be alert to the four signal words:

• DANGER

• WARNING

• CAUTION• NOTE

Pay particular attention to the information provided under these headings whichare defined below (in descending order of severity).

DANGER!

Information appearing under the DANGER caption concerns the

protection of personnel from the immediate and imminent hazards

that, if not avoided, will result in immediate, serious personal injury

or loss of life in addition to equipment damage.

WARNING!

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

CAUTION!

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

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

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MAN 2-3 UP165-100 Manipulator Manual

2.3 General Safeguarding Tips

All operators, programmers, plant and tooling engineers, maintenance personnel,supervisors, and anyone working near the robot must become familiar with theoperation of this equipment. All personnel involved with the operation of theequipment must understand potential dangers of operation. General safeguardingtips are as follows:

• Improper operation can result in personal injury and/or damage to theequipment. Only trained personnel familiar with the operation of this robot,the operator's manuals, the system equipment, and options and accessoriesshould be permitted to operate this robot system.

• Do not enter the robot cell while it is in automatic operation. Programmersmust have the teach pendant when they enter the robot cell.

• Improper connections can damage the robot. All connections must be madewithin the standard voltage and current ratings of the robot I/O (Inputs andOutputs).

• The robot must be placed in Emergency Stop (E-STOP) mode whenever it is

not in use.• In accordance with ANSI/RIA R15.06, section 6.13.4 and 6.13.5, use

lockout/tagout procedures during equipment maintenance. Refer also toSection 1910.147 (29CFR, Part 1910), Occupational Safety and HealthStandards for General Industry (OSHA).

2.4 Mechanical Safety Devices

The safe operation of the robot, positioner, auxiliary equipment, and system isultimately the user's responsibility. The conditions under which the equipmentwill be operated safely should be reviewed by the user. The user must be aware of the various national codes, ANSI/RIA R15.06 safety standards, and other local

codes that may pertain to the installation and use of industrial equipment.Additional safety measures for personnel and equipment may be requireddepending on system installation, operation, and/or location. The following safetymeasures are available:

• Safety fences and barriers

• Light curtains

• Door interlocks

• Safety mats

• Floor markings

• Warning lights

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

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2.5 Installation Safety

Safe installation is essential for protection of people and equipment. Thefollowing suggestions are intended to supplement, but not replace, existing federal,local, and state laws and regulations. Additional safety measures for personnel andequipment may be required depending on system installation, operation, and/orlocation. Installation tips are as follows:

• Be sure that only qualified personnel familiar with national codes, localcodes, and ANSI/RIA R15.06 safety standards are permitted to install theequipment.

• Identify the work envelope of each robot with floor markings, signs, andbarriers.

• Position all controllers outside the robot work envelope.

• Whenever possible, install safety fences to protect against unauthorized entryinto the work envelope.

• Eliminate areas where personnel might get trapped between a moving robotand other equipment (pinch points).

• Provide sufficient room inside the workcell to permit safe teaching andmaintenance procedures.

2.6 Programming Safety

All operators, programmers, plant and tooling engineers, maintenance personnel,supervisors, and anyone working near the robot must become familiar with theoperation of this equipment. All personnel involved with the operation of theequipment must understand potential dangers of operation. Programming tips areas follows:

• Any modifications to PART 1 of the controller PLC can cause severe

personal injury or death, as well as damage to the robot! Do not make anymodifications to PART 1. Making any changes without the writtenpermission of Motoman will VOID YOUR WARRANTY!

• Some operations require standard passwords and some require specialpasswords. Special passwords are for Motoman use only. YOURWARRANTY WILL BE VOID

if you use these special passwords.

• Back up all programs and jobs onto a floppy disk whenever program changesare made. To avoid loss of information, programs, or jobs, a backup mustalways be made before any service procedures are done and before anychanges are made to options, accessories, or equipment.

• The concurrent I/O (Input and Output) function allows the customer to

modify the internal ladder inputs and outputs for maximum robotperformance. Great care must be taken when making these modifications.Double-check all modifications under every mode of robot operation toensure that you have not created hazards or dangerous situations that maydamage the robot or other parts of the system.

• Improper operation can result in personal injury and/or damage to theequipment. Only trained personnel familiar with the operation, manuals,electrical design, and equipment interconnections of this robot should bepermitted to operate the system.

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• Inspect the robot and work envelope to be sure no potentially hazardousconditions exist. Be sure the area is clean and free of water, oil, debris, etc.

• Be sure that all safeguards are in place.

• Check the E-STOP button on the teach pendant for proper operation beforeprogramming.

• Carry the teach pendant with you when you enter the workcell.

• Be sure that only the person holding the teach pendant enters the workcell.

• Test any new or modified program at low speed for at least one full cycle.

2.7 Operation Safety

All operators, programmers, plant and tooling engineers, maintenance personnel,supervisors, and anyone working near the robot must become familiar with theoperation of this equipment. All personnel involved with the operation of theequipment must understand potential dangers of operation. Operation tips are asfollows:

• Be sure that only trained personnel familiar with the operation of this robot,

the operator's manuals, the system equipment, and options and accessoriesare permitted to operate this robot system.

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

• Inspect the robot and work envelope to ensure no potentially hazardousconditions exist. Be sure the area is clean and free of water, oil, debris, etc.

• Ensure that all safeguards are in place.

• Improper operation can result in personal injury and/or damage to theequipment. Only trained personnel familiar with the operation, manuals,electrical design, and equipment interconnections of this robot should be

permitted to operate the system.• Do not enter the robot cell while it is in automatic operation. Programmers

must have the teach pendant when they enter the cell.

• The robot must be placed in Emergency Stop (E-STOP) mode whenever it isnot in use.

• This equipment has multiple sources of electrical supply. Electricalinterconnections are made between the controller, external servo box, andother equipment. Disconnect and lockout/tagout all electrical circuits beforemaking any modifications or connections.

• All modifications made to the controller will change the way the robot

operates and can cause severe personal injury or death, as well as damage therobot. This includes controller parameters, ladder parts 1 and 2, and I/O(Input and Output) modifications. Check and test all changes at slow speed.

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YASKAWA

YASKAWA MANUAL NO. HW9483105

MOTOMAN-UP165-100

INSTRUCTIONSSUPPLEMENTARY TO YR-UP165-A30

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

MOTOMAN INSTRUCTIONS

MOTOMAN SETUP MANUALMOTOMAN-!!! INSTRUCTIONSYASNAC XRC INSTRUCTIONSYASNAC XRC OPERATOR’S MANUALYASNAC XRC OPERATOR’S MANUAL for BEGINNERS

The YASNAC XRC operator’s manuals above correspond to specific usage.

Be sure to use the appropriate manual.

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1

1 INTRODUCTION

This supplementary instruction manual describes how the YR-UP165-A30 (the following

UP165-A30) is different from the YR-UP165-A00 (the following UP165-A00).

Read this instruction manual thoroughly together with the following:

“MOTOMAN-UP130, -UP165 INSTRUCTIONS” (Manual No. RE-MTO-A214)

2 DIFFERENCES BETWEEN THEUP165-A30 AND THE UP165-A00

The UP165-A30 differs from the UP165-A00 in the following:

1. Basic specifications

2. Dimensions and working envelope

3. Allowable wrist load

4. Locations of mounting plate and tapped holes

For the matters described above, refer to this instruction manual instead of the “MOTOMAN-

UP130, -UP165 INSTRUCTIONS” (Manual No. RE-MTO-A214).

When using the UP165-A30, read both manuals thoroughly.

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2.1 Basic Specifications

2


This section replaces page 5-1 of “MOTOMAN-UP130, -UP165 INSTRUCTIONS” (ManualNo. RE-MTO-A214).

Table 2 Basic Specifications

Item Model MOTOMAN-UP165-100

Operation Mode Vertically articulated

Degree of Freedom 6

Payload 100kg

Repetitive Positioning Accuracy* ±0.3mm

MotionRange

S-axis (turning) ±180°

L-axis (lower arm) +76°, -60°

U-axis (upper arm) +240°, -130°

R-axis (wrist roll) ±360°

B-axis (wrist pitch/yaw) ±130°

T-axis (wrist twist) ±360°

MaximumSpeed

S-axis 1.92rad/s (110° /s)

L-axis 1.92rad/s (110° /s)

U-axis 1.92rad/s (110° /s)

R-axis 3.05 rad/s (175° /s)

B-axis 2.53 rad/s (145° /s)

T-axis 4.19 rad/s (240° /s)

Allowable

Moment

R-axis 833N•m (85kgf•m)

B-axis 833N•m (85kgf•m)

T-axis 490N•m (50kgf•m)

NOTE

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3

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

Conformed to ISO 9283

AllowableMoment of

Inetia

(GD2 /4)

R-axis 75kg•m2

B-axis 75kg•m2

T-axis 25kg•m2

Mass 1325kg

AmbientConditions

Temperature 0 to 45°C

Humidity 20 to 80% RH (non-condensing)

Vibration Less than 0.5G

Others

• Free from corrosive gasses or liquids, or explosive

gasses

• Clean and dry

• Free from excessive electrical noise (plasma)

Power Capacity 7.5kVA

Table 2 Basic Specifications

Item Model MOTOMAN-UP165-100

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2.2 Dimensions and Working Envelope

4

2.2 Dimensions and Working Envelope

Fig.10 Dimensions and Working Envelope


NOTE

230

Point P working range

Point P

1049

715

384

3480

00

592

217

6 0

553 1 0 0

6 0

275 275

R 5 2 5

126

160

R 9 5 0

2716

1600

1 3 0

6 9

. 2

3 6

8 5

8 5

5312

285

285

25

2 0. 8

8 0

1 0 0

9 0 °

95

6 0 ° 7 6

1 4 0 1

9 5 0

8 5 3

5 0

3 7 2

0

0 8 9

2311

1 8 9

1 1 5 0

2 0 6 9

7 3 0

2691

715

1305

1 6 8 5

1 5 1 1

8100

R 3 0 0 1

Dimensions in mm

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2.3 Allowable Wrist Load

5


The allowable wrist load for the UP165-A30 is 100kg, including the weight of the mount/grip-

per.

Fig. 12 Mount Arm Rating


Table 4 Allowable Wrist Load

Model Axis Moment N"m (kgf"m)Total Moment of Inertia (GD2 /4)

kg"m2

YR-UP165-A30R-axisB-axisT-axis

833 (85)833 (85)490 (50)

757525

NOTE

T- and R-axis rotation

center line

BL (mm)

40kg

1200

60kg

800 1000 1400

100kg

600400

TL (mm)

600

400

200

800

B-axis rotation center line

400

200

TL (mm)

800

600

80kg

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2.4 Locations of Mounting Plate and Tapped Holes

6

2.4 Locations of Mounting Plate and Tapped Holes

Fig.14 Locations of Mounting Plate and Tapped Holes


NOTE

6 0

6 0

275

8

5

275

8 5

160126

553

1 0 0

3×4-M8×P1.25, Depth: 15mm

2×2-M8×P1.25, Depth: 15mm

25

Dimensions in mm

95 1 0 0

8 0

1 8 9

2×4-M12×P1.75, Depth: 25mm

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YASKAWA

YASKAWA MANUAL NO. RE-MTO-A214 4

MOTOMAN-UP130, -165

INSTRUCTIONSYR-UP130-A00, -A01

YR-UP165-A00, -A01

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

MOTOMAN INSTRUCTIONS

MOTOMAN SETUP MANUALMOTOMAN-UP130, -165 INSTRUCTIONSYASNAC XRC INSTRUCTIONSYASNAC XRC OPERATOR’S MANUALYASNAC XRC OPERATOR’S MANUAL For BEGINNERS

The YASNAC XRC operator’s manuals above correspond to specific usage.

Be sure to use the appropriate manual.

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• This instruction manual is intended to explain operating instructions

and maintenance procedures primarily for the MOTOMAN-UP130, -165.

• General items related to safety are listed in the Safety Manual Section

1: Safety. To ensure correct and safe operation, carefully read the Setup

Manual before reading this manual.

• Some drawings in this manual are shown with the protective covers or

shields removed for clarity. Be sure all covers and shields are replaced

before operating this product.

• The drawings and photos in this manual are representative examples

and differences may exist between them and the delivered product.

• YASKAWA may modify this model without notice when necessary due to

product improvements, modifications, or changes in specifications. If

such modification is made, the manual number will also be revised.

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

resentative to order a new copy. The representatives are listed on the

back cover. Be sure to tell the representative the manual number listed

on the front cover.

• YASKAWA is not responsible for incidents arising from unauthorized

modification of its products. Unauthorized modification voids your prod-

uct’s warranty.

MANDATORY

CAUTION

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iii

NOTES FOR SAFE OPERATIONRead this manual carefully before installation, operation, maintenance, or inspection of the

YASNAC XRC.

In this manual, the Notes for Safe Operation are classified as “WARNING”, “CAUTION”,

“MANDATORY”, or “PROHIBITED”.

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

any rate, be sure to follow these important items.

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

Indicates a potentially hazardous situation which, if not avoided,could result in minor or moderate injury to personnel and dam-age to equipment. It may also be used to alert against unsafepractices.

Always be sure to follow explicitly the items listed under this

heading.

Must never be performed.

To ensure safe and efficient operation at all times, be sure to follow all instructions, even ifnot designated as “CAUTION” and “WARNING”.

WARNING

CAUTION

MANDATORY

PROHIBITED

NOTE

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• Before operating the manipulator, check that servo power is turned offwhen the emergency stop buttons on the playback panel or program-

ming pendant are pressed.

When the servo power is turned off, the SERVO ON READY lamp on the

playback panel and the SERVO ON LED on the programming pendant are

turned off.

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

Emergency Stop Button

• Once the emergency stop button is released, clear the cell of all items

which could interfere with the operation of the manipulator. Then turn

the servo power ON.

Injury may result from unintentional or unexpected manipulator motion.

Release of Emergency Sto

• Always set the Teach Lock before entering the robot work envelope to

teach a job.

Operator injury can occur if the Teach Lock is not set and the manipulator is started fromthe playback panel.

• Observe the following precautions when performing teaching operations

within the working envelope of the manipulator :

- View the manipulator from the front whenever possible.

- Always follow the predetermined operating procedure.

- Ensure that you have a safe place to retreat in case of emergency.

Improper or unintended manipulator operation may result in injury.

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

and that you are in a safe location before:

- Turning on the YASNAC XRC power

- Moving the manipulator with the programming pendant

- Running check operations

- Performing automatic operations

Injury may result if anyone enters the working envelope of the manipulator during opera-

tion. Always press an emergency stop button immediately if there are problems.Theemergency stop button is located on the right side of both the YASNAC XRC playbackpanel and programming pendant.

W A R N I N G

TURN

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Definition of Terms Used Often in This Manual

The MOTOMAN manipulator is the YASKAWA industrial robot product.

The manipulator usually consists of the controller, the playback panel, the programming pen-

dant, and supply cables.

In this manual, the equipment is designated as follows:

• Perform the following inspection procedures prior to conducting manip-

ulator teaching. If problems are found, repair them immediately, and be

sure that all other necessary processing has been performed.

-Check for problems in manipulator movement.

-Check for damage to insulation and sheathing of external wires.

• Always return the programming pendant to the hook on the XRC cabinet

after use.

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

• Read and understand the Explanation of the Alarm Display in the SetupManual before operating the manipulator.

Equipment Manual Designation

YASNAC XRC Controller XRC

YASNAC XRC Playback Panel Playback Panel

YASNAC XRC Programming Pendant Programming Pendant

CAUTION

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AN EXPLANATION OF WARNING LABELS

The following warning labels are attached to the manipulator.

Always follow the warnings on the labels.

Also, an indentification label with important information is placed on the body of the manipula-

tor. Prior to operating the manipulator, confirm the contents.

MOTOMAN

TYPE

!!!!!!

ORDER NO.

!!!!!!

PAYLOAD

!! kg

MASS

!!! kg

SERIAL NO.

!!!!!!

DATE

!!

YASKAWA EL ECTRI C CORPORATI ON JAPAN

Do not enter

robot work area

WARNING

Moving parts may

cause injury

WARNING

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1 Receiving1.1 Checking Package Contents. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

1.2 Checking the Order Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2

2 Transporting2.1 Transporting Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1

2.1.1 Using the Crane. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1

2.2 Shipping Bolts and Jigs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2

3 Installation3.1 Safety Guard Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2

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

3.2.1 When the Manipulator and Mounting Fixture are Installedon a Common Flat Steel Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

3.2.2 When the Manipulator is Mounted Directly on the Floor . . . . . . . . . . .3-3

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

4 Wiring4.1 Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4.2 Cable Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24.2.1 Connection to the Manipulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2

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

5 Basic Specifications5.1 Basic Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

5.2 Part Names and Working Axes . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2

5.3 Baseplate Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2

5.4 Dimensions and Working Range. . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3

5.5 B-Axis Working Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4

5.6 Alterable Working Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4

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

6.2 Wrist Flange. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

7 System Application7.1 Mounting Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1

7.2 Incorporated Wire and Airduct . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-2

http://-/?-http://-/?-http://-/?-http://-/?-

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viii

8 Motoman Construction8.1 Position of S-Axis Limit Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

8.2 Internal Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2

9 Maintenance and Inspection9.1 Inspection Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1

9.2 Notes on Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . 9-59.2.1 Battery Unit Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5

9.2.2 Grease Replenishment/Replacement for S-Axis Speed Reducer. . . . 9-7

# Grease Replenishment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7

# Grease Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7

9.2.3 Grease Replenishment/Replacement for L-Axis Speed Reducer . . . . 9-8

# Grease Replenishment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8

# Grease Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-99.2.4 Grease Replenishment/Replacement for U-Axis Speed Reducer . . 9-10

# Grease Replenishment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10


9.2.5 Grease Replenishment/Replacement for R-Axis Speed Reducer . . 9-11



9.2.6 Grease Replenishment/Replacement for B-Axis Speed Reducer. . . 9-13



9.2.7 Grease Replacement for T-Axis Speed Reducer and Gear . . . . . . . 9-14



9.2.8 Grease Replenishment for Balancer Connection Part . . . . . . . . . . . 9-15

9.2.9 Notes for Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-17

# Battery Unit Connection for S-, L-, and U-Axis Motors. . . . . . . . 9-17

# Battery Unit Connection for R-, B-, and T-Axis Motors . . . . . . . 9-17

10 Recommended Spare Parts

11 Parts List11.1 S-Axis Driving Unit(1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1

11.2 S-Axis Driving Unit(2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-3

11.3 L-Axis Driving Unit(1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-5

11.4 L-Axis Driving Unit(2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-8

11.5 U.R.B.T-Axis Link Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-10

11.6 Wrist Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-12

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1.2 Checking the Order Number

1-2

1.2 Checking the Order Number

Check that the order number of the manipulator corresponds to the XRC. The order number is

located on a label as shown below.

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

Fig. 1 Location of Order Number Labels

Label (Enlarged view)

THE MANIPULATOR AND THE CONTROLLERSHOULD HAVE SAME ORDER NUMBER.

ORDER. No. $$$$$$

Check that the manipulator

and the XRC have the

same order number.

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2.1 Transporting Method

2-1

2 Transporting

2.1 Transporting Method

2.1.1 Using the Crane

As a rule, when removing the manipulator from the package and moving it, a crane should be

used. The manipulator should be lifted using wire rope threaded through attached eyebolts.

Be sure the manipulator is fixed with jigs before transporting, and lift it in the posture as shown

in " Fig. 2 Transporting Position ".

Fig. 2 Transporting Position

• Sling applications and crane or forklift operations must be performed by

authorized personnel only.

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

• Avoid excessive vibration or shock during transporting.

The system consists of precision components, so failure to observe this caution may

adversely affect performance.

CAUTION

CB

A

CB

A

(Standard)

(2Piece)(2Piece)

Fig. 2-a Without cable accessory Fig. 2-b With cable accessory

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2.2 Shipping Bolts and Jigs

2-2

2.2 Shipping Bolts and Jigs

The manipulator is provided with shipping bolts and jigs at points A, B, and C ( " Fig. 2 Trans-

porting Position ").

• The jigs are painted yellow.

• The rubber board is attached at point D.

• Check that the eyebolts are securely fastened.

• The weight of the manipulator is approximately 1400kg including the shipping bolts and

jigs. Use a wire rope strong enough to withstand the weight.

• Attached eyebolts are designed to support the manipulator weight. Do not use them for

anything other than transporting the manipulator.

• Mount the shipping bolts and jigs for transporting the manipulator.

• Avoid exerting force on the arm or motor unit when transporting, use caution when using

transporting equipment other than a crane or forklift, as injury may occur.

Position Screw Type Pcs

a-A Hexagon socket head cap screw M8 X 20Hexagon socket head cap screw M12 X 35

22

a-B Hexagon socket head cap screw M16 X 55 2X3

a-C Hexagon socket head cap screw M16 X 55 2X3

Position Screw Type Pcs

b-A Hexagon socket head cap screw M8 X 20 4

b-B Hexagon socket head cap screw M12 X 50 4

b-C Hexagon socket head cap screw M12 X 50 4

Before turning on the power, check to be sure that the shipping bolts and jigs have beenremoved. The shipping bolts and jigs then must be stored for future use, in the event thatthe robot must be moved again.

NOTE

NOTE

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3-1

3 Installation

• Install the safety guards.

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

• Install the manipulator in a location where the fully extended arm and

tool will not reach the wall, safety guards, 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.

• Do not install or operate a manipulator that is damaged or lacking 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 jigs have been removed.

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

WARNING

C A U T I O N

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3.1 Safety Guard Installation

3-2

3.1 Safety Guard Installation

To insure safety, be sure to install safety guards. They prevent unforeseen accidents with per-

sonnel and damage to equipment. The following is quoted for your information and guidance.

(ISO 10218)

Responsibility for Safeguarding

The user of a manipulator or robot system shall ensure that safeguards are provided and used

in accordance with Sections 6, 7, and 8 of this standard. The means and degree of safeguard-

ing, including any redundancies, shall correspond directly to the type and level of hazard pre-

sented by the robot system consistent with the robot application. Safeguarding may include

but not be limited to safeguarding devices, barriers, interlock barriers, perimeter guarding,

awareness barriers, and awareness signals.

3.2 Mounting Procedures for Manipulator Baseplate

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

port the robot and withstand repulsion forces during acceleration and deceleration.

Construct a solid foundation with the appropriate thickness to withstand maximum repulsion

forces of the manipulator.

During installation, if out of the plane is not right, the manipulator shape may change and itsfunctional ability may be compromised. Out of the plane for installation must be kept at 0.5mm

or less. Mount the baseplate in either of the following ways: 3.2.1 or 3.2.2.

Table. 1 Maximum Repulsion Forces of the Manipulator

Horizontal rotating maximum torque(S-axis moving direction)

32000N • m

Vertical rotating maximum torque(LU-axis moving direction)

78500N • m

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3-3

3.2.1 When the Manipulator and Mounting Fixture areInstalled on a Common Flat Steel Plate

The common base should be rugged and durable to prevent shifting of the manipulator or the

mounting fixture. The thickness of the common base is 50mm or more and a size of theanchor bolt of M20 or larger is recommended. Affix the manipulator by fastening the plate with

the eight M20 (mm) anchor bolts. The plate is tapped for M20 (90mm length) bolts. Tighten

the bolts and anchor bolts securely so that they will not work loose during operation. See " Fig.

4 Affixing the Manipulator on the Floor " for the method.

Fig. 3 Mounting the Manipulator Baseplate

3.2.2 When the Manipulator is Mounted Directly on theFloor

The floor should be strong enough to support the manipulator. Construct a solid foundation

with the appropriate thickness to withstand maximum repulsion forces of the manipulator as

shown in Table 1. As a rough standard, when there is a concrete thickness (floor) of 200mm or

more, the base of the manipulator can be fixed directly to the floor with M20 anchor bolts.

Before mounting the manipulator, however, check that the floor is level and that all cracks, etc.

are repaired. Any thickness less than 200mm is insufficient for mounting, even if the floor is

concrete.

5 0

Spring Washer 8 XM20 Bolts

Washer

Common Base

Manipulator Base

Out of plane: 0.5mm or less

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3-4

Fig. 4 Affixing the Manipulator on the Floor

5 0 0

4 6 0

3 6

3 2

1 0 0

3 5 0 2

5 0

100200

5 0

320320

160160

*640

*540

* 6 4 0

* 5 4 0

FL

41040

440

1 2 0 0

1 1 0 0

9 6 0

8 8 0

2 0 0

Manipulator base 8-M20 Tapped holes

(Bolts A)

4-28φ Drilled holes

(Base B)

4-28φ Drilled holes (Base A)

4-M24 Tapped holes (Base B)(Bolts B)

Weld these portionsafter installation andadjustment

(Base A)

(Base B)

The surface mustbe level and even.

Dimensions in mm

JA type anchor bolts

M24 × 315 long

Bolts A: 8-M20 ×90, Spring washer, Flat washer Bolts B: 8-M24 × 70, Spring washer Bolts, Base A and Base B should be equipped by user.

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3.3 Location

3-5

3.3 Location

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

conditions:

• 0° to 45°C (Ambient temperature)

• 20 to 80%RH (no moisture)

• Free from dust, soot, or water

• Free from corrosive gases or liquid, or explosive gases

• Free from excessive vibration (less than 0.5G)

• Free from large electrical noise (plasma)

• Out of the plane for installation is 0.5mm or less.

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3.3 Location

3-6

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4.1 Grounding

4-1

4 Wiring

4.1 Grounding

Follow local regulations for grounding line size.

• Ground resistance must be 100 Ω or less.

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

• Before wiring, make sure to turn the primary power supply off, and put

up a warning sign. (ex. DO NOT TURN THE POWER ON.)

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

• 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 dis-charsed.

• Do not use this line in common 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 Electric Equipment Technical Standards.

WARNING

C A U T I O N

NOTE

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4.2 Cable Connection

4-2

Fig. 5 Grounding Method


There are three cables for the power supply; a signal cable for detection (1BC), a power cable

(2BC and 3BC). Connect these cables to the manipulator base connectors and the XRC.

4.2.1 Connection to the Manipulator

Before connecting the cables to the manipulator, verify the numbers: 1BC, 2BC, and 3BC on

both power supply cables and the manipulator base connectors. When connecting, adjust the

cable connector positions to the main key positions of the manipulator, and insert cables in the

order of 2BC, 3BC, and 1BC, and then set the lever until hearing a “click”.

4.2.2 Connection to the XRC

Remove the cover on the XRC side. Pass the signal cable for detection (1BC), the power

cable (2BC and 3BC) through the opening for the cables, and then fasten bolts on the open-ing.

Connect the 2BC and 3BC cable to the terminals inside of the XRC. Be sure to verify the num-

bers on both the cable and board connectors before connecting.

Connect the 1BC cable to the boards. Be sure to verify the numbers on both the cable and

board connectors before connecting, and to fasten the bolts on connectors to prevent cables

from loosening.

A

5.5mm2or more

M8 Bolt (For Grounding)

(Provided at factory)

View A

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4-3

Fig. 6 (a) Power Cables (1BC, 2BC)

BA2

BB1

BA1

BA3

U32

U31

U32

V32

V31

V31

V32

W31

W32

W31

W32

E32

E31

E31

E32

U31

E22

W21

W22

W21

E21

E21

E22

W22

U22

U21

U22

U21

V22

V21

V21

V22

E11

E11

E12

W12

W11

W11

V11

V12

V11

U12

U11

U112 B C

E

1 B C

SHOCK-

+24V SHOCK-

E

1BC

2BCE

U11U11U12

V11V11V12W11W11W12

E11E11E12

U21U21U22U22V21V21V22

V22W21W21W22W22E21E21E22E22

U31U31U32U32V31V31V32

V32W31W31W32W32E31E31E32E32

BA1BB1BA2BA3

WRCA01-CNPG123

WRCA01-CNPG456

XIU01-CN25

Connection to the XRC Connection to the manipulator

Signal cable

Power cable

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4-4

Fig. 6 (b) Power Cables (3BC)

Fig. 7 (a) Power Connection to the Manipulator

3 B C

EE

CN4

CN5

CN6

BA4BA5BA6BB4

CACR-UP130AAB

3BC

Connection to the XRC Connection to the manipulator

Power cable

3BC2BC1BC

Key position

Connector details(Manipulator side)

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4-5

Fig. 7 (b) Power Connection to the XRC

Connector No.

XIU01-CN25

Signal Cable

Tighten the screws with

screw driver(+).

Grounding plate

for Signal and power line

Terminal No.: E

Signal Cable

Connector No.

WRCA01-CNPG456 (upper)

WRCA01-CNPG123 (lower)

Power Cable

Power CableBB1 to BA

E11 to U22 V21 to W32

onnector No.

ACR-UP130AAB-CN4, CN5, CN6

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4-6

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5-1

5 Basic Specifications


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

* 2 Conformed to ISO9283

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

Table. 2 Basic Specifications* 1

Item Model MOTOMAN-UP130 MOTOMAN-UP165

Operation Mode Vertically Articulated

Degree of Freedo 6

Payload 130kg 165kg

Repetitive Positioning Accuracy* 2 ±0.2mm

Motion

Range

S-Axis (turning) ±180°

L-Axis (lower arm +76°, -60°

U-Axis (upper arm +240°, -130°

R-Axis (wrist roll) ±360°

B-Axis (wrist pitch/yaw) ±130°

T-Axis (wrist twist) ±360°

Maximum

Speed

S-Axi 2.27 rad/s, 130° /s 1.92 rad/s, 110° /s

L-Axis 2.27 rad/s, 130° /s 1.92 rad/s, 110° /s

U-Axis 2.27 rad/s, 130° /s 1.92 rad/s, 110° /s

R-Axis 3.75 rad/s, 215° /s 3.05 rad/s, 175° /sB-Axi 3.14 rad/s, 180° /s 2.53 rad/s, 145° /s

T-Axis 5.24 rad/s, 300° /s 4.19 rad/s, 240° /s

Allowabl

Moment* 3

R-Axis 735N•m (75kgf•m) 883N•m (90kgf•m)

B-Axi 735N•m (75kgf•m) 883N•m (90kgf•m)

T-Axis 421N•m (43kgf•m) 490N•m (50kgf•m)

Allowabl

Inertia

(GD2 /4)

R-Axis 45kg•m2 51.25kg• 2

B-Axi 45kg•m2 51.25kg• 2

T-Axis 15kg•m2 15kg•m2

Mass 1300kg

Ambient

Conditions

Temperature 0° to 45 °

Humidity 20 to 80% RH (non-condensing

Vibration Less than 0.5G

Others

• Free from corrosive gasses or liquids, o

explosive gasses

• Clean and dry

• Free from excessive electrical noise (plasma

Power Capacity 7.5kVA

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5.2 Part Names and Working Axes

5-2

5.2 Part Names and Working Axes

Fig. 8 Part Names and Working Axes

5.3 Baseplate Dimensions

Fig. 9 Baseplate Dimensions (mm)

T-

T+

B-R-

R+ B+

L- L+

S-

S+

U-

U+

Lower arm(L-arm)

Rotary head

(S-head)

Base

Upper arm

(U-arm)

Wrist

Wrist flange

5 0

3 2 0

0 . 1

50540

365–0.1

855

2 0

4 6 0

2

0

5090

2 0

5 0

2 0

40

7 2 5

3 6 5

0 . 1

5 0

A

12-φ22 Holeφ12H7

View A

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5.4 Dimensions and Working Range

5-3

5.4 Dimensions and Working Range

Fig. 10 Dimensions and Working Range

6 9

. 2

2 0 .8

7 6

6 0

1 3 0

3 5

2650

3 1 3 0

552.5

1250

200

230

90 2 0 6 9

1 1 5 0

2 4 2

5 0

7 3 0

R 2 6 5 0

R 7 2 9

4611

R 5 2 5

1961

285

1 8 9

2 2 2

nagao

Point P

Point PWorking Range

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5.5 B-Axis Working Range

5-4

5.5 B-Axis Working Range

The working range of the B-Axis maintaining a constant angle to the center of U-axis is shown

in " Fig. 11 B-Axis Working Range ".

Fig. 11 B-Axis Working Range

5.6 Alterable Working Range

The working range of the S-Axis can be altered according to the operating conditions as

shown in " Table. 3 S-Axis Working Range ". If alteration is necessary, contact your Yaskawarepresentative in advance.

Table. 3 S-Axis Working Range

Item Specifications

S-AxisWorkingRange

±180° (standard)±150°±120°±90°±60°±30°

1 3 0

1 3 0

U-Axisrotation center

L-Axisrotation center

S-Axisrotation center

B-Axisrotation center

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6-1

6 Allowable Load for Wrist Axis and WristFlange


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

• YR-UP130-A00, -A01: 130kg maximu

• YR-UP165-A00, -A01: 165kg maximu

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. 4 Moment and Total Inertia ". Contact your Yaskawa representa-

tive for further information or assistance.

* 1 ( ): Gravitational unit

When the volume load is small, refer to the moment arm rating shown in " Fig. 12 MomentArm Rating ".The allowable total inertia is calculated when the moment is at the maximum. Contact yourYaskawa representative when only inertia moment, or load moment is small and inertia

moment is large. Also, when the load is combined as a force but a mass, contact yourYaskawa representative.

Fig. 12 Moment Arm Rating

Table. 4 Moment and Total Inertia

Model AxisMoment N•m

(kgf•m)* 1GD2 /4 Total Inertia kg•m2

YR-UP130-A00, -A01R-AxisB-AxisT-Axis

735 (75)735 (75)421 (43)

454515

YR-UP165-A00, -A01R-AxisB-AxisT-Axis

883 (90)883 (90)490 (50)

51.2551.25

15

B

T

L (mm)

L (mm)

600

400

200

600

400

200

1000800600400

40kg

60kg

80kg

100kg

130kg

TL (mm)

Point P

T-, R-axesrotationcenter line

B-axis rotation center line

YR-UP130-A00,-A01

B

T

T

165kg

600 800 1000 L (mm)

60kg

100kg

80kg

130kg

40kg

400

200

600

L (mm)

200

600

400

L (mm)

400

T-, R-axes rotation

center line

B-axis rotation center lineYR-UP165-A00,-A01

Point P

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6.2 Wrist Flange

6-2

6.2 Wrist Flange

The wrist flange dimensions are shown in " Fig. 13 Wrist Flange ". In order to see the tram

marks, it is recommended that the attachment be mounted inside the fitting. Fitting depth of

inside and outside fittings must be 8mm or less.

Fig. 13 Wrist Flange

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

8

8

P C D 1 2 5

P C D 9 2

2-φ10 Depth:8

2-φ9 Depth:8

6-M10 Tapped hole,Depth: 12

6-M10 Tapped hole,Depth: 12

+0.015 0

+0.015 0

6 3

D I A

1 6 0

D I A

0 - 0 . 0

2 5

+ 0 . 0

3 0

0

NOTE

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7.1 Mounting Equipment

7-1

7 System Application

7.1 Mounting Equipment

When peripheral equipment is attached to the U-axis, the following conditions should be

observed.

Fig. 14 Clamp and Tapped Holes

A2

A1

126 160

1 0 0

6 0

497.5200552.5

120

8 0

8 0 1

8 9

B

C

1 0 0

2 × 2-M8P1.25, Depth: 15mm

2 × 2-M8P1.25, Depth: 15mm

2 × 2-M8P1.25, Depth: 15mm

2 × 4-M12 P1.75, Depth: 25mm

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7.2 Incorporated Wire and Airduct

7-2


Wires and an air line are incorporated into the manipulator for user application. There are 23

wires and air duct rating. The allowable current for wires must be 6.6A or below for each wire.

(The total current value for pins 1 to 23 must be 60A or below). The maximum pressure for the

air duct is 490kPa (5kgf/cm2) and its inside diameter is φ8mm.

Table. 5 Constraint for Attaching

Application Note

A1, A2 Cable Processing Attaching load weight is:130kg max. for YR-UP130-A00, -A01165kg max. for YR-UP165-A00, -A01 including wrist load

B Cable Processing andValve Load

30 kg max.49N•m max. for moment increaseamount of upper arm

C Others 200 kg max.

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7-3

Fig. 15 Incorporated Wire and Airduct

The same pin number (1-23) of two connectors is connected in the lead line of single

0.75mm2.

4

9

32

7 812131415

6510

3

654

21

1

1117 20

23

1819

22

16

1112

10987

181716

1415

13

2223

2021

19

21

A

Cable connector provided on U-axis

is type JL05-2A24-28SC(with cap).

Mating plug type is JL05-6A24-28P

Air A outlet: PT3/8

with bull plug

Air B outlet: PT3/8

with bull plug

Air B inlet: PT3/8

with bull plug Air A inlet: PT3/8with bull plug

Cable connector provided on S-axisis type JL05-2A24-28PC(with cap).

Mating plug type is JL05-6A24-28S

View A

Pins used

Internal wires: 23-0.75mm2

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7-4

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8.1 Position of S-Axis Limit Switch

8-1

8 Motoman Construction

8.1 Position of S-Axis Limit Switch

The limit switches for the S-, L-, and U-Axes are located as shown in " Fig. 16 Location of

Limit Switches ". The limit switch for the S-Axis is standard (Model: YR-UP130-A00, YR-

UP165-A00). The limit switch for the L- and U-Axes are optional (Model YR-UP130-A01, YR-

UP165-A01). The inspection and adjustment of the limit switches should be made after

removing the cover.

Fig. 16 Location of Limit Switches

YR-UP130-A01YR-UP165-A01

YR-UP165-A01YR-UP130-A01

LU-Axes Interference L.S.(option)

L-Axis Overrun L.S.(option)

S-Axis Overrun L.S.(standard)

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8.2 Internal Connections

8-2

8.2 Internal Connections

High reliability connectors which can be easily removed are used with each connector part.

For the number and location of connectors, see" Fig. 17 Location and Numbers of Connec-

tors " and " Table. 6 List of Connector Types ".

Fig. 17 Location and Numbers of Connectors

Table. 6 List of Connector Types

Name Type of Connector

Connector for User Cable onbase

JL05-2A24-28PC(JL05-6A24-28S: Optional)

Connector for User Cable onU-arm

JL05-2A24-28SC(JL05-6A24-28P: Optional)

4BC

3BC2BC1BC

Connector for internal wire

Connector for internal wire

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R

BAT1 R

hw1 7198 hw91 7084 704h w711 .0t

h w172 69hw 917 1211 03hw 711.0 t

hw 1719 5hw9 1710 8706 hw71 1.0t

hw1 7198 hw91 7084 704h w711 .0t

DATA-1

DATA-2DATA+2

P

P

DATA+1PK

BAT1R

P

P

P

P

P

P

DATA-4DATA+4

P

P

P

P

P

P

P

P

P

P

P

R

1BC(6X6)

CN1-2

CN1-4CN1-3

CN2-2CN2-1

CN2-4CN2-3

CN2-5

CN3-2CN3-1

CN1-1P

P

P

P

PP

P

CN3-4CN3-3

CN4-1

CN4-3

CN4-2

CN5-1

CN5-4CN5-3

CN5-2

CN4-4

CN6-1CN6-2

CN6-3CN6-4CN6-5

LB1CN2-6CN3-6 +24V

PP

P

P

PP

P

P

P

PP

P

CN6-6CN5-6

CN1-6CN1-5

P

P

E

CN4-6

BAT40BT4K

0BT1K

No.13CN

No.10CN

No.2CN

BATOBT

OBTBAT

OBTBAT

OBTBAT

B A

2CN-

BATOBT13CN-

AB

11CN- AB

BATOBT

BATTERY

-H

-J-G

-S-T

-D1CN-CNo.1CN

+5V

FG30V

BATOBT

DATA+3DATA-3

PG

S-AXISPG

L-AXISPG

U-AXIS

No.11CN

0V

BATOBT+5V

FG1

-H-G

-S-T-D

12CN-C-D

-J

No.12CN

0V+5V

FG2

OBT-H-G-J

-S-T BAT

10CN-C

BATTERY

PG

PG

-5

-2-3-4

4CN-1No.4CN

-7

5CN-1No.5CN

-4-3

-5-6-7

-2

-6FG40V+5VOBTBAT

DATA+5DATA-5BATOBT+5V0VFG5

PG

-2-3

No.6CN6CN-1

-7-6-5-4

BC2

BC1

FG60V+5VOBTBATDATA-6DATA+6

R-AXIS

B-AXIS

T-AXIS

FOR LAMP(OPTION)

LA4LB4

E

CASING

E4BC-1

E1

4BC(24-28)

B1SS1

K

B1

BC1

LB1LA1

SS1

BAT4

AL2 AL1

LB3LA3

LA1LB1LA2LB2

LB1

SS2B2

MANIPULATOR

BC2 S-AXIS OVERRUN L.S.

S-AXIS(FAN ALM)(OPTION)

0BT1

FG2

DATA-1

+5V-10V-1

DATA+2DATA-2

0V-2+5V-2

DATA+3DATA-3

DATA+1

1945

22

1614

4721

13

1137

39

54306-5011

(MOLEX)

68

24

DATA-4

0V-5+5V-5

DATA-5DATA+5

+5V-40V-4

DATA+4

+5V-30V-3

0BT4

-3

-4-5

-2

FG6

+5V-60V-6

DATA+6DATA-6

315293

2422

19

16

4721

113713

(MOLEX)

54306-5011

14

45

86

5293

31FG

-A3-D1

-B1-A1

39

EE

E

E

BASE

SS20V

AL1 AL2

E

E1

E4BC-1

4BC(24-28)

-D2-C3-D3

BC2 -6-C1

No.16CN16CN-1

A terminal1.25-4

YASNAC-XRC

B

A

CNPG123WRCA01

CNPG456WRCA01

178214-1(AMP)

A terminal1.25-4

XIU01-CN25

Fig.18 (a)Internal Connection Diagram

8-3

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E2BC(8X6)

MU1CN1-2C N1 -1 M U1

E

V11

V12V11

U12U11

E11

E12E11

W12W11W11

U11

U21

BB1BA1

V21V21

U22U22

V22

U21

V22

E21W22W22W21W21

E22E22E21

BA2

3BC(6X6)

MU5

MW5

MV5MU5

MV5

ME5ME5

MW5

ME4BA4BB4

E

U31U31U32

W31

V31

V32V32V31

U32

E31E31E32

W32W32

BA3

E32

E

W31

B1

A2

B2

A1

B1

A1

B2

A2

AC1

MU6

MV6

MW6

MU6

MV6

MW6

ME6ME6

BA5

BA6

AC2

A2

B1

B2

A1

BA4

BB4

BA5

BA6

AC2

AC1

CN4

CN5

CN6

Brake

Brake

Brake

Brake

Brake

Brake

INCORPRATED CABLE

1.25-3.5 A Terminal

A terminal

1.25-3.5

1.25-4

A Terminal

A Terminal

1.25-3.5

A Terminal

1.25-4

1.25-3.5

A Terminal

A Terminal

A Terminal

A Terminal

1.25-4

1.25-4

-6-5

CN4-1

CN4-3CN4-4CN4-5

CN4-6

CN4-2

L AND U-AXIS INTERFERENCE L.S.

LB4LA4

LA3

LA1LB1LA2

S-AXIS OVERRUN L.S.

LB3

LB1

LB2

LB1LB2

L-AXIS OVERRUN L.S.(OPTION)

LB2LB1

L-AXIS OVERRUN L.S.(OPTION)

LA4LB4

LA3LB3

LA2

LB1

LB2

LB1LA1 S-AXIS OVERRUN L.S.

A Terminal

A Terminal

MV3

ME3

BB3BA3

MW3

MU3No.3CN3CN-A

-F

-B

-E-D-C SM

YB

E

CASING

4BC-34BC-4

E

4BC-24BC-1

34

E

21

4BC-104BC-9

4BC-5

4BC-74BC-8

4BC-6

910

78

56

4BC-15

4BC-11

4BC-144BC-134BC-12

1514131211

4BC-21

4BC-184BC-19

4BC-17

2021

171819

1 6 4 BC- 1 6

4BC-20

4BC(24-28)

SP1SP2

MANIPULATOREE

E

E

BASE

34

E

21

4BC-34BC-4

E

4BC-24BC-1

910

5

876

4BC-94BC-10

4BC-5

4BC-74BC-8

4BC-6

15

11121314

4BC-15

4BC-11

4BC-144BC-134BC-12

2021

191817

4BC-21

4BC-174BC-184BC-194BC-20

4 BC -1 6 1 6

4BC(24-28)

23

YB

SM S-axis motor

4BC-23

SM

YB

L-axis motor

U-axis motor

R-axis motor SM

YB

B-axis motor SM

YB

MV4MU4MU4

-2-7

ME4

MW4MW4ME4

-3

-4-9

-10

MV4-8

No.7CN7CN-1

MU5MV5

BB4

-2

ME5

BB5BA5

MW5

-5-6

-4-3

No.8CN8CN-1

BA4

No.14CN14CN-A

-B-C-D-E-F

MW1

MU1MV1

BA1BB1

ME1

No.15CN

-B-C-D-E-F

MW2

BA2BB2

ME2

MV2MU215CN-A

T-axis motor SM

YB

MW6ME6

MU6MV6-3-4

-2

BA6BB6

-5-6

9CN-1

No.9CN

S-AXIS(FAN)(OPTION)

234BC-23

MV1MV1

MV1MU1

CN1-6CN1-7

CN1-5CN1-3

ME1ME1

MW1ME1

MW1

CN2-7CN2-6

CN2-2

CN2-5CN2-3

C N2 -1 M W1

BB1

CN3-1

CN1-8

CN3-7

CN3-4CN3-3

CN3-6CN3-5

CN3-2

CN4-5

CN4-3CN4-4

CN4-2CN4-1

CN4-7CN4-8CN2-4

CN4-6

CN3-8

MU2MU2

MU2

ME2ME2BA2

MW2MW2

ME2ME2

MW2

MV2MV2MW2

MV2MV2

MU2

BA1CN1-4

CN5-2

CN5-4CN5-3

CN5-1

CN5-7CN5-8

CN5-6CN5-5

CN6-1CN6-2

CN6-4CN6-5CN6-6CN6-7

CN6-3

CN2-8

CN6-8

MU3MU3

ME3ME3ME3

BA3

MW3MW3

MW3ME3

MW3

MV3MV3MV3

MU3MV3

MU3

CN1-1

CN1-3CN1-2

CN1-5CN1-6

CN2-2CN2-1

CN1-4

CN3-2CN3-1

CN5-4

CN3-6

CN3-4CN3-5

CN3-3

CN2-4CN2-3

CN5-1

MU4MU4

MW4MW4ME4

MV4MV4

(AMP)

(AMP)1-917807-2

1-917807-2

CN5-2

CN2-6CN2-5

CN5-3

CN5-6CN5-5

(AMP)1-917807-2

4BC-22 22 4BC-2222

L,U-axis limit switch

YR-UP165-A01

YR-UP130-A01

L-axis overrun limit switch(option)

PE

B

A

A

L-axis limit switchNote

1.These drawings are applicable to UP130-A00,UP165-A00.

was changed as shown in the right drawing.

2.In case of UP130-A01,UP165-A01,connevtion of part A

Fig.18 (b)Internal Connection Diagram

8-4

1.25-4

1.25-4

1.25-4

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9.1 Inspection Schedule

9-1

9 Maintenance and Inspection


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 inter-

vals are displayed in six levels. Conduct periodical inspections according to the inspection

schedule in " Table. 7 Inspection Items ".

In " Table. 7 Inspection Items ", the inspection items are classified into three types of opera-

tion: operations which can be performed by personnel authorized by the user, operations

which can be performed by personnel being trained, and operations which can be performed

by service company personnel. Only specified personnel are to do inspection work.

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

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

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

• Maintenance and inspection must be performed by specified personnel.

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

• For disassembly or repair, contact your Yaskawa representative.

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

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

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

tor when maintenance and inspection.

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

WARNING

C A U T I O N

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9-2

• The inspection interval must be based on the servo power supply on time.

• For axes which are used very frequently (in handling applications, etc.), it is recom-

mended that inspections be conducted at shorter intervals. Contact your Yaskawa repre-

sentative.

Table. 7 Inspection Items

Items* 4

Schedule

Method Operation

Inspection Charge

Daily

1000

H

Cycle

6000

H

Cycle

12000

H

Cycle

24000

H

3600

HSpecifiedPerson

LicenseeService

Company

% Tram mark & Visual

Check tram markaccordance anddamage at the homeposition.

& & &

' External lead & VisualCheck for damageand deterioration ofleads.

& & &

(

Working area

and

manipulator& Visual

Clean the work areaif dust or spatter ispresent. Check fordamage and outsidecracks.

& & &

)LU-axes

motor & Visual

Check for grease

leakage.* 5 & & &

*

Baseplate

mounting

bolts&

SpannerWrench

Tighten loose bolts.Replace if necessary. & & &

+Cover mount

ing screws &

Screw-driver,

Wrench

Tighten loose bolts.Replace if necessary. & & &

,

SLU-axes

motor

connecto& Manual

Check for loose con-nectors and tighten ifnecessary.

& & &

-Base connec-

tors & Manual

Check for loose con-nectors. & & &

. Balancer &Grease

GunSupply grease.See Par. 9.2.8 & &

/RBT-axes

timing belt & Manual

Check for belttension and wear. & &

Wire harness

in manipulator

(SLURBT-

axes leads))

&

Multimeter

Check for conduc-tion between themain connector ofbase and intermedi-ate connector withmanually shaking thewire. Check for wear

of protective spring* 1

& &

& Replace* 2

&

NOTE

11

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9-3

* 1 When checking for conduction with multimeter, connect the battery to “BAT” and “OBT” of connectors on the

motor side for each axis, and then remove connectors on detector side for each axis from the motor. Other-

wise, the home position may be lost. (Refer to 9.2.9

* 2 Wire harness in manipulator to be replaced at 24000H inspection.

* 3 For the grease, refer to " Table. 8 Inspection Parts and Grease Used ".

* 4 Inspection No. correspond to the numbers in " Fig. 19 Inspection Parts and Inspection Numbers ".

* 5 The occurrence of a grease leakage indicates the possibility that grease has seeped into the motor. This can

cause a motor breakdown. Contact your Yaskawa representative.

Battery unit in

manipulator &

Replace the batteryunit when the batteryalarm occurs or themanipulator drove for36000H.See Par.9.2.9

& &

S-axis speed

reducer,

S-axis gear& &

GreaseGun

Check for malfunc-tion. (Replace if nec-essary.) Supply

grease* 3 (6000Hcycle). See Par. 9.2.2

Replace grease* 3 .(12000H cycle).

See Par. 9.2.2

& &

L-axis speed

reducer & &

GreaseGun



Replace grease* 3 (12000H cycle). See

Par. 9.2.3

& &

U-axis speed

reducer & &

GreaseGun



Replace grease* 3 (12000H cycle). SeePar. 9.2.

& &

R-axis speed

reducer & &

GreaseGun



Replace grease* 3 (12000H cycle). SeePar. 9.2.5

& &

B-, T-axis

speedreducer & &

Grease

Gun


grease* 3 (6000H

cycle). See Par.9.2.6, 9.2.7

Replace grease* 3 (12000H cycle). SeePar. 9.2.6, 9.2.7

&

Overhaul & &

Table. 7 Inspection Items

Items* 4

Schedule

Method Operation

Inspection Charge

Daily

1000

H

Cycle

6000

H

Cycle

12000

H

Cycle

24000

H

36000

H

Specified

Person

LicenseeService

Company

12

13

14

15

16

17

18

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9-4

Fig. 19 Inspection Parts and Inspection Numbers

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

Table. 8 Inspection Parts and Grease Used

No. Grease Used Inspected Parts

13, 14, 15,16, 17

Molywhite RE No. 00 S-, L-, U-, R-, B-, and T-axes speed reducersS-, B-, and T-Axes gears

9 Alvania EP Grease 2 L-Axis Balancer

1

4

2

2

11

7

4

1

13

6

9

8

6

2

714

1 ,6

6

10

6

17

15

5

1 1 1

16

R-axis B-axis T-axis

U-axis

L-axis

S-axis

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9.2 Notes on Maintenance Procedures

9-5


9.2.1 Battery Unit ReplacementIf a battery alarm occurs in the XRC, replace the battery according to the following procedure:

Fig. 20 (a) Battery Location (Side View)

Fig. 20 (b) Battery Location (Top View)

Manipuatorbase

Battery unit

M5 screwConnector base

M4 Screw M4 Screw

Battery unit for SLU-axes(HW9470932-A)

Battery unit for RBT-axes(HW9470932-B)

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9-6

Fig. 21 (a) Battery Connection for SLU-Axes

Fig. 21 (b) Battery Connection for RBT-Axes

1. Turn the XRC main power supply off.

2. Remove the connector base, and grease tube from the union.

3. Remove the battery unit mounting screw on the support.

4. Remove the plastic tape (insulation tape) protecting the connection part of the battery

unit in the manipulator.

5. Connect the new battery.6. Remove the old battery.

7. Protect the connection part of the battery unit in the manipulator with plastic tape (insu-

lation tape).

8. Mount the battery unit with the screw, connect the grease tube to the union, and then

mount the connector base.

Remove the old battery unit after connecting the new one so that the encoder absolutedata does not disappear.

a

b 0BT1

BAT1

0BT1

BAT1a

ba

bBAT1

0BT1

b

a0BT1

BAT1

See Procedure 7

See Procedure 6

See Procedure 4

Internal wiresfor SLU-axes

Battery unit for SLU-axesbefore replacement

New battery unit

See Procedure 5 a: Insertion-type pin terminal (Male)b: Insertion-type pin terminal (Female)

b

a

0BT4b

a BAT4

BAT4a

0BT4b

BAT4

0BT4

See Procedure 7

See Procedure 6Battery unit for RBT-axesbefore replacement

Internal wires

for RBT-axes

New battery unitSee Procedure 4

See Procedure 5 a: Insertion-type pin terminal (Male)b: Insertion-type pin terminal (Female)

b

a0BT4

BAT4

NOTE

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9-7

9.2.2 Grease Replenishment/Replacement for S-AxisSpeed Reducer

Fig. 22 S-Axis Speed Reducer Diagram

# Grease Replenishment (Refer to " Fig. 22 S-Axis Speed ReducerDiagram ".)

1. Remove the So exhaust plug

2. Inject the grease into the Si grease inlet using a grease gun

3. Reinstall the So exhaust plug.(Spread the Modifier silicon Caulk on the screw of the

plug.)

# Grease Replacement (Refer to " Fig. 22 S-Axis Speed ReducerDiagram ".)

1. Remove the So exhaust plug

Do not pinch the cable when the base connector is installed.

If grease is added without removing the exhaust plug, the grease will go inside the motorand may damage it. It is absolutely necessary to remove the plug.

Grease type: Molywhite RE No.00Amount of grease: 530cc(1060cc for 1st supply)

If grease is added without removing the exhaust plug, the grease will go inside the motorand may damage it. It is absolutely necessary to remove the plug.

NOTE

So: Grease outlet

Hexagon socket head PT1/8 plug Si: Grease inlet

G Nipple A-PT1/4

S-axis speed reducer

NOTE

NOTE

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9-8

2. Inject the grease into the Si grease inlet using a grease gun.

3. The grease replacement is complete when new grease appears in the So exhaust port.

The new grease can be distinguished from the old grease by color.

4. Wipe the So exhaust port with a cloth and reinstall the plug.(Spread the Modifier silicon

Caulk on the screw of the plug.)

9.2.3 Grease Replenishment/Replacement for L-AxisSpeed Reducer

Fig. 23 L-Axis Speed Reducer Diagram

# Grease Replenishment (Refer to " Fig. 23 L-Axis Speed ReducerDiagram ".)

1. Make the L-Arm vertical for ground.

2. Remove the Lo exhaust plugs.

Grease type: Molywhite RE No.00Amount of grease: 3650cc

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

If grease is added without removing the exhaust plugs, the grease will go inside the motorand may damage it. It is absolutely necessary to remove the plugs.

NOTE

L-axis speed reducer

Lo: Grease outlet

Hexagon socket head PT1/8 plug

Li: Grease inlet

G Nipple A-PT1/8

NOTE

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9-9

3. Inject grease into the Li grease inlet using a grease gun.

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

5. Wipe the Lo exhaust plugs with a cloth and reinstall the plugs.(Spread the Modifier sili-

con Caulk on the screw of the plug.)

# Grease Replacement (Refer to " Fig. 23 L-Axis Speed Reducer Dia-gram ".)

1. Make the L-Arm vertical for ground.

2. Remove the Lo exhaust plugs.

3. Inject grease into the Li grease inlets using a grease gun

4. The grease replacement is complete when new grease appears in the Lo exhaust

ports. The new grease can be distinguished from the old grease by color.

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

6. Wipe the Lo exhaust plugs with a cloth and reinstall the plugs.(Spread the Modifier sili-

con Caulk on the screw of the plug.)


(800cc for 1st supply)


Grease type: Molywhite RE No.00Amount of grease: approx. 2000cc

NOTE

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9-10

9.2.4 Grease Replenishment/Replacement for U-AxisSpeed Reducer

Fig. 24 U-Axis Speed Reducer Diagram

# Grease Replenishment (Refer to " Fig. 24 U-Axis Speed ReducerDiagram ".)

1. Make the U-Arm horizontal for ground.

2. Remove the Uo exhaust plugs.

3. Inject grease into the Ui grease inlet using a grease gun.

4. Wipe the Uo exhaust plugs with a cloth and reinstall the plugs. (Spread the Modifier sil-

icon Caulk on the screw of the plug.)



(500cc for 1st supply)

Uo: Grease outlet


U-axis speed reducer

Ui: Grease inlet

G Nipple A-PT1/8

NOTE

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9-11

# Grease Replacement (Refer to " Fig. 24 U-Axis Speed ReducerDiagram ".)

1. Make the U-Arm horizontal for ground.

2. Remove the Uo exhaust plugs

3. Inject grease into the Ui grease inlet using a grease gun

4. The grease replacement is complete when new grease appears in the Uo exhaustports. The new grease can be distinguished from the old grease by color.

5. Wipe the Uo exhaust plugs with a cloth and reinstall the plugs. (Spread the Modifier sil-


9.2.5 Grease Replenishment/Replacement for R-Axis

Speed Reducer

Fig. 25 R-Axis Speed Reducer Diagram


Grease type: Molywhite RE No.00Amount of grease: approx. 1650cc

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

NOTE

NOTE

R-axis speed reducer

Ro: Grease outlet


Ui: Grease inletHexagon socket head PT1/8 plug

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9-12

# Grease Replenishment (Refer to " Fig. 25 R-Axis Speed ReducerDiagram ".)

1. Remove the Ro exhaust plugs

2. Remove the Ri plug: PT1/8 and install the G Nipple A-PT1/8 and inject grease into the

Ri grease inlet using a grease gun

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

4. Wipe the Ro exhaust plugs with a cloth and reinstall the plugs. (Spread the Modifier sil-


# Grease Replacement (Refer to " Fig. 25 R-Axis Speed ReducerDiagram ".)

1. Remove the Ro exhaust plugs

2.

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