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YASKAWA YR-1-06VX50-A00 OPERATING AND

MAINTENANCE MANUAL
 ROBOTICS

YR-1-06VX50-A00
GP50 (Standard)

Operating and Maintenance Manual

Created on: 2018-11
Revision: 04
Document number: E1101000258GB04 Author: WOE

Modifications made:
Rev 01: Revised version of the original HW1484659.0 in YEU R style (2017-11)
Rev. 02: Add a new chapter 1.3 "YASKAWA manual list"
Rev. 03: Revised version of the original HW1484659.1 (Chapter 6 "Technical data" and
chapter 7.5 "Maximum capacity load")(2018-04)
Rev. 04: Revision of the chapter 4.3 "Installation example"

© Copyright 2018
This documentation (or parts of it) must not be reproduced or made available to third parties without
the express approval of YASKAWA Europe "Robotics Division GmbH”.
We have checked the content of this publication for compatibility with the hardware described.
Nevertheless, discrepancies cannot be ruled out. Therefore, we cannot guarantee full compliance.
However, the information given in this publication is checked regularly and any necessary corrections
will be made in subsequent editions.
Subject to technical modifications.
Table of contents

Table of contents

1 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.1 Notes for safe operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.2 Frequently used terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.3 YASKAWA manual list. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.4 Target group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.5 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.6 Improper use. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.7 About this manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.8 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.9 Manufacturer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.10 Authorized representative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

2 Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.1 Checking the scope of delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.2 Position type plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

3 Transportation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.1 Transporting method. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.1.1 Using a crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.1.2 Using a forklift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.2 Shipping brackets and bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.3 Damping material during transportation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

4 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4.1 Protection measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4.2 Ambient conditions and installation location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.3 Installation example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4.4 Notes on dust-proof/water-poof specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

5 Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
5.1 Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
5.2 Cable connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
5.2.1 Connecting the robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
5.2.2 Connection of the robot controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
5.2.3 Connecting the programming pendant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

6 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
6.1 Parts and work axis label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
6.2 Robot base dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
6.3 Dimensions and defined working area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
6.4 Adjustable working area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
6.4.1 Instructions for Installing the Mechanical Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
6.4.2 Components for Changing the Working Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
6.4.3 Adjusting the S-Axis Pulse Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
6.5 Stopping Angle and Time at the Emergency Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
6.5.1 Stop category 0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
6.5.2 Stop category 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

3
Table of contents

7 Allowable load for wrist axis and wrist flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

7.1 Wrist flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
7.2 Maximum load of the S-axis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
7.3 Optimal robot performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
7.4 Allowable Wrist Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
7.5 Maximum capacity load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

8 Internal cables and compressed air lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

9 Maintenance and inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

9.1 Inspection schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
9.2 Note on battery unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
9.2.1 Battery pack replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
9.2.2 Multiple connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
9.3 Home position check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
9.4 Seeped oil check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
9.5 Axis motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
9.6 Refill/Replace grease.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
9.6.1 Grease filling the main axes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
9.6.2 Grease filling the wrist axes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

10 Recommended spare parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

11 Parts lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
11.1 S-axis unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
11.2 L-axis unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
11.3 U-axis drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
11.4 R- B-, and T-axes drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
11.5 Wrist unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

4
General

1 General

1.1 Notes for safe operation

DANGER!
Indicating immediate danger at high risk, hazard that can cause death or serious bodily
injuries if no precautions are taken.

WARNING!
Indicating possible medium risk hazard situation which can cause death or serious bodily
injuries if it is not avoided.

CAUTION!
Indicating potentially dangerous situation with low risk of minor or moderate bodily injuries
result if it is not avoided. This signal word can also be used for property damage warnings.

NOTICE
Indicates important background information and application advice.

1 -5
General

1.2 Frequently used terms

The YASKAWA robot is a product of YASKAWA Electric Corporation, and is provided by
default with the robot control, the programming pendant and robot cable.
The terms are designated as follows in this manual:

Term Description
Control Robot control
Industrial robot Robot
Programming pendant / teach box Programming pendant or PP
Supplying cable between robot and robot Cable
control
Robot, robot control and cable Robot system
YASKAWA Electric Corporation YEC
YASKAWA Robotics Division YEU-R
Moving, calibrating and setting up of the ro- Teachen
bot
Movement sequences of the robot JOBs
Technical customer service TCS
General purpose GP
FEEDBACK FB
Time Measuring TM
Personal computer PC
Switch SW

1.3 YASKAWA manual list

NOTICE
It is important to have all the manuals of the YASKAWA control or robot available and to
know their contents. Please make sure you have all these manuals. If any manuals are
missing, contact your salesman from YASKAWA local branch office.
You must have the YASKAWA manuals listed below available:
• Instructions (E1102000214XX01* and higher).
• Maintenance (Variable "Handbuch Maintenance" not defined.
• Upgrade procedure manual (Variable "Upgrade Procedure Manual" not defined.).
• Installation and wiring (Variable "Handbuch Aufstellung und Anschluss" not defined.).
• Alarm list (Variable "Handbuch Alarm Liste" not defined.).
• General operators manual (E1102000220XX01 or higher).
• CIO (Variable "CIO" not defined.
• The operating and maintenance instructions of the respective robot type.
* XX is the language of the document.

1 -6
General

1.4 Target group

This manual is directed at users with the following knowledge:
• Advanced knowledge of mechanical engineering
• Advanced knowledge of electrical engineering
• System knowledge of the robot control
• Specially trained staff

NOTICE
According to the international DIN EN ISO 10218-1 standard, operators of a robot system
must receive training before they operate the robot.
For optimal use of our products, we recommend our customers to take part in a training
session at the YASKAWA Academy. For more detailed information on the training
programs, please visit www.yaskawa.eu.com or directly get in touch with your YASKAWA
branch office.

1.5 Intended use

Typical applications:
• Flange-mounting tools
• Installation of spot welding guns
• Installation of arc welding equipment
• Installation of grippers
• Machining and transporting workpieces or products

1.6 Improper use

Any use that deviates from the intended use shall be regarded as impermissible misuse.
This includes:
• Transport of people and animals
• Use as ascending aid.
• Use outside the permissible operating limits.
• Use in environments with risk of explosion (except for ATEX-approved robots).
• Overload
• Use without protective equipment.

NOTICE
Modifications to the robot, e.g. drilling holes or similar modifications, can damage parts.
This will be regarded as improper use (i.e. use that deviates from the intended use) and will
lead to loss of warranty and liability claims as well as loss of the declaration of incorporation.

1 -7
General

CAUTION!
The robot system is an incomplete machine.
The robot system may be put into operation only after it has been determined that the
incomplete or complete machine in which the robot system is being installed:
 Corresponds to the provisions of the machinery directive.
 Complies with all relevant (harmonized) standards.
 Corresponds to the state of the art.

1.7 About this manual

NOTICE
• This manual describes the mechanics of the robot for the purpose of operation,
maintenance and inspection. It contains information on safety and handling, technical
data, the tools and materials required for maintenance and inspection and instructions
for operation and maintenance. Read this manual carefully and make sure you are
familiar with its contents before installing and operating the robot.
• Variable "Ordnungsgemäßen Betrieb" not defined.
• In order to illustrate details clearly, some drawings are shown with the protective covers
or shields removed. All protective covers and shields must be mounted before the robot
is operated.
• The drawings and figures in this manual are representative illustrations. They may differ
from the product delivered.
• YEU-R reserves the right to make technical changes. These changes may include
product improvements, modifications or changes in specifications
• If your copy of the operating and maintenance instructions is damaged or lost, please
contact the local YASKAWA branch office to order a new copy. The official branch
offices are listed on the last page. Please mention the manual number in your order.
• YASKAWA Europe GmbH is not responsible for damage caused due to unauthorised
modification of the system. If any impermissible modifications are made to the system
and to the robot, all warranty and liability claims as well as the declaration of
incorporation will expire.

1 -8
General

1.8 Safety

Programming pendant

1 Emergency stop button

1

WARNING!
Danger of death or injury from crushing
If the emergency stop button is not working properly, the robot cannot be stopped in the
event of an emergency.
 The robot should not be used if the emergency stop button is not working.
 Before operating the robot, check the function of the EMERGENCY STOP button. The
servo power must go off immediately when the EMERGENCY STOP button is pressed
on the programming pendant (see ).
 When the servo power is turned off, the "SERVO ON" LED on the programming
pendant goes out (see ).

Fig. 1-1: "SERVO ON" LED

OP
EM

ER T
G ENCY S

Fig. 1-2: Emergency stop button

1 -9
General

WARNING!
Danger of death or injury from crushing
Before you release the emergency stop button (see ), note the following.
 Make sure there is no one within the maximum operating range of the robot.
 Clear the cell of all items with which the robot could collide.
 Only then should you switch on the servo power by pressing the enabling switch on the
programming pendant.

Fig. 1-3: Releasing the emergency stop button by rotating it

WARNING!
Danger of death or injury from crushing
If anyone enters the working area of the robot during operation or any problems occur,
always press the EMERGENCY STOP button immediately. It is located on the
programming pendant (see figure „Programming pendant“).
Take the following precautions when performing teaching operations within the robot’s
operating range:
 Position yourself in front of the robot whenever possible.
 Always follow the prescribed operating steps (see the instructions for the robot
controller, as well as the „Handling“ and „Universal Application“ manuals).
 There must be a free space into which the operator can retreat in the event of an
emergency.

The following test steps absolutely must be performed before you teach the robot. Deal with
any problems you find immediately, and make sure that any other necessary steps have
been taken.
• Check for any problems in the movements of the robot.
• Check that the connectors are well secured and none of the cables are damaged.
• Hang the programming pendant back on the robot controller after use.
• Make sure that the key for the mode selector (teach/automatic) on the programming
pendant is kept by a competent person who has been specially trained by us.
• The key may only be inserted into the key switch of the programming pendant during
teaching. After teaching, it must be immediately removed and kept in a safe place.

1 - 10
General

1.9 Manufacturer
Address:
YASKAWA ELECTRIC CORPORATION
2-1 KUROSAKISHIROISHI
YAHATANISHI-KU
KITAKYUSHU
JAPAN

1.10 Authorized representative

Address:
YASKAWA Europe GmbH
Robotics Division
Yaskawastr. 1
85391 Allershausen
Germany

1 - 11
Supply

2 Supply

2.1 Checking the scope of delivery

The standard delivery includes the following items:

Scope of delivery

1 Programming pendant
2 Robot controller 1
3 Robot 3
2
4 Cable
5 The present assembly instruc-
tions

䠮䡋䠾䡋䡐
䠮 䠾 䡐 䠩
䠩䠽䡊䡑䠽䡈 䡈
READ ONLY MEMORY

5
4
䠮䡋䠾䡋䡐
䠮 䠾 䠩䠽䡊䡑䠽䡈
䠩 䡈
READ ONLY MEMORY

Accessories of robot Pcs Remark

Hexagon socket head cap screw M20 x 8
70 (Strength category 12.9)
For mounting the robot
Spring washer M20 8
Washer M20 8
Grease zerk A-PT1/4 1 For grease replenishment of S-axes
Grease zerk A-PT1/8 1 For grease replenishment of L-axis
Grease zerk A-PT3/8 3 For grease replenishment of U-, R-, B-
, T-axes and gears

2 - 12
Supply

2.2 Position type plate

NOTICE
Please contact the local YASKAWA branch office if the serial numbers do not match the
information on the delivery note.

Verify whether the serial number of the robot, the robot controller and the programming
pendant with the delivery.
The serial number can be found on the type plate as shown below.

NJ4014-1

Fig. 2-1: Position type plate

2 - 13
Transportation

3 Transportation

3.1 Transporting method

CAUTION!
Damage to persons and damage to property due to external force influences
 External forces must not be exerted on the robot or the motors.

• Check that the eyebolts are securely fastened.

• The robot weights approximately 570 kg. Use load carrying devices strong enough to
withstand the weight.
• The transport safety devices support the robot; therefore, use them exclusively for the
transport of the robot.
• Before transport, be sure to mount the shipping bolts and brackets to the robot.

3 - 14
Transportation

3.1.1 Using a crane

Adequate load handling devices must be used to transport the robot. Make sure that the
robot is lifted as shown in the diagram "Transport by crane".

Transport with crane

1 8 screws M12 x 25
2 Shipping bracket
3 Position of the center
of gravity
4 Wire rope (at least
2000 mm long)

3 - 15
Transportation

3.1.2 Using a forklift

If the robot is transported using a forklift, it should be fixed on a pallet with transport securing
devices and shipping bolts. Make sure that the forklift and the transportation route have
sufficient bearing capacity.
Always take due care when transporting the robot.

Using a forklift

1 8 M20 screws
2 Pallet
3 Openings for the fork
prongs

3 - 16
Transportation

3.2 Shipping brackets and bolts

NOTICE
Before turning ON the power, check to be sure that the shipping bolts and brackets are
removed.
After removing the transport securing devices and the shipping bolts, keep them at a safe
place. The transport securing devices and shipping bolts will be required again if the system
is transported again.

The robot is equipped with transport securing devices and shipping bolts to reduce external
forces to a minimum during transport.
• The shipping brackets and bolts are painted yellow.
• The shipping bracket will be fastened by 2 screws M12.

Shipping brackets and bolts

1 Shipping bracket
2 Hole Ø 30
3 4 Screws M12 x 25, 4 Spring
washers M12

3.3 Damping material during transportation

To protect the robots machinery from external forces during transportation, shipping
brackets are installed (Refer to figure below).

NOTICE
Before turning ON the power, check to be sure that the rubber buffer are removed.
After removing the rubber pads, keep them at a safe place. The rubber pads will be required
again if the system is transported again.

For transportation purposes the robot is fitted in the range A and B with a rubber
buffer (see ).

Fig. 3-1: Damping material for transport

3 - 17
Installation

4 Installation
CAUTION!
Personal injury and damage to property
The following precautions must be taken.
 Check that the robot controller is complete and not damaged.
 Do not put into operation a robot controller that is damaged or incomplete.
 Check that all transport safety devices and transport screws have been removed.

4.1 Protection measures

DANGER!
Personal injury and material damage
The robot system must not be operated without protective devices. Starting up without
appropriate protective measures can lead to death of people, serious bodily harm or
material damage.
Implement the following protection measures
 Separating protection devices
 Non-contact protection devices
 Enclosures
 Marked areas
 Signs
 Emergency Stop button
 Display elements

NOTICE
Operator's responsibility
The operator of a robot or a robot system must ensure that all specifications and
requirements of the standards DIN EN ISO 10218-1 and DIN EN ISO 10218-2 are met.
In the first instance, the following must be observed:
 Preparing a risk assessment
 The installation of protective devices
 Regular training of the employees
 Regular inspection of all protective devices
 Checking for compliance with intended use

4 - 18
Installation

4.2 Ambient conditions and installation location

When installing a robot, it is necessary to satisfy the undermentioned environmental
conditions:
• Ambient temperature: From 0°C to +45°C.
• Air humidity: 20% to 80% relative humidity (non-condensing).
• Free of corrosive gases, liquids, or explosive gases. No water, oil or dust and free from
excessive electrical noise (plasma).
• Free from excessive vibration (Vibration acceleration: 4.9 m/s² [0.5 G] or less).
• Maximum unevenness of the support surface of the robot base: 0.5 mm.
• Altitude: 1000 m or less

NOTICE
When the operation is started after the robot has been out of operation and left in the low
temperature (almost 0°C) for a long period, the alarm may occur since the friction torque of
the drive unit is large. If the alarm occurs, perform the break-in for few minutes.

4 - 19
Installation

4.3 Installation example

NOTICE
 YASKAWA Europe recommends to use the robot only with a base plate.
 Please contact the manufacturer of the mounting material you use

1. At the first set out, anchor the base plate firmly onto the floor.
2. The robot base is tapped for 4 mounting holes. Fix the robot base with the screws M20
(strength class 12.9) Minimum length: 70 mm.
3. Next, fix the robot base to the base plate. Tighten the hexagon head bolts and anchor
bolts securely so that they will not work loose during operation (see figure „Mounting of
the robot on the base plate“).

Mounting the robot to the base plate

1 Screws
2 Spring
3 Washer
4 Robot base
5 Base plate
6 At least At least 25 mm

30
7 Anchor bolt (At least M20 or
larger)
8 2 Holes Ø 12 H7
9 8 Holes Ø 22
10 Adhesive anchor

400

230
±0.1

±0.1
230

195
320
385

280
455

±0.1
195

±0.1 ±0.1
195 195

±0.1
230

455
608

4 - 20
Installation

400

5 230

8
8 x M20

xM
30 12 x Ø26
0.2

16

180 x 45°
710
500

385
360

320
900
1000

360
500
710
900
1000

Fig. 4-1: Base plate

Thread desig- Strength Maximum tightening torque MA in Nm

nation category Sliding friction coefficient μ1
0.10 0.15 0.20
8.8 40 50 60
M10 10.9 59 73 87
12.9 69 84 100
8.8 110 135 160
M16 165 200 235
12.9 190 235 275
8.8 225 275 320
M20 10.9 325 395 470
12.9 375 465 550
8.8 390 480 570
M24 10.9 560 675 810
12.9 650 800 950
1. μ = 0.10: very good surface, lubricated; μ = 0.15: good surface, lubricated or dry; μ = 0.20: Surface, black or
phosphatized dry

4 - 21
Installation

Direction of move- Horizontal Vertical

ment
Force FH Moment MH Force FV Torque MV
Emergency stop 23544 N 24525 Nm 27468 N 45126 Nm
(Stop category 0)
Acceleration/Decelera- 5886 N 6161 Nm 5396 N 11282 Nm
tion
(Stop category 1)

Tab. 4-1: Forces and torques

MV

FV

MH

FH

Fig. 4-2: Forces and torques of the robot

4 - 22
Installation

Types of Mounting
The robot can be mounted in the following positions:

1 0° = standing (standard)
2 90°= hanging on the wall
3 180° = hanging from the ceiling
4 10° - 90° = mounted on an angle

1 2

Suspended mounting
Suspended mounting differs from assembly in a standing position in the following points.
• S-axis working range
• Fixing the robot base

NOTICE
For suspended mounting in any position, please contact the local YASKAWA branch office.

S-axis working range

For the wall-mounted type, the S-axis movable range is ±30° (the range is adjusted prior to
the shipment).
In case of tilt mounting the working area of the S axis will vary (see the illustration below).

Installation angle of the S-axis operating range

1 Robot installation angle 

2 S-axis operating range [°]
3 Degrees or less (No Limit)
T

Robot installation S-axis operating range

angle (deg.) T (rdeg)
0‫أ‬T‫أ‬30 r180 (Standard)
30 < T‫أ‬35 r60
35 < T‫أ‬45 r45
45 < T r30

4 - 23
Installation

NOTICE
For the wall-, tilt-, and ceiling-mounted type, the installation angle relative to the ground
must be input by using the programming pendant. For the input procedures, refer to
“YRC1000 INSTRUCTIONS chapter ARM Control (E1102000214XX01* and higher)“. Also,
the operating range of S-axis must be altered by referring to chapter “Alterable Operating
Range”.

Precaution against falling

In case of suspended mounting, take measures to prevent the robot from falling down.

NOTICE
If the setup is changed, please contact the local YASKAWA branch office.

Fastening the robot base

With suspended mounting, the robot must be fastened with 4 screws M20 (strength class
12.9) . Use a torque of 206 Nm in tightening the screws.

4 - 24
Installation

4.4 Notes on dust-proof/water-poof specifications

The MOTOMAN-GP50 (YR-1-06VX50-A00) conforms to:
• IP67 for the wrist part
• IP54 for the main part of the robot

NOTICE
< Definition of IP (protection class) >
• Definition of IP67
IP6□: Protection from the entry of dust
IP □7: Protection from immersion in water with being submerged for a specified duration
and pressure.
• Definition of IP54
IP5□: Protection from a certain amount of dust which is harmful enough to affect the
normal operation of equipments.
IP □4: Protection from sprays and splashing of water in all directions
However, the following precautions must be observed:
• Do not use the following liquids, because the rubber parts of the robot (gasket, oil seal,
O-ring, etc.) may be deteriorated or corroded:
– Organic solvent
– Chlorine-based cutting fluid
– Amine-based cleaning fluid
– Corrosive substances such as acids, alkalis or liquids/solutions causing rust
– Other liquids/solutions to which nitrile-butadiene rubber (NBR) is not resistant
• After removing a gasket for parts replacement or maintenance/inspection, make sure to
replace the gasket with a new one.
• Do not use cutting fluid or cleaning fluid which contains unknown chemical substances.

4 - 25
Wiring

5 Wiring
DANGER!
Danger to life due to electric shock, risk of fire due to short circuit.
Wiring must be performed by authorized or certified personnel.
Follow the instructions given below before wiring.
 Make sure that the earthing resistance does not exceed 0.1 Ω.
 Turn OFF the main power supply.
 Put up the warning sign prescribed, e.g. "Do not turn the power on!".
 Install a switch-on guard as prescribed.

5.1 Grounding
Follow the applicable electrical installation standards and wiring regulations for earthing.
The cable cross-section must be 6 mm² or more.
With regard to the direct connection of the earthing cable, see figure “Earthing connection”

NOTICE
Note on the earthing connection
Never use the earthing cable together with an earthing cable of, for example:
 A different electrical consumer
 A different motor-driven consumer
 Welding devices, etc.

If the earthing cable is laid in a metal duct, metal conduit or some other metal system, this
must be earthed in accordance with the applicable electrical installation standards.

Earthing connection

1 M8 screw for earthing is supplied with the robot (at least 6 mm²
protective earth conductor). 1

5 - 26
Wiring

5.2 Cable connections

Fig. 5-1: Connecting the robot system

One cable are delivered with the robot (refer to Fig. Robot cable).
• Encoder cable / power cable (1BC)
Before connecting the robot cable, check the marking on the robot cable and the
connections on the connector plate of the robot (see the following diagram "Robot cable").
Connect these cable to the robot base connectors and to the robot controller (see the
following chapter "Connection robot" and "Connection robot control").

Robot cable

1 Robot control side 114

2 Robot side

67
1BC
-X1

3 Encoder cable / power cable

(1BC) ;

81/2&.
81/2&.

72
/2&.

/2&.

5 - 27
Wiring

5.2.1 Connecting the robot

1. Check the cable.

2. Connect the cable 1BC with the connection 1BC to the connector plate of the robot.
Make sure that you hear each locking clip snap into place (clicking sound).

Distance between A
Outside diameter Minimum bending radius
and B
Fixed part C Moving part
25.1 mm less than 240 mm
less than 90 mm 260 mm

A B
1BC

Fig. 5-2: Overhead view of robot cable connection (robot side)

䠝䠞䠯䠊䚷䠡䠪䠟䠫䠠䠡䠮
䠱䠰䠰䠝䠤䠉䠞䠎䠌䠮䠦

䠝䠞䠯䠊䚷䠡䠪䠟䠫䠠䠡䠮
䠱䠰䠰䠝䠤䠉䠞䠎䠌䠮䠦
䠝䠞䠯䠊䚷䠡䠪䠟䠫䠠䠡䠮
䠱䠰䠰䠝䠤䠉䠞䠎䠌䠮䠦

1BC

AIR1

AIR2
S1

Fig. 5-3: Connector details (Robot side)

5 - 28
Wiring

5.2.2 Connection of the robot controller

1. Check the cable

2. Connect the cable X1 at connection X1 to the robot controller.
Make sure that you hear the locking clips snap into place (clicking sound).

81/2&.

/2&.
;

Fig. 5-4: Connection robot controller

5.2.3 Connecting the programming pendant

Connect the programming pendant cable to the connection (X81) (see diagram
"Connecting the programming pendant").

Fig. 5-5: Connection programming pendant

1 Alignment marks

5 - 29
Technical data

6 Technical data
Type: A00
Types of Mounting: Floor, ceiling, wall and angle mounting
Degree of freedom: 6
Payload: Wrist: 50 kg / U-arm 10 kg
1
Repeatability: ±0.07 mm
Power consumption: 4.5 kVA
Weight: 570 kg
Working area of main axes:
S-axis (turning) -180° - +180°
L-axis (lower arm)2 -90° - +135°
U-axis (upper arm)² -80° - +206°
Working area wrist axes:
R-axis (wrist roll)² -360° - +360°
B-axis (wrist yaw/pitch) -125° - +125°
T-axis (wrist twist) -360° - +360°
Protection class (IP):
Main axes 54
Wrist axes 67
Maximum speed:
S-axis 3.14 rad/s, 180°/s
L-axis 3.11 rad/s, 178°/s
U-axis 3.11 rad/s, 178°/s
R-axis 4.36 rad/s, 250°/s
B-axis 4.36 rad/s, 250°/s
T-axis 6.28 rad/s, 360°/s
Allowed moment (Nm):3
R-axis 216 Nm
B-axis 216 Nm
T-axis 147 Nm
Permissible moment of inertia (kgm²):
R-axis 28 kgm²
B-axis 28 kgm²
T-axis 11 kgm²
Sound pressure level (dB):4 72 dB or less
1. Tested according to ISO 9283

2. The range of motion of L, U and R axes is limited depending on their position.

3. See the following diagram "Moment of arm rating in section 7" for further information on the permissible moment
of inertia.

4. Sound pressure level measured according to ISO 11201 (EN31201). It is measured at maximum load and
speed of the robot. The measurement is performed at height of 1.2 m and 1.5 m above the floor and at distance
of 400 mm to the working area.

6 - 30
Technical data

6.1 Parts and work axis label

Parts designation and working axes

1 Upper arm (U arm)

R+
2 Wrist flange B+
3 Lower arm (L arm) T+
4 Rotary head of the S-axis
5 Robot base
U+
U- R-
T-
B-

L- L+

S+

S-

6.2 Robot base dimension

Robot base dimensions

1 2 holes Ø 12 H7 400
2 8 Holes Ø 22
All dimensions in mm 230
±0.1

±0.1
230

195
320
385

280
455

±0.1
195

±0.1 ±0.1
195 195

±0.1
230

455
608

6 - 31
Technical data

6.3 Dimensions and defined working area

0q
72
R3

18

98
50
50

127
18
R
54

0q
3 R20
61
611.5 200

2456

145 1025 175 346 203

191

57
210

1369

q
80
20
6q q
870
1811

90
925 253
223.5

343
135

3578
q

0q
12 437
540

118
40

0 0

105 105 234 234

453
460

170q

1121

1771 1056 605 213 87 0 248 530 543 2061

3832

Fig. 6-1: Dimensions and defined work area

1 P point 2 Working area, defined with point P

All dimensions in mm

6 - 32
Technical data

Home position and operating range of each axis

1 S-axis
+180q 0q
2 L-axis
0q
3 U-axis -9

4 R-axis

+13
5q
5 B-axis 0q

6 T-axis

-180q

0q

0q

0q
-8
+20
6q

+360q
-360q

12
5q

q 0q
25 +36 q
-1 0
-36

6 - 33
Technical data

6.4 Adjustable working area

The work area of the s-axis may be changed depending on the type of application.
If any modification is necessary, please contact the local YASKAWA branch office.

Item Specifications
S-axis working range ± 180° (standard)
± 165°
± 150°
± 135°
± 120°
± 105°
± 90°
± 75°
± 60°
± 45°
± 30°
± 15°
± 0°

6.4.1 Instructions for Installing the Mechanical Limit

NOTICE
 Always use the specified components when installing the S-axis limit
 Switch OFF the supply voltage before you start mounting.

• Mount the mechanical limit of S axis so that as shown in the figure "Components of the
S axis limit".
• When inserting the pin in the limit, apply Loctite 242 on the screw-on surface of the pin.
• Fasten the dog on the S-head using 3 screws M20 x 40 (Strength category 12.9).
Tighten the screws with a tightening torque of 167 Nm.
• With a working area of ±180°, the stop must be mounted (as shown in the figure
"Components of the S axis limit").
• The stop can be mounted at 15-degree intervals. To avoid a mechanical interference
from stop duplication, install the mechanical stop as shown in the following table Fig. 6-
2: "Adjustable angle for the S-axis limit".

6 - 34
Technical data

6.4.2 Components for Changing the Working Area

If you change the working area of S-axis, the following components are required (see the
following figure).

Components of the S-axis limitation

1 Screw M20 x 40 180q

2 Collar 15q
15q 15q
15q
h g
3 M6 washers 15q i f 15
q
j e
Pin

15
15

q
k d

15q

15q
l c

15q

15q
b

15q
15q
m

15q
l

15q k c

q
15

15
q 15 j d 5q
q 1
i e
15q h g f 15q
15q 15q
180q

S-axis working range Stop position

±180° a
±165° b
±150° c
±135° d
±120° e
±105° f
±90° g
±75° h
±60° i
±45° j
±30° k
±15° l
±0° m

6 - 35
Technical data

6.4.3 Adjusting the S-Axis Pulse Limit

NOTICE
To change the movement range of the machine, set both the pulse limit and the angle of the
mechanical S-axis limit.

For altering the range of motion of S-Axis, refer to “YRC1000 GENERAL OPERATOR'S
MANUAL chapter ”Softlimit setting function (Document No.: E1102000220XX01 or higher)”.
With programming pendant, input the numeric value as shown in the following table to
modify the parameter.

Degrees  ±15° ±30° ±45° ±60° ±75° ±90°

Number - - ± 40242 ±- ± 80483 - ± 120725
of pulses

Degrees  ±120° ±135° ±150° ± 165 ± 180

Number - ± 160966 - ± 201208 Variable Variable
of pulses "Anzahl "Anzahl
der Im- der Im-
pulse pulse
165°" not 180°" not
defined. defined.

1
-180° -165° -150° -135° -120° -105° -90° -75° -60° -45° -30° -15° 0° -15° -30° -45° -60° -75° -90° -105° -120° -135° -150° -165° -180°
-180°
-165°
-150°
-135°
-120°
-105°
-90°
-75°
-60°
-45°
-30°
2 -15°
0°
15°
30°
45°
60°
75°
90°
105°
120°
135°
150°
165°
180°

Fig. 6-2: Adjustable angle for the S-axis limit

1 The angle in plus direction = adjustable angle

2 The angle in minus direction = non-adjustable angle

6 - 36
Technical data

6.5 Stopping Angle and Time at the Emergency Stop

The definition of the coastdown times is important for determining the safety distance for
protective devices. The overrun time is the time that elapses from the point of time when
the stop signal is triggered until the robot comes to a complete stop. The overrun distance
is the angle that the robot travels from the point of time when the stop signal is triggered
until the robot comes to a complete stop.
The following diagrams show only the values for the S, L, and U axes since these axes have
the largest deflection. For a safety stop with stop category 0, the mean values determined
through testing and simulation are specified.
The actual overrun distances and overrun times may differ due to internal and external
influence on the braking torque. According to the mode, robot application, and number of
triggered safety stops with stop category 0, a different brake wear may occur. We
recommend that the coastdown path be checked once a year.

100%

66%
33%

Fig. 6-3: Main axes at 100%, 66%, and 33% deflection

In the S, L, and U axes are shown at 33%, 66%, and 100% deflection according to DIN EN
ISO 10218-1.
In these three positions, the coastdown paths and coastdown times were determined during
a safety stop with stop category 0 and stop category 1. In the following diagrams, they are
specified at payloads of 33%, 66%, and 100%.
The pertinent legend can be found in the following table:

Definitions Description
Load 100% pink
Load 66% green
Load 33% gray
Load 100% blue
Overrun distance degrees° [deg]
Overrun time second [sec]
Robot speed degrees°/second [deg/s]

6 - 37
Technical data

6.5.1 Stop category 0

Measurement condition by category 0

• Maximum load
• Maximum speed
• Posture of maximum inertia

Axis Overrun distance (degrees°) Overrun time (second)

S-axis 20.6 0.292
L-axis 8.7 0.153
U-axis 13.48 0.185

6 - 38
Technical data

6.5.2 Stop category 1

6.5.2.1 Stop position S-axis

• 100% deflection

80 0.8
70 0.7
60 0.6
50 0.5
40 0.4
30 0.3
20 0.2
10 0.1
0 0.0
0 50 100 150 200 0 50 100 150 200

• 66% deflection

80 0.8

70 0.7

60 0.6

50 0.5

40 0.4
30 0.3
20 0.2
10 0.1
0 0.0
0 50 100 150 200 0 50 100 150 200

• 33% deflection

80 0.8
70 0.7
60 0.6
50 0.5
40 0.4

30 0.3

20 0.2

10 0.1

0 0.0
0 50 100 150 200 0 50 100 150 200

6 - 39
Technical data

6.5.2.2 Stop position L-axis

• 100% deflection

80 0.8

70 0.7

60 0.6

50 0.5

40 0.4

30 0.3

20 0.2

10 0.1

0 0.0
0 50 100 150 200 0 50 100 150 200

• 66% deflection

80 0.8

70 0.7

60 0.6

50 0.5

40 0.4

30 0.3

20 0.2

10 0.1

0 0.0
0 50 100 150 200 0 50 100 150 200

• 33% deflection

80 0.8

70 0.7

60 0.6

50 0.5

40 0.4

30 0.3

20 0.2

10 0.1

0 0.0
0 50 100 150 200 0 50 100 150 200

6 - 40
Technical data

6.5.2.3 Stop position U-axis

• 100% deflection

80 0.8
70 0.7
60 0.6
50 0.5
40 0.4
30 0.3
20 0.2
10 0.1
0 0.0
0 50 100 150 200 0 50 100 150 200

6 - 41
Allowable load for wrist axis and wrist flange

7 Allowable load for wrist axis and wrist flange

7.1 Wrist flange

The dimensions of the wrist flange are shown in the following figure "Wrist flange". To
ensure that the home position marks can be seen at all times, the tool may only be flange-
mounted with the inner diameter. Fitting depth of inside fittings must be 5 mm.

NOTICE
Before mounting a tool, remove anticorrosive coating on the flange. Thinner or light fuel oil
are the most suitable for this purpose.

1 Hole Ø 6H7 x 10 6

Ø 68
2 P.C.D Ø 80
3 6 threaded holes M8 x 14

42
4 Hole Ø 8H7 x 14

40
5 Ø 100h6
6 Ø 50H7
8
All dimension in mm

7.2 Maximum load of the S-axis

For peripheral devices of specific applications, additional mounting options are provided on
the robot.

7.3 Optimal robot performance

To achieve optimal robot performance, the maximum load of the S-axis must never exceed
the permissible bearing capacity of the robot.

7 - 42
Allowable load for wrist axis and wrist flange

7.4 Allowable Wrist Load

The allowable wrist loads amounts to a maximum of Wrist: 50 kg / U-arm 10 kg. Should
however force instead of load be exercised on the wrist axis, the power has to be at the
axes within the moments (see the following figure and table).
For further information or help, please contact your YASKAWA branch office.

Axis Allowable torque (Nm) Allowable moment of inertia (kgm²)

R-axis 216 Nm 28 kgm²
B-axis 216 Nm 28 kgm²
T-axis 147 Nm 11 kgm²

Tab. 7-1: Allowable torque and allowable moment of inertia

Keep the centroidal distance of the load/mass within the specifications; refer to the following
figure, "Hand loads."
When the volume of the load is relatively small, refer to the moment arm rating (LB, LT)
shown in figure “Moment Arm Rating”. Each value of the allowable inertia above is
calculated assuming that the moment load is at the maximum. Thus, in the case when only
the inertia load is applied, when the moment load is small while the inertia load is large or
when the load is not applied as mass but applied as force, etc.,contact your YASKAWA
representative in advance.
When a tool is installed, the tool information and the load information must be set. For the
setting, refer to chapter “Tool data setting” and chapter “ARM control” of YRC1000
INSTRUCTIONS (Document No.: E1102000214XX01* and higher).

7 - 43
Allowable load for wrist axis and wrist flange

Keep the centroidal distance of the load/mass within the specifications; refer to the fig.:
Moment of arm rating

Moment of arm rating

1 P point LT(mm)
300
2 T-axes rotation center line
3 B-axes rotation centre line 204
200
All dimensions in mm 5kg

145
7kg
127
100

100 200 300 400

216 346
 247 LB(mm)

1 P point LT [mm]
1200
2 R-, T-axes rotation centre
1049
line 1000
W=10
3 B-axes rotation centre line 800
742
All dimensions in mm 600
W=20
500
W=30
400
375 W=40
300
200
W=50

LB [mm]
440 550 733 1100 1673
200 400 600 800 1000 1200 1400 1600 1800
0 175

7 - 44
Allowable load for wrist axis and wrist flange

7.5 Maximum capacity load

NOTICE
Failure to observe this instruction may adversely affect the safety and/or
performance of the robot.
YASKAWA provides no guarantee against damages, malfunctions, failures, etc. caused by
using any means other than the tapped holes shown in the following figure. The tightening
bolts used for the mechanical parts of the manipulator must be used only to secure the
mechanical parts. Do not additionally secure or attach any other things by using these
tightening bolts.
 Do not make any additional holes or tapped holes on the robots body.

When a load is applied on the upper arm or the rotary head, the load setting must be
performed. For setting procedures, refer to INSTRUCTIONS manual chapter "ARM
Control” (Document-No.: E1102000214XX01* and higher).
The maximum permissible load for U-axis, including wrist, is 50 kg.

Installing peripheral equipment mounts

1 4 threaded holes 200

M8 x 16
2 From the center of
the U-axis 811.5
3 Install the peripher-
50

al equipment within
this range.
4 From the center of
the U-axis 98.5
5 From the center of
50 50
60 60

the U-axis 60
6 4 threaded holes
100
M12 x 18
All dimensions in mm 180 223.5
40

105 105

Section Notice
A Up to Variable "Lastmasse Handgelenksgewicht" not defined. for attach-
ing load mass including wrist load.
B Maximum 10 kg. 49 Nm max. for increased moment amount of upper arm

7 - 45
Allowable load for wrist axis and wrist flange

Section Notice
C Up to 30 kg. (only for floor- and ceiling-mounted types)

7 - 46
Internal cables and compressed air lines

8 Internal cables and compressed air lines

Internal cables (4 wires 1.25 mm², 2 wires 0.75 mm², 8 wires 0.20 mm²) and air hoses are
used in order to use peripheral devices (e.g. gripper). They are mounted on the upper arm
as shown in the following diagram "Connector for internal cables and compressed air lines".
The pins 1 to 16 are assigned as shown in the following figure. Wiring must be performed
by the user.
The following requirements must be met:
• The total current value for the internal wiring harness must be 40 A .
• The current-carrying capacity per single conductor (cross-section 0.20 mm²) must not
exceed 3 A or less .
• The air pressure for the air hose must not exceed 600 kPA (the inner diameter of the air
hose is Ø 6.5 mm (with air line A)).

8 - 47
Internal cables and compressed air lines

Connectors for internal user I/O wiring harness and air line

1 Connector for the internal user I/O wiring

harness. Position of the main key (upper
side)
2 Connector plug for the internal cable feed
through on the casing cover.
3 Air outlet port 1 (PT3/8)
4 Air outlet port 2 (PT3/8)
5 Cover for fieldbus (Tube internal Ø 12)
6 Air inlet 2 (PT3/8)
7 Air inlet 2 (PT3/8)
8 Connector plug for the internal cable
feedthrough on the base

Moly White
RE No.00
1BC Grease
IN

AIR1

AIR2

S1

8 - 48
Internal cables and compressed air lines

Detailed drawing of connector

● = used
P12
○ = not used P34
1 Pins used P56
2 Detailed drawing connector on casing P78 1 2 3 4
P910
3 Detailed drawing connector on base 5 6 7 8 9
P 11
12 10 11 12 13 14 15
P 13
14 16 17 18 19 20
P 15
16 21 22 23
P 17
18
P 19
20
P 21
22
23

P12
P34
P56
4 3 2 1
P78
P910
9 8 7 6 5
P 11
12
15 14 13 12 11 10
P 13
14
20 19 18 17 16
P 15
16 23 22 21
P 17
18
P 19
20
P 21
22
23

The internal connections of the robot are shown in the following diagrams "Connection
diagram A" and "Connection diagram B".
Mating connector for internal wiring harness (Option)
The mating connector for internal wiring harness is optional.For the mating connector for
internal wiring harness, two different types of the end bell are prepared depending on the
form: Straight type
Straight type
The appearance of the robot with the connector installed is shown in figure Mating
connector for internal user I/O wiring harness (straight type)”. When the connector with the
straight type of end bell is installed, the connector of the U-arm part sticks out to the back
of the robot. Thus, the operating range of the U-axis must be limited.

8 - 49
Internal cables and compressed air lines

When operating, be careful not to let the connector and/or the cable touch the robots body.

Mating connector for internal user I/O wiring harness (straight type)

1 U-arm part: Straight

2 Base part: Straight

8 - 50
 Multi-port Connector ( )
LA1 LA1 7 2Slot(T-PG) T-PG
LB1 LB1 S-AXIS OVERRUN L.S. Connected to A1 -1 S+(OUT) -1 S+(OUT) -4 S+(OUT)
-4 S-(OUT) -4 S-(OUT) P -5 S-(OUT) T
LB1 LA2 LA2 -9 S+(IN) -9 S+(IN) -2 S+(IN)
LB2 LB2 LB2 L-AXIS OVERRUN L.S. Connected to A2 -8 S-(IN) -8 S-(IN) P -7 S-(IN)
-3 +5V -3 +5V -6 +5V PG
LB2 LA3 LA3 0V 0V -3 0V
-6 -6
LB1 LB3 LB3 L-AND U-AXIS INTERFERENCE L.S. Connected to A3 -2 OBT -2 OBT -8 OBT
-5 BAT -5 BAT P -9 BAT
-7 FG -7 FG -1 FG
LC1 LC1 BAT( )
LD1 LD1 S-AXIS OVERRUN L.S. Connected to B1 0BT -2
LC2 LC2 K R BAT -1
LD1
LD2 LD2 LD2 L-AXIS OVERRUN L.S. Connected to B2 Signal in( ) 1Slot(B-PG) B-PG
LC3 LC3 -1 S+(OUT) -1 S+(OUT) -4 S+(OUT)
LD1 LD3 LD3 -4 S-(OUT) -4 S-(OUT) P -5 S-(OUT) B
L-AND U-AXIS INTERFERENCE L.S. Connected to B3 -9 S+(IN) -9 S+(IN) -2 S+(IN)
P -8 S-(IN) -8 S-(IN) P -7 S-(IN)
S-, L-, and U--axes with Limit Switch Specification -3 +5V -3 +5V -6 +5V PG
P -6 0V -6 0V -3 0V
-2 OBT -2 OBT -8 OBT
LA1 LA1 -5 BAT -5 BAT P -9 BAT
LB1 LB1 S-AXIS OVERRUN L.S. Connected to A1 -7 FG -7 FG -1 FG
LB1 LA2 LA2
LB2 LB2 L-AXIS OVERRUN L.S. Connected to A2
Multi-port Connector ( )
Internal cables and compressed air lines

LC1 LC1 Signal out( ) 2Slot(R-PG) R-PG

LD1 LD1 S-AXIS OVERRUN L.S. Connected to B1 -1 S+(OUT) -1 S+(OUT) -4 S+(OUT)
-4 S-(OUT) -4 S-(OUT) P -5 S-(OUT) R
LD1 LC2 LC2 -9 S+(IN) -9 S+(IN) -2 S+(IN)
LD2 LD2 LD2 L-AXIS OVERRUN L.S. Connected to B2 -8 S-(IN) -8 S-(IN) P -7 S-(IN)
-3 +5V -3 +5V -6 +5V PG
-6 0V -6 0V -3 0V
S- and L-axes with Limit Switch Specification -2 OBT -2 OBT -8 OBT
-5 BAT -5 BAT P -9 BAT
-7 FG -7 FG -1 FG
LA1 LA1
LB1 LB1 BAT( )
S-AXIS OVERRUN L.S. Connected to A1 0BT -2
LC1 LC1 K R BAT -1
LD1 LD1 S-AXIS OVERRUN L.S. Connected to B1 Signal in( ) 1Slot(U-PG) U-PG
-1 S+(OUT) -1 S+(OUT) -4 S+(OUT)
S-axis with Limit Switch Specification -4 S-(OUT) -4 S-(OUT) P -5 S-(OUT) U
-9 S+(IN) -9 S+(IN) -2 S+(IN)
P -8 S-(IN) -8 S-(IN) P -7 S-(IN)
-3 +5V -3 +5V -6 +5V PG
-6 0V -6 0V -3 0V
-2 OBT -2 OBT -8 OBT
-5 BAT -5 BAT P -9 BAT
-7 FG -7 FG -1 FG

Board for encoder power Multi-port Connector ( )

CN1 CN2 CN3 Signal out( ) 2Slot(L-PG) L-PG
- -1 -1 S+(OUT) -1 S+(OUT) -1 S+(OUT) -1 S+(OUT) -4 S+(OUT)
- -2 -4 S-(OUT) P -4 S-(OUT) -4 S-(OUT) -4 S-(OUT) P -5 S-(OUT) L
- -4 -9 S+(IN) -9 S+(IN) -9 S+(IN) -9 S+(IN) -2 S+(IN)
- -5 -8 S-(IN) -8 S-(IN) -8 S-(IN) -8 S-(IN) P -7 S-(IN)
S- -3 -3 -3 -3 +5V -3 +5V -6 +5V PG
+5V +5V
P S+ -6 -6 0V P -6 0V -6 0V -6 0V -3 0V
24V -8 -2 OBT -2 OBT -2 OBT -2 OBT -8 OBT
P 0V -9 -5 BAT -5 BAT -5 BAT -5 BAT P -9 BAT

DC/DC
FG -7 -7 FG -7 FG -7 FG -7 FG -1 FG
BAT( )

Fig. 8-1: Internal connection diagram (a)

0BT -2
K R BAT -1

Signal in( ) 1Slot(S-PG) S-PG

-1 S+(OUT) -1 S+(OUT) -4 S+(OUT)
The YRC1000 -4 S-(OUT) -4 S-(OUT) P -5 S-(OUT) S
-9 S+(IN) -9 S+(IN) -2 S+(IN)
P -8 S-(IN) -8 S-(IN) P -7 S-(IN)
-3 +5V -3 +5V -6 +5V PG
CN4-1 CN4-1 DATA- -6 0V -6 0V -3 0V
CN4-2 P CN4-2 DATA+ -2 OBT -2 OBT -8 OBT
CN4-3 CN4-3 +24V(SS1) -5 BAT -5 BAT P -9 BAT
CN4-4 CN4-4 +24V(OT1-1+) LA1 -7 FG -7 FG -1 FG
CN4-5 CN4-5 LB1 LB1 A1
CN4-6 CN4-6 +24V(OT1-2+) LC1
CN4-7 CN4-7 LD1 LD1 B1
CN4-8 CN4-8 +24V
CN4-9 CN4-9 0V LB1 LA2
CN4-10 CN4-10 DATA7- LB2
A2
CN4-11 DATA7+ LB2
P CN4-11
CN4-12 CN4-12 BC2(LAMP-) LB2 LA3
CN4-13 CN4-13 SS2 LD1 LC2 A3
CN4-14 CN4-14 +24V(LAMP+) LB1 LB3
LD2 LD2 B2
CN4-15 CN4-15 FG7
CN4-16 CN4-16 - LD2 LC3
CN4-17 CN4-17 +5V

8
LD1 LD3 B3
CN4-18 CN4-18 0V LAMP
SIG shield SIG shield -1 BC1
-2 BC2

- 51
8
- 52
CN1-1 CN1-1 MU1
CN1-2 CN1-2 MU1
CN1-3 CN1-3
CN1-4 CN1-4
CN1-5 CN1-5 MV1 S-PW
CN1-6 CN1-6 MV1 -A MU1
CN1-7 CN1-7 MW1 -B MV1 S
CN1-8 CN1-8 MW1 -C MW1
CN1-9 CN1-9 ME1 SM
CN1-10 CN1-10
CN1-11 CN1-11 ME1
CN1-12 CN1-12 ME1 -D BA1
R-PW -E BB1
-3 MU4
-4 MV4
-5 MW4
-6 ME4
CN2-1 CN2-1 MW4 -1 BA4
CN2-2 CN2-2 MU4 -2 BB4
CN2-3 CN2-3 MV2
CN2-4 CN2-4 MV2
CN2-5 CN2-5 ME2
CN2-6 CN2-6 ME2
CN2-7 CN2-7 MV4
CN2-8 CN2-8 ME4 L-PW
CN2-9 CN2-9 MW2 -A MU2
CN2-10 CN2-10 MW2 -B MV2 L
CN2-11 CN2-11 MU2 -C MW2
CN2-12 CN2-12 MU2 ME2 SM

CN3-1 CN3-1 -D BA2

CN3-2 CN3-2 BA1 -E BB2
CN3-3 CN3-3 BB1
Internal cables and compressed air lines

CN3-4 CN3-4 BA2

CN3-5 CN3-5 BA3
CN3-6 CN3-6
CN3-7 CN3-7
CN3-8 CN3-8
CN3-9 CN3-9
CN3-10 CN3-10 BA4
CN3-11 CN3-11 BB4
CN3-12 CN3-12 BA5
CN3-13 CN3-13 BA6 U-PW
CN3-14 CN3-14 BA7 -A MU3 U
CN3-15 CN3-15 BB7 -B MV3
CN3-16 CN3-16 -C MW3
CN3-17 CN3-17 ME3 SM
CN3-18 CN3-18 -D BA3
B-PW -E BB3
CN5-1 CN5-1 MV6 -3 MU5
CN5-2 CN5-2 MU6 -4 MV5
CN5-3 CN5-3 MW5 -5 MW5
CN5-4 CN5-4 ME5 -6 ME5 R-PW
CN5-5 CN5-5 -1 BA5 -3 MU4 R
CN5-6 CN5-6 -2 BB5 -2 MV4
CN5-7 CN5-7 MW6 -1 MW4
CN5-8 CN5-8 ME6 -PE ME4 SM
CN5-9 CN5-9 MU5 -4 BA4
CN5-10 CN5-10 MV5 T-PW -5 BB4
CN5-11 CN5-11 -3 MU6
CN5-12 CN5-12 -4 MV6
-5 MW6
-6 ME6 B-PW
-1 BA6 -3 MU5 B
CN6-1 CN6-1 MV7 -2 BB6 -2 MV5
CN6-2 CN6-2 ME7 -1 MW5
CN6-3 CN6-3 ME3 -PE ME5 SM
CN6-4 CN6-4 ME3 -4 BA5
CN6-5 CN6-5 MV3 -5 BB5
CN6-6 CN6-6 MV3
CN6-7 CN6-7 MU7
CN6-8 CN6-8 MW7
CN6-9 CN6-9 MW3 T-PW
CN6-10 CN6-10 MW3 -3 MU6 T
CN6-11 CN6-11 MU3 -2 MV6
CN6-12 CN6-12 MU3 -1 MW6
-PE ME6 SM
E E -4 BA6
-5 BB6

Fig. 8-2: Internal connection diagram (b)

E E E
Base E
PE
S1(24-28) No.8CN(24-28)

1 1 SP1
2 P 2 SP2
3 3 SP3
P 4
4 5 SP4
5 P 6 SP5
6 SP6
7
7 P 8 SP7
8 9 SP8
9 P 10 SP9
10 11 SP10
11 P 12 SP11
12 SP12
13
13 P 14 SP13
14 15 SP14
15 P 16 SP15
16 17 SP16
17 P 18 SP17
18 SP18
19
19 P 20 SP19
20 21 SP20
21 P 22 SP21
22 23 SP22
23 SP23
Maintenance and inspection

9 Maintenance and inspection

DANGER!
Danger to life due to electric shock
Maintenance and inspections must be performed by specified personnel.
The instructions given below must be followed before taking maintenance and inspection
measures:
 Turn OFF the main power supply.
 Put up the required warning sign, e.g "Do not turn the power on!".
 Install a switch-on guard as prescribed.

If you have any questions regarding disassembly or repair, please contact the local
YASKAWA branch office.

NOTICE
Home position data is lost
Before removing the connector of the encoder cable to perform maintenance or inspection,
 Connect the spare battery unit.

9 - 53
Maintenance and inspection

9.1 Inspection schedule

Proper inspections are essential not only to assure that the mechanism will be able to
function for a long period. But also to prevent malfunctions and assure safe operation.
Inspection are classified into several time levels as shown by the following table „Inspection
intervals“.
In the table of „Inspection intervals“, the inspections are divided according to three levels of
requirement:
• Works, carried out by trained staff.
• Work carried out by staff trained by YASKAWA.
• Works, carried out by YASKAWA staff.
Inspections are only carried out by trained staff.

NOTICE
 The inspection intervals depend on the SERVO power time (see point 1 in ).
 The table „Inspection intervals“ applies to normal cases.
 Deviations are to be determined by the TCS service department of YEU-R.

DATA EDIT DISPLAY UTILITY

DATA EDIT DISPLAY UTILITY

SYS MONITORING TIME
SYS MONITORING TIME

CONTROL POWER TIME (2017/07/06 10:00 )

2385:42'02
SERVO POWER TIME (2017/07/06 10:30 )
36000:00'00
PLAYBACK TIME (2017/05/22 11:12 )
CONTROL POWER TIME (2017/07/06 10:00 )
2210:00'20
MOVING TIME
1875:15'30
(2017/05/22 15:30 ) 2385:42'02
OPERATING TIME (2017/05/22 16:12 )
0:0'0 SERVO POWER TIME (2017/07/06 10:30 )
36000:00'00
PLAYBACK TIME (2017/05/22 11:12 )
Main Menu ShortCut 2210:00'20
MOVING TIME (2017/05/22 15:30 )
1875:15'30
OPERATING TIME (2017/05/22 16:12 )
0:0'0

Main Menu ShortCut

Fig. 9-1: SERVO power time

9 - 54
 Maintenance and inspection
1 Trained staff
2 YASKAWA trained staff
3 YASKAWA personnel

Item numbers1 Schedule (h) Method Operation To be per-

formed by:

Daily
1000
12000
24000
36000
1 2 3
1 Alignment marks  Visual inspection Check alignment mark correspondence and dam-   
age at the zero position.
2 Working area and robot  Visual inspection If the working area is dirty, it must be cleaned. Check   
the robot for damage and external cracks.
3 Baseplate mounting bolts  Visual inspection Tighten loose screws (replace if necessary).   
4 Covers, bolts for the connector  Using a correspond- Tighten loose screws (replace if necessary).   
base ing tool,
5 Connector for robot cable  Using a correspond- Check for loose connections.   
ing tool,
6 Protective tubing  Manually Clean the spatter and check for holes or tears.   
7 Wiring harness in the robot  Visual Check for damage and clean this part if it is dirty.  
(wires of the S-, L-, U-, R-, B-  Visual inspection Check the bushing between the connector on the
and T-axis) (Power supply with multimeter stand and the intermediate connectors by manually
board included) moving the wires. Check the protection spring2.
 Replace3 
8 Battery unit in robot  If a battery alarm appears or after the robot has  
been operated for 24,000 hours, the battery must be
replaced.
9 Motors for all axes  Visual inspection Check for grease leakage.   
10 All axes gear  Grease gun Check for malfunctions (replace if necessary). The  
B- and T-axes pinion grease4 has to be replaced every 12000 hours (see
following chapters 9.6.1 "Grease filling the main ax-
9
- 55

es" and 9.6.2 "Grease filling the wrist axes").

 Item numbers1
9 - 56

Maintenance and inspection

Schedule (h) Method Operation To be per-
formed by:

Daily
1000
12000
24000
36000
1 2 3
11 Overhaul  
1. The item numbers correspond to the following diagram "Inspection intervals"

2. When checking for conduction with multimeter, connect the battery to "BAT" and "OBT" of connectors on the motor side for each axis. Now remove the connectors of the encoders of the
respective motor. Failure to observe this sequence can lead to loss of home positions.

3. The internal wiring harness in the robot (for the S, L, U, R, B and T axes) must be replaced at the 24,000 hours inspection.

4. The grease and/or lubricants used can be found in the table "Inspection parts and grease used".

Tab. 9-1: Inspection intervals

Maintenance and inspection

Fig. 9-2: Inspection intervals

9 - 57
Maintenance and inspection

9.2 Note on battery unit

NOTICE
The absolute encoder data will be lost
Removing the battery unit, make sure you not to remove the plug from circuit board.

The battery units are installed as shown in picture "The location of the battery unit".
If battery alarm occuring in the robot controller, battery unit has to be changed in the
following form.

9.2.1 Battery pack replacement

Normal (The control power supply of the robot controller can be turned ON)

1 Multi-port connector (board)

1 3
2 Connector 2
3 Old battery unit
4 New battery unit

1. Turn the robot controller ON and the SERVO power OFF.

2. Remove the fastening bolts from the cover plate.
3. The old battery pack is fixed with the protective tube and the cable tie. Cut the cable tie
to remove the old battery pack from the protective tube.
4. Remove the old battery pack from the multi-port connector and mount the new battery
pack.
5. After placing the new battery pack into the protective tube, fix it with the cable tie T18L.
6. Tighten the cover mounting bolts by using the tightening torque shown in figure
“Location of the battery and multi-port connector” to reinstall the cover.

NOTICE
When reinstalling the cover, be careful not to get caught the cable.

Battery connection (the control power supply of the robot controller cannot be
turned ON)

1 Multi-port connector (board)

1 3
2 Connector 2
3 Old battery unit
4 New battery unit
IN
5 Line for battery replacement
4
6 Backup battery
5
6

1. Prepare the lead for battery replacement and the battery pack for backup (Apart from
the new battery pack for replacement, prepare the battery pack for backup).
2. Loosen the cover mounting bolts and remove the cover.

9 - 58
Maintenance and inspection

3. Remove the connector from the “IN” port of the multi-port connector. Connect the lead
for battery replacement to the “IN” port of the multi-port connector.
4. Connect the battery pack for backup to the lead for battery replacement.
5. The old battery pack is fixed with the protective tube and the cable tie. Cut the cable tie
to remove the old battery pack from the protective tube.

NOTICE
Before removing the old battery pack, make sure to connect the battery pack for backup to
prevent the encoder absolute data from disappearing.

6. Remove the old battery pack from the multi-port connector and mount the new battery
pack.
7. Remove the lead for battery replacement and the battery pack for backup from the
multi-port connector, connect the connector which has been removed in no.3 of this
procedure to the “IN” connector again.

NOTICE
If the battery pack for backup remains connected, an electric current flows from the new
battery to the backup battery and which may result in the voltage drop in the new battery.
Remove the battery pack for backup immediately after connecting the new battery.

8. After placing the new battery pack into the protective tube, fix it with the cable tie T18L.
9. Tighten the cover mounting bolts by using the tightening torque shown in figure
“Location of the battery and multi-port connector” to reinstall the cover.

NOTICE
When reinstalling the cover, be careful not to get caught the cable.

9 - 59
Maintenance and inspection

Fig. 9-3: Battery unit location

1 Battery unit for B- and T-axes 6 Battery unit for S- and L-axes
2 Battery unit for U- and R-axes 7 2 screws M4 x 8 (Tightening torque 2.8 Nm)
3 Cable tie 8 Cover for S- and L-axis
4 Protective tube 9 3 screws M4 x 8 (Tightening torque 2.8 Nm)
5 Multi-port connector (board) 10 Cover for U-, R- and T-axis

9 - 60
Maintenance and inspection

9.2.2 Multiple connection

The multi-port connector includes 4 terminals.

• 2 connections for the motor
• 2 connections for the cable harness

NOTICE
The absolute encoder data will be lost
Absolute encoder data are lost if you remove the plug between engine and multi-port
connector during battery replacement.
 Do not disconnect the connection between motor and the multi-port connector

Multi-port connector
1 Motor 1
2 Motor 2
S IN
L OUT
1 3
3 Wire harness “IN”
4 Wire harness “OUT”

2 4

Connection diagram of the multi-port

1 Motor
2 Battery pack 1
3 Wire harness “IN” and “OUT”
4 Multi-port connector

1
2

4 3

9 - 61
Maintenance and inspection

9.3 Home position check

There are alignment marks on each axis to check the home position (Refer to figure
“Alignment mark check” below). With those alignment marks, check for home position
deviation on regular basis.
When home position is disappeared or deviated, contact YASKAWA representative.

Alignment mark check

1 S-axis alignment mark

2 L-axis alignment mark
3 U-axis alignment mark
4 R-axis alignment mark
5 B-axis alignment mark
6 T-axis alignment mark

9 - 62
Maintenance and inspection

9.4 Seeped oil check

Check for seeped oil and/or oil spot periodically. Especially the parts indicated in figure
“Inspection parts for seeped oil check” must be inspected carefully. Wipe off seeped oil or
oil spot with a cloth before use.

Fig. 9-4: Inspection parts for seeped oil check

9 - 63
Maintenance and inspection

9.5 Axis motors

For the all axis motors, there are holes for grease-leakage detection. Remove the screws
from the holes to check for grease leaking from the motor. For these procedures of each
axis, refer to figure “Positions of grease-leakage detection hole".
When grease leakage is detected, contact YASKAWA representative.

Positions of grease-leakage detection hole

1 Grease-leakage detection hole

for L-axis (Hexagon socket
head plug PT1/8)
2 Grease-leakage detection hole
for S-axis (Hexagon socket
head plug PT1/8).
3 Grease-leakage detection hole
for R-axis
4 Grease-leakage detection hole
for B-axis
5 Grease-leakage detection hole
for T-axis
6 Grease leakage detection tube
for U-axis (Ø 6)
7 “ * ” part: Grease-leakage de-
tection hole for R-, B-, and T-
axes

For the “ * ”parts, the screw whose head faces to the ground must be removed to check the
hole.

9 - 64
Maintenance and inspection

9.6 Refill/Replace grease.

Make sure to follow the instructions. If the following instructions are not followed, it might
cause damage to motor or gear.

CAUTION!
Burns from heated grease
The grease may be under pressure and may spray out of the threaded hole when opening
the threaded hole.
 Wear safety goggles

NOTICE
 Make sure that the plug has been removed from the grease outlet. If the plug is not
removed, grease will enter the motor or the oil seal of the gear will be damaged. This
might cause damage to the motor or gear.
 Lubrication or grease replacement is only allowed at operating temperature.
 Lack the labels "IN and" OUT "is generally lubricated from the bottom up.
 Do not install a joint, hose, etc. to the grease outlet. If this instruction is not followed, the
motor will be damaged.
 Avoid air getting into the gear.
 Insert grease with a grease gun.
 If an automatic lubricating pump is used, the grease supply pressure must be 0.3 kPa.
 Set the grease injection rate to a value not higher than 7 g/s.
 The limit values may not be exceeded also if a conventional grease gun is used.
 In ceiling-mounted robots the grease outlet and the grease inlet are located the other
way around (related to the figures in the operating and maintenance instructions).
 Install a receptacle at the grease outlet.
 Exchanged grease must be disposed of in an environmentally sound manner.

Inspection points and grease used

Grease used Material no. Inspected parts

Molywhite RE No. 00 176891 All axes and pinions

The safety data sheets for the grease can be requested from YEU-R.

9 - 65
Maintenance and inspection

Designation Tightening torque (Nm)

M2 0.15
M4 1.4
M5 2.8
M6 8.0
PT1/8 4.9
PT3/8 16.5

Tab. 9-2: Tightening torque of sealing plug

1. Remove plug from grease exhaust port (OUT) and grease inlet (IN) port.
2. Mount the lubricating nipple to the grease inlet opening.
3. Press the grease into the grease inlet opening using a grease gun.
4. To squeeze out the excess fat, all taxes must be brought to operating temperature.
• In a operating JOB or a special moving JOBs (about 20 minutes at 100% speed).
5. Wipe away excess grease with a cloth.
6. Remove the lubricating nipple from the grease inlet opening and mount the plug again.
Before mounting the plug, apply to thread part.

Amount of grease
Axis types Refill grease Replace grease
S-axis gear - approx. 1650 g1
L-axis gear - approx. 750 g1
U-axis gear - approx. 370 g1
R-axis gear approx. 7 g -
B-axis gear approx. 7 g -
R-axis pinion approx. 5 g -
T-axis pinion approx. 2 g -
1. The grease exchange is complete when new grease appears from the exhaust port. (The new grease can be
distinguished from the old grease by color.)

9 - 66
Maintenance and inspection

9.6.1 Grease filling the main axes

Figure the axes

S-axis gear1

PT3/8

Moly White
RE No.00
Grease
OUT

Moly White
RE No.00
Grease
1BC IN

S1
AIR1

AIR2
PT1/4

L-axis gear1

PT3/8
PT3/8 Moly White
RE No.00
Grease
OUT

Moly White
Grease
RE No.00
IN

U-axis gear1

PT3/8
Moly White
Grease
RE No.00
OUT

Moly White
Grease
RE No.00
IN

PT1/8

1 Grease inlet opening

2 Grease outlet opening
1. In ceiling-mounted robots the grease outlet and the grease inlet are located the other way around

9 - 67
Maintenance and inspection

9.6.2 Grease filling the wrist axes

Figure the axes

R-axis gear1

Moly White
Grease
RE No.00
OUT

PT3/8

PT1/8
Moly White
Grease
RE No.00
IN

B-axis gear1

PT1/8 PT1/8
OUT

Moly White
Grease
RE No.00
IN

1 Grease inlet opening

2 Grease outlet opening
1. In ceiling-mounted robots the grease outlet and the grease inlet are located the other way around

9 - 68
Recommended spare parts list

10 Recommended spare parts list

It is recommended to keep in stock parts and components in the following table as spare
parts. Product performance cannot be guaranteed when using spare parts from any
company other than YASKAWA.

NOTICE
Please contact your YASKAWA branch office if you need spare or replacement parts.

Part List robot

Designation Type Material no.

Grease Molywhite RE No. 00 176891
Adhesive LOCTITE 243 -
Sealing bonds for flange LOCTITE 518 191068
Liquid gasket TB1206C 175522
Sealant tape TB4501 164019
Battery unit in robot HW1483880-A 186742
Battery unit in robot controller ER6BD_WK77P 3.6V 186743
Wrist unit HW1173110-A 194181
Cable harness in robot HW1173234-A 194180
Lead wire for battery replacement HW1471281-A 186744
Multi-port connector HW1384619-A 191114
Battery board HW1372944-A 194833
Sealant
S-axis:
Gear HW382898-A 173386
Pinion HW0313741-1 146392
Motor SGM7G-30APK-YR1* 194182
Lead wire for signal HW1372597-AD 194183
Shaft seal input-pinion Y507212.5 111737
Bearing 6310 144374
L-axis:
Gear HW9381465-B 112513
Pinion HW9482771-A 112595
Motor SGM7G-37APK-YR1* 194184
Lead wire for signal HW1372597-AE 194186
O-Ring gear G270 111687
Shaft seal input-pinion HW9482447-A 111686
Sealing plug EZ5002A0 193837

10 - 69
Recommended spare parts list

Part List robot

Designation Type Material no.
U-axis:
Gear HW0387753-A 144090
Pinion HW0313740-1 146393
Motor SGM7G-13APK-YR1* 192010
Lead wire for signal HW1372597-AF 194188
Shaft seal input-pinion Y426012.5 126684
O-Ring gear G195 173937
R-axis:
Gear HW0387754-A 144091
Motor SGM7G-09APK-YR1* 186828
Lead wire for signal HW1372597-AG 194190
Shaft seal AC1306-G00X6 167787
B-axis:
Gear HW0387737-B 144092
Motor SGM7G-09APK-YR1* 186828
Lead wire for signal HW1372597-AH 194190
Shaft seal SC39528-FKM 164972
Bearing (2 pcs. need) 6808LLU 112786
Out/Input conical gear drive set HW0312827-1/ 165792
HW0312828-1
Shim input gear 10045 (0.05 mm) HW0412683-1 174839
Shim input gear 10045 (0.10 mm) HW0412683-2 174840
Shim input gear 10045 (0.50 mm) HW0412683-5 174841
Shim input gear 10046 (0.05 mm) HW0412695-1 182629
Shim input gear 10046 (0.10 mm) HW0412695-2 182630

10 - 70
Recommended spare parts list

Part List robot

Designation Type Material no.

T-axis:
Gear HW0389043-A 144093
Motor SGM7G-09APK-YR1* 186828
Lead wire for signal HW1372597-AI 194191
Out/Input conical gear drive set HW0313630-1/ 176828
HW0313631-1
Shim input gear 10048 (0.05 mm) HW0412696-1 184485
Shim input gear 10047 (0.05 mm) HW9405885-1 121010
Shim input gear 10047 (0.10 mm) HW9405885-2 121596
Shim input gear 10047 (0.30 mm) HW9405885-3 122063
Shim input gear 10047 (0.50 mm) HW9405885-5 126977
Tapered roller bearing (4pcs. need) HW9480086-A 136327
Out/Input conical gear drive set HW9381667-A/ 139594
HW9381668-A
Shim input gear 10012 (0.05 mm) HW9405888-1 192245
Shim input gear 10012 (0.10 mm) HW9405888-2 192246
Shim input gear 10012 (0.30 mm) HW9405888-3 192247
Shim input gear 10013 (0.05 mm) HW0412694-1 174835
Shim input gear 10013 (0.10 mm) HW0412694-2 174837
Shim input gear 10013 (0.50 mm) HW0412694-5 174838
Bearing 6905 143489
Shaft seal SC15247-FKM 164970
Bearing wrist unit 6912DU 112666
Shaft seal AE3092E2 152580
O-Ring S34 136328

Part List robot controller

Designation Type Material

no.
Control power supply CSRA-CPS01KA 186782
CPU rack JZNC-ARK01-E 186783
CPU board JANCD-ACP01-E 186785
Robot I/F board (Standard 2 MB) JANCD-AIF01-1E 186786
Robot I/F board (Optional 4 MB) JANCD-AIF01-1E 186787
General I/O board - (PNP-Type) JANCD-AIO02-E 186789
Converter CSRA-CV05D01A 186790
Safety circuit board JANCD-ASF01-E 186791
Power supply contactor unit JZRCR-APU0□-1 186792
Inverter unit (With the SERVO control CSRA-SDA01H01A 186794
board: CSRA-SDCA01AA)
Programming pendant (8 m cable) JZRCR-APP01-1 183100

10 - 71
Recommended spare parts list

Part List robot controller

Designation Type Material

no.
Key Sheet/General AKS-000E 183101
Key Sheet/ARC AKS-001E 184842
Key Sheet/Handling AKS-002E 186795
DC24V fuse for I/O 02173.15P 3,15A, 250V 103985
Control power supply fuse (2 pieces) FNQ-10 10A, 500VAC 186796
Encoder power supply fuse HM10 1A, 250V 174069
Filter for heat exchanger HB20 186798
Filter kit for heat exchanger GRM80-30 186799
Exterior fan for heat exchanger 08038RA-24Q-GA-04 186801
Interior fan for heat exchanger 08038RA-24Q-EA-02 186802
Backside duct fan (4 pieces) 09225VE-24P-CA-02 186803
Control power supply unit fan CSRA-CPS01KA-FN 186804
Heat exchanger TCMSY-312DC

10 - 72
Parts lists

11 Parts lists

11.1 S-axis unit

1035 1013
1036
1014

1019

1010 1002
1011
1036

1029
1032
1009 1031
1030

1023
1020
1033
1024

1007 1021
1008 1022 1005
1003 1001
1016
1004 1018

1017
1012

1028
1026

1025

Fig. 11-1: S-axis unit

11 - 73
Parts lists

Parts list S-axis unit

No. DWG No. Name Pcs.

1001 HW1382898-A Gear 1
1002 SGM7G-30APK-YR1* Motor 1
1003 HW9404486-1 Shaft 1
1004 HW0400405-3 Stopper 1
1005 6310 Bearing 1
1007 M8 x 45 Screw 1
1008 2H-8 Washer 1
1009 HW0102237-4 S-head 1
1010 M12 x 45 Screw 16
1011 2H-12 Washer 16
1012 C-30-SG-22A Grommet 1
1013 M12X x 55 Screw 3
1014 2H-12 Washer 3
1016 STW-50 Retaining ring C-type 1
1017 M8 x 100 Screw 1
1018 2L-8 Washer 1
1019 PT3/8 Plug 1
1020 HW1405948-10-25 Parallel pin 1
1021 M12 x 55 Screw 12
1022 2H-12 Washer 12
1023 HW9405875-2 Collar 1
1024 M20 x 40 Screw 1
1025 HW0102236-1 Base 1
1026 KQ2L10-01AS Elbow 1
1028 NB-1075-0.43 Tube 1
1029 HW0314010-1 Motor base 1
1030 Y507212.5 Oil seal 1
1031 M6 x 20 Screw 2
1032 2L-6 Washer 2
1033 HW0313741-1 Pinion 1
1034 PT1/8 Plug 1
1035 M12 x 35 Screw 2
1036 2H-12 Washer 2

11 - 74
Parts lists

11.2 L-axis unit

2021
2022
2001
2027
2024
2023
2018

2027
2025

2019
2010 2025
2011 2027

2020
2012
2014
2013
2026

2015

2016

1009
2005

2004
2026
2003
2009
2008
2002
2007
2006

Fig. 11-2: L-axis unit

Parts list L-axis unit

No. DWG No. Name Pcs.

2001 SGM7G-37APK-YR1* Motor 1
2002 HW0102425-1 L-arm 1
2003 M12 x 55 Screw 16
2004 SW-2H-12 Washer 16
2005 HW9381465-B Gear 1
2006 M10 x 40 Screw 18
2007 2L-10 Washer 18
2008 M16 x 45 Screw 6
2009 2H-16 Washer 6

11 - 75
Parts lists

Parts list L-axis unit

No. DWG No. Name Pcs.

2010 HW9481343-A Shaft 1
2011 HW9482771-A Pinion 1
2012 HW9405902-1 Pipe 1
2013 M8 x 130 Screw 1
2014 2L-8 Washer 1
2015 M8 Washer 1
2016 G270 O-ring 1
2018 HW0314011-1 Motor base 1
2019 HW0312815-2 Shaft 1
2020 HW9482447-A Oil seal 1
2021 M12 x 65 Screw 4
2022 2H-12 Washer 4
2023 M6X30 Screw 2
2024 2L-6 Washer 2
2025 EZ5002A0 Cap 3
2026 PT3/8 Plug 2
2027 PT1/8 Plug 4
1009 HW0102237-4 S-head 1

11 - 76
Parts lists

11.3 U-axis drive

5017

5007

5027
5028
2002

5015
5014 5002
5004
5022 5003
5013
5012

5024 5026
5023 5025

5001

5019
5020 5005
5011 5016
5021 5006
5018
5008
5009
5010

Fig. 11-3: U-axis unit

Parts list U-axis unit

No. DWG No. Name Pcs.

5001 SGM7G-13APK-YR1* Motor 1
5002 HW0413914-1 Stopper 1

11 - 77
Parts lists

Parts list U-axis unit

No. DWG No. Name Pcs.

5003 M6 x 55 Screw 1
5004 2L-6 Washer 1
5005 M8 x 55 Screw 4
5006 2H-8 Washer 4
5007 HW0387753-A Gear 1
5008 HW0313740-1 Pinion 1
5009 HW8411125-3 Washer 1
5010 M6 x 115 Screw 1
5011 2L-6 Washer 1
5012 M12 x 30 Screw 12
5013 SW-2H-12 Washer 12
5014 M10 x 30 Screw 6
5015 2L-10 Washer 6
5016 HW9405257-1 Collar 1
5017 HW0102239-2 Casing 1
5018 Y426012.5 Oil seal 1
5019 M6 x 30 Screw 2
5020 2L-6 Washer 2
5021 HW0314012-1 Motor base 1
5022 G195 O-ring 1
5023 M10 x 40 Screw 16
5024 2L-10 Conical spring washer 16
5025 TSH6-01M Union 2
5026 UB-0640-0.1C Tube 2
5027 PT1/8 Plug 1
5028 PT3/8 Plug 1
2002 HW0102425-1 L-arm 1

11 - 78
Parts lists

11.4 R- B-, and T-axes drive

7018

7006

7020 7051
7016 7024 7045
7019

7025
7033 7001 7050
7044
7032
7031 7029

7028 7037 7013 7037

7007 7036
7012
7040 7048 7007
7041
7014
7003
7022
7023
7031
7032 7021
7046
7004
7047 7017
R-axis 7049 7008
7049
7031
7002 7032
7015
7009 7031
7049 7043 7032
7046
7042
7047 7046 7011
7047
B-axis 7049 7005
7049 7049
T-axis 7030
7002

7002 7049 7010

7035
7049 7034

7039
7049 7038

7026
7027

5017
(6017)

Fig. 11-4: RBT-axis unit

Parts list RBT-axis unit

No. DWG No. Name Pcs.

7001 HW0387754-A Gear 1
7002 SGM7G-09APK-YR1* Motor 3
7003 AC1306-G00X6 Oil seal 1

11 - 79
Parts lists

Parts list RBT-axis unit

No. DWG No. Name Pcs.

7004 TC20367 *FKM* Oil seal 1
7005 ISTW-17 Retaining ring 1
7006 HR32913J Bearing 1
7007 HR32005XJ Bearing 2
7008 HR32909J Bearing 1
7009 6003 Bearing 1
7010 HW0313628-1 Pinion 1
7011 HW0313627-1 Pinion 1
7012 HW0313629-1 Pinion 1
7013 HW0312826-1 Pinion 1
7014 HW0404196-8 Washer 1
7015 HW0313626-1 Pinion 1
7016 HW1408161-8-20 Pin 1
7017 HW0312834-1 Shaft 1
7018 HW0312832-1 Shaft 1
7019 HW0312831-1 Gear 1
7020 HW0312833-1 Shaft 1
7021 HW0312835-1 Shaft 1
7022 HW0312838-1 Flange 1
7023 HW1408161-6-15 Pin 1
7024 HW0200768-1 Shaft 1
7025 HW0312837-1 Housing 1
7026 HW9405662-1 Washer 1
7027 HW0312825-1 Gear 1
7028 HW0412720-1 B nut 1
7029 PT1/8 Plug 2
7030 PT3/8 Plug 1
7031 M5 x 16 Screw 18
7032 2L-5 Washer 18
7033 M4 x 6 Screw 1
7034 M6 x 25 Screw 1
7035 2L-6 Washer 1
7036 M8 x 25 Screw 18
7037 2L-8 Washer 19
7038 M6 x 20 Screw 1
7039 2L-6 Washer 1
7040 M6 x 25 Screw 6
7041 2L-6 Washer 6
7042 M6 x 50 Screw 1
7043 2L-6 Washer 1

11 - 80
Parts lists

Parts list RBT-axis unit

No. DWG No. Name Pcs.

7044 M6 x 35 Screw 16
7045 M8 x 30 Screw 8
7046 M8 x 25 Screw 10
7047 2H-8 Washer 10
7048 M8 x 20 Screw 1
7049 M4 x 6 Screw 9
7050 2L-6 Washer 16
7051 2L-8 Washer 8
5017 HW0102239-2 Casing 1

11 - 81
Parts lists

11.5 Wrist unit

10115 10058
10015 10093
10016 10094
10095
10096 10005 10114
10113 10115
10060
10040
10039
10039 10005
10013 10055 10014
10008 10039
10057 10033
10007 10022
10039
10053 10047
10091 10048
10090 10002
10082

10035 10104
10112 10103 10101
10111
10108 10035
10107 10034
10105 10116 10100
10056 10106 10102
10054

10117
10118 10001
10075 10010
10118
10097 10045 10117
10115
10009
10098 10041
10046 10017
10027 10093 10032 10031
10006 10094 10068 10012 10059
10038 10011 10110
10030 10092
10028 10029 10042
10044
10036 10043
10109

5017

10049

10003
10037
10099

10117
10118
10004

Fig. 11-5: Wrist unit

Parts list Wrist unit

No. DWG No. Name Pcs.

10001 HW0387737-B Gear 1
10002 HW0389043-A Gear 1
10003 HW9405880-1 Cover 1

11 - 82
Parts lists

Parts list Wrist unit

No. DWG No. Name Pcs.

10004 HW9405445-1 Nut 1
10005 HW9405881-1 Nut 2
10006 HW9405882-1 Nut 1
10007 S34 O-ring 1
10008 AE3092E2 Oil seal 1
10009 SC15247-FKM Oil seal 1
10010 SC39528-FKM Oil seal 1
10011 HW9405883-1 Collar 1
10012 HW9381667-A Pinion 1
10013 HW9381668-A Pinion 1
10014 HW9381669-A Pinion 1
10015 HW9381672-A Pinion 1
10016 WR60 Cir clip 1
10017 HW9405888-* Shim *
10022 HW9405885-* Shim *
10027 HW9482772-A Shaft 1
10028 HW9482765-A Shaft 1
10029 HW9381675-A Shaft 1
10030 RTW42 Retaining ring 1
10031 STW-25 Retaining ring C-type 1
10032 ISTW40 Retaining ring 1
10033 HW9405891-1 Housing 1
10034 PT3/8 Plug 2
10035 PT1/8 Plug 3
10036 HW9405892-1 Flange 1
10037 HW9481234-A Bearing 1
10038 6004LBD2PX24V1 Bearing 1
10039 HW9480086-A Bearing 4
10040 6912DU Bearing 1
10041 6808LLU Bearing 2
10042 6905 Bearing 1
10043 HW9405901-1 Washer 1
10044 BG3000-15X19 Ring 1
10045 HW0312827-1 Gear 1
10046 HW0312828-1 Gear 1
10047 HW0313630-1 Gear 1
10048 HW0313631-1 Gear 1
10049 HW0201297-A Shaft 1
10053 HW1300244-1 Flange 1
10054 HW0314705-1 Flange 1

11 - 83
Parts lists

Parts list Wrist unit

No. DWG No. Name Pcs.

10055 HW9302630-3 Housing 1
10056 HW0102233-1 U-arm 1
10057 HW0102491-1 Wrist 1
10058 HW0201226-1 Cover 1
10059 HW0414884-1 Cover 1
10060 HW0412694-* Shim *
10068 HW0412683-* Shim *
10075 HW0412695-* Shim *
10082 HW0412696-* Shim *
10090 M8 x 85 Screw 12
10091 2L-8 Washer 12
10092 M4 x 12 Screw 4
10093 M5 x 16 Screw 10
10094 2L-5 Washer 10
10095 M5 x 35 Screw 6
10096 2L-5 Washer 6
10097 M4 x 25 Screw 6
10098 2L-4 Washer 6
10099 M4 x 6 Screw 1
10100 M8 x 18 Screw 8
10101 2L-8 Washer 8
10102 M6 x 30 Screw 10
10103 Washer (provided with gear) Washer 1
10104 FC00SC (provided with gear) Fine U-nut 1
10105 M6 x 25 Screw 16
10106 2L-6 Washer 16
10107 M8 x 25 Screw 12
10108 2L-8 Washer 12
10109 M6 x 16 Screw 1
10110 2L-6 Washer 1
10111 M8 x 20 Screw 16
10112 2L-8 Washer 16
10113 M4 x 14 Screw 4
10114 2L-4 Sasher 4
10115 M5 x 7 Screw 6
10116 2L-6 Washer 10
10117 M4 x 12 Screw 13
10118 2L-4 Washer 13
5017 HW0102239-2 Casing 1

11 - 84
Parts lists

11 - 85
YASKAWA Headquarters YASKAWA ACADEMY
YASKAWA Europe GmbH and sales office Frankfurt
Robotics Division YASKAWA Europe GmbH
Yaskawastraße 1 Robotics Division
D-85391 Allershausen Hauptstraße 185
Tel. +49 (0) 8166 / 90 - 0 D-65760 Eschborn
Fax +49 (0) 8166 / 90-103 Tel. +49 (0) 6196 / 77725 - 0
Fax +49 (0) 6196 / 77725 - 39

YASKAWA GROUP DISTRIBUTORS

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+420-257-941-718
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+34-93-6303478
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