Motoman HP3JC Manipulator Manual

Motoman NXC100 Controller

HP3JC
Manipulator Manual

Part Number: 151562-1CD

Revision: 0

Motoman, Incorporated
805 Liberty Lane
West Carrollton, OH 45449
TEL: [phone]
FAX: [phone]
24-Hour Service Hotline: [phone]

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received with your Motoman robotic solution.

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The information contained within this document is the proprietary property of Motoman, Inc., and may not be

copied, reproduced or transmitted to other parties without the expressed written authorization of Motoman,

©2007 by MOTOMAN

Because we are constantly improving our products, we reserve the right to change specifications without

notice. MOTOMAN is a registered trademark of YASKAWA Electric Manufacturing.

Inc.

All Rights Reserved

HP3JC*

151562-1

Chapter 1

Introduction

1.1 About This Document

This manual provides information for the HP3JC manipulator and contains the following sections:

CHAPTER 1 - INTRODUCTION

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

CHAPTER 2 - SAFETY

This section provides information regarding the safe use and operation of Motoman products.

CHAPTER 3 - HP3JC* INSTRUCTIONS

Provides detailed information for the HP3JC manipulator.

1.2 Reference to Other Documentation

For additional information refer to the following:

• NXC100 Controller Manual (P/N 150975-1)

• Concurrent I/O Manual (P/N 149230-1)

• Operator’s Manual for your application

• 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 [phone]. Please have
the following information ready before you call:

• Robot Type (HP3JC)

• Application Type (welding, handling, etc.)

• Robot Serial Number (located on back side of robot arm)

• Robot Sales Order Number (located on back of controller)

Final page 1

User’s Manual
Chapter 1 Introduction

Notes

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151562-1

Chapter 2

Safety

2.1 Introduction

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.

We suggest that you obtain and review a copy of the ANSI/RIA National Safety Standard for
Industrial Robots and Robot Systems. This information can be obtained from the Robotic Industries
Association by requesting ANSI/RIA R15.06-1999. The address is as follows:

Robotic Industries Association

900 Victors Way

P.O. Box 3724

Ann Arbor, Michigan 48106

TEL: [phone]
FAX: [phone]

INTERNET: www.roboticsonline.com

Ultimately, the best safeguard is trained personnel. The user is responsible for providing personnel
who are adequately trained to operate, program, and maintain the robot cell. The robot must not be

operated by personnel who have not been trained!

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

Final page 3

User’s Manual
Chapter 2 Safety

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, Operation, and Maintenance Safety (Section 2.6)

2.2 Standard Conventions

This manual includes the following alerts – in descending order of severity – that are essential to the
safety of personnel and equipment. As you read this manual, pay close attention to these alerts to
insure safety when installing, operating, programming, and maintaining this equipment.

DANGER!

Information appearing in a DANGER 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 in a WARNING 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 in a CAUTION 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 provides additional information which is helpful in understanding the item being
explained.

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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 the operation of this equipment. All
personnel involved with the operation of the equipment must understand potential dangers of
operation. General safeguarding tips are as follows:

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

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

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

• The robot must be placed in Emergency Stop (E-STOP) mode whenever it is not in use.

• In accordance with ANSI/RIA R15.06-1999, section 4.2.5, Sources of Energy, use
lockout/tagout procedures during equipment maintenance. Refer also to Section 1910.147
(29CFR, Part 1910), Occupational Safety and Health Standards for General Industry
(OSHA).

2.4 Mechanical Safety Devices

The safe operation of the robot, positioner, auxiliary equipment, and system is ultimately the user's
responsibility. The conditions under which the equipment will be operated safely should be reviewed
by the user. The user must be aware of the various national codes, ANSI/RIA R15.06-1999 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 required depending on system
installation, operation, and/or location. The following safety equipment is provided as standard:

• Safety fences and barriers

• Light curtains and/or safety mats

• Door interlocks

• Emergency stop palm buttons located on operator station, robot controller, and
programming pendant

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

Final page 5

User’s Manual
Chapter 2 Safety

2.5 Installation Safety

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

• Be sure that only qualified personnel familiar with national codes, local codes, and
ANSI/RIA R15.06-1999 safety standards are permitted to install the equipment.

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

• Position all controllers outside the robot work envelope.

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

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

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

2.6 Programming, Operation, and Maintenance Safety

All operators, programmers, plant and tooling engineers, maintenance personnel, supervisors, and
anyone working near the robot must become familiar with the operation of this equipment. Improper
operation can result in personal injury and/or damage to the equipment. Only trained personnel
familiar with the operation, manuals, electrical design, and equipment interconnections of this robot
should be permitted to program, operate, and maintain the system. All personnel involved with the
operation of the equipment must understand potential dangers of operation.

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

• Be sure that all safeguards are in place. Check all safety equipment for proper operation.
Repair or replace any non-functioning safety equipment immediately.

• Do not enter the robot cell while it is in automatic operation. Be sure that only the person
holding the programming pendant enters the workcell.

• Check the E-STOP button on the programming pendant for proper operation before
programming. The robot must be placed in Emergency Stop (E-STOP) mode whenever it is
not in use.

• Back up all programs and jobs onto suitable media before program changes are made. To
avoid loss of information, programs, or jobs, a backup must always be made before any
service procedures are done and before any changes are made to options, accessories, or
equipment.

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• Any modifications to PART 1, System Section, of the robot controller concurrent I/O
program can cause severe personal injury or death, as well as damage to the robot! Do not
make any modifications to PART 1, System Section. Making any changes without the written
permission of Motoman will VOID YOUR WARRANTY!

• Some operations require standard passwords and some require special passwords. Special
passwords are for Motoman use only. YOUR WARRANTY WILL BE VOID if you use
these special passwords.

• The robot controller allows modifications of PART 2, User Section, of the concurrent I/O
program and modifications to controller parameters for maximum robot performance. Great
care must be taken when making these modifications. 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 the robot and other parts of the system. Double-check all
modifications under every mode of robot operation to ensure that you have not created
hazards or dangerous situations.

• Check and test any new or modified program at low speed for at least one full cycle.

• This equipment has multiple sources of electrical supply. Electrical interconnections are
made between the controller and other equipment. Disconnect and lockout/tagout all
electrical circuits before making any modifications or connections.

• Do not perform any maintenance procedures before reading and understanding the proper
procedures in the appropriate manual.

• Use proper replacement parts.

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

Final page 7

User’s Manual
Chapter 2 Safety

Notes

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YASKAWA

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MOTOMAN-HP3J

INSTRUCTIONS

TYPE: YR-HP3J-J00

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

MOTOMAN INSTRUCTIONS

MOTOMAN-HP3J INSTRUCTIONS
NXC100 INSTRUCTIONS
NX100 OPERATOR’S MANUAL
NXC100 MAINTENANCE MANUAL

The NX100 operator’s manual above corresponds to specific usage.
Be sure to use the appropriate manual.

YASKAWA

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MANDATORY

• This instruction manual is intended to explain operating instructions
and maintenance procedures primarily for the MOTOMAN-HP3J.

• General items related to safety are listed in the Section 1: Safety of the
NXC100 Instructions. To ensure correct and safe operation, carefully
read the NXC100 Instructions before reading this manual.

CAUTION

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

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

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

• If your copy of the manual is damaged or lost, contact a YASKAWA rep­resentative to order a new copy. The representatives are listed on the
back cover. Be sure to tell the representative the manual number listed
on the front cover.

• YASKAWA is not responsible for incidents arising from unauthorized
modification of its products. Unauthorized modification voids your prod­uct’s warranty.

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Notes for Safe Operation

Read this manual carefully before installation, operation, maintenance, or inspection of the
NXC100.
In this manual, the Notes for Safe Operation are classified as “WARNING”, “CAUTION”,
“MANDATORY”, or “PROHIBITED”.

WARNING

CAUTION

MANDATORY

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.

NOTE

To ensure safe and efficient operation at all times, be sure to follow all instructions, even if
not designated as “CAUTION” and “WARNING”.

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 damage to equipment. It may also be used to alert
against unsafe practices.

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

Must never be performed.

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WARNING

• Before operating the manipulator , c hec k tha t servo power is turned OFF
when the emergency stop buttons on the front face of the NXC100 and
on the right side of the programming pendant are pressed.
When the servo power is turned OFF, the SERVO ON LED on the program­ming pendant is turned OFF.

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

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.

TURN

Release of Emergency Stop

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WARNING

• Observe the following precautions when performing teaching opera­tions:

-Always follow the predetermined operating procedure.

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

Improper operation or unintended manipulator motion may result in injury.

• Confirm that no persons are present in the P-point maximum envelope of
the manipulator and that you are in a safe location before:

-Turing ON the robot system power.

-Moving the manipulator with the programming pendant.

-Running the system in the check mode.

-Performing automatic operations.

Injury may result if anyone enters the P-point maximum envelope of the manipulator dur­ing operation. Always press an emergency stop button immediately if there is a problem.
The emergency stop button is located on the right side of the programming pendant and
on the front face of the NXC100.

Mode selector switch

REMOTE

TEACH

PLAY

Programming pendant

Start button

Hold button

HOLDSTART

Emergency
stop button

DATE

SER NO.

44A220-011

TYPE

ERCR-NS00-A200
YASKAWA ELECTRIC CORPORATION

JAPAN

POWER SUPPLY
AC200/220V 50/60Hz 1 1 KVA

Approx mass.

16 Kg

NJ2520-2

ON (I)

F1

FU1

ON

SOURCE

FU2

OFF

OFF (O)

F2

Emergency stop button

3-2005

NJ2518-2

NJ2519-2

X52

SOURCE

X51

X31

BATTERY
FUSE

AC FUSE : F1,F2

15A / 250V
SLOW BLOW

I/O FUSE : F1,F2,F3,F4

3.15A / 250V
FAST BLOW

X81

NXC100

BAT

NXC100

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CAUTION

• Perform the following inspection procedures prior to conducting manip­ulator teaching. If problems are found, repair them immediately,
and be sure that all other necessary processing has been performed.

-Check for problems in movement of the manipulator and servo track.

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

• Read and understand the Explanation of Warning Labels before operat­ing the robot system.

• For safety, operate under the proper lighting.

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 programming pendant, and supply
cables.
In this manual, the equipment is designated as follows:

Equipment Manual Designation

NXC100 Controller NXC100

NXC100 Programming Pendant Programming Pendant

Cable between the Manipulator and the Controller Manipulator Cable

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Explanation of Warning Labels

The following warning labels are attached to the manipulator.
Always follow the warnings on the labels.
Also, an identification label with important information is placed on the body of the manipula­tor. Prior to operating the manipulator, confirm the contents.

Nameplate

Nameplate

MOTOMAN

TYPE
PAYLOAD

ORDER NO.

SERIAL NO.

YASKAWA ELECTRIC CORPORAION JAPAN

Warning label B

Warning label A

Warning label B

Warning Label A:

WARNING

kg

MASS
DATE

kg

Moving parts
may cause
injury

Warning Label B:

WARNING

Do not enter
robot
work area.

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1 Product Confirmation

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

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

2 Transporting

2.1 Transporting Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2

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

2.1.2 Using a Forklift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

3 Installation

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

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

3.2.1 When the Manipulator and Mounting Fixture are Installed on a

Baseplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

3.2.2 When the Manipulator is Mounted Directly on the Floor

without the Mounting Fixture. . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

3.3 Installation Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5

3.4 Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6

4 Wiring

4.1 Grounding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2

4.2 Manipulator Cable Connection . . . . . . . . . . . . . . . . . . . . . 4-3

4.2.1 Connection to the Manipulator . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

4.2.2 Connection to the NXC100. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

5 Basic Specifications

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

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

5.3 Manipulator Base Dimensions. . . . . . . . . . . . . . . . . . . . . .5-2

5.4 Dimensions and P-Point Maximum Envelope . . . . . . . 5-3

5.5 Special Interference Area . . . . . . . . . . . . . . . . . . . . . . . . . .5-4

5.6 B-Axis Operating Range. . . . . . . . . . . . . . . . . . . . . . . . . . . .5-5

5.7 Alterable Operating Range . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

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6 Allowable Load for Wrist Axis and Wrist Flange

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

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

7 System Application

7.1 Peripheral Equipment Mount. . . . . . . . . . . . . . . . . . . . . . . 7-1

7.2 Internal User I/O Wiring Harness and Air Lines . . . . 7-2

8 Electrical Equipment Specification

8.1 Internal Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

9 Maintenance and Inspection

9.1 Inspection Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1

9.2 Notes on Maintenance Procedures . . . . . . . . . . . . . . . . 9-5

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

9.2.2 Grease Replenishment for S-axis Speed Reducer . . . . . . . . . .9-7

 Grease Replenishment (Refer to " Fig. 22 S-axis

Speed Reducer Diagram ".) . . . . . . . . . . . . . . . . . . . . . . . . .9-7

9.2.3 Grease Replenishment for L-axis Speed Reducer . . . . . . . . . .9-8

 Grease Replenishment (Refer to " Fig. 23 L-axis

Speed Reducer Diagram ".) . . . . . . . . . . . . . . . . . . . . . . . . .9-8

9.2.4 Grease Replenishment for Speed Reducers of U- and R-axes.9-9

 Grease Replenishment (Refer to " Fig. 24 UR-Axis Speed

Reducer Diagram ".) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-9

9.2.5 Grease Replenishment for Speed Reducers of

B- and T-axes, and T-axis Gear . . . . . . . . . . . . . . . . . . . . . . .9-10

 Grease Replenishment (Refer to " Fig. 25 BT-Axis

Speed Reducer and T-axis Gear Diagram ".) . . . . . . . . . . .9-10

9.2.6 Notes for Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-11

 Battery Pack Connection. . . . . . . . . . . . . . . . . . . . . . . . . . .9-11

10 Recommended Spare Parts

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1.1 Contents Confirmation

1 Product Confirmation

CAUTION

• Confirm that the manipulator and the NXC100 have the same order num­ber. Special care must be taken when more than one manipulator is to
be installed.

If the numbers do not match, manipulators may not perform as expected and cause injury
or damage.

1.1 Contents Confirmation

Confirm the contents of the delivery when the product arrives.
Standard delivery includes the following four items (information for the content of optional
goods is given separately):

• Manipulator

• NXC100

• Programming pendant

• Manipulator cable (2 cables, between the manipulator and NXC100)

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1.2 Order Number Confirmation

1.2 Order Number Confirmation

Check that the order number of the manipulator corresponds to the NXC100. The order
number is located on a label as shown below.

Label (Enlarged View)

THE MANIPULATOR AND THE CONTROLLER
SHOULD HAVE SAME ORDER NUMBER.

ORDER NO.

WARNING

HEAVY OBJECT

Can cause muscle strain or
back injury. Use lifting aids

proper lifting technjques

when removing or replacing

WARNING

HAZAARDOUS VOLTAGE

208/110 VAC PRESENT

Contact may cause
electric shock or burn
Turn off and lock out
system power before servicing

(a) NXC100 (Top View)

Fig. 1 Location of Order Number Labels

Check that the manipulator
and the NXC100 have the
same order number.

(b) Manipulator (Top View)

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2 Transporting

CAUTION

• Sling 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 transportation.

The system consists of precision components, so failure to observe this caution may
adversely affect performance.

NOTE

• Be sure to mount two eyebolts and check that the eyebolts are securely fastened before
transporting the manipulator.

• The mass of the manipulator is approximately 27 kg. Use a wire rope strong enough to
withstand the mass.

• Attached eyebolts are designed to support the manipulator mass. Do not use them for
anything other than transporting the manipulator.

• Avoid exerting external force on the arm or motor unit when transporting the manipulator.
Use caution when using transporting equipment other than a crane or forklift to avoid
injury.

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2.1 Transporting Method

2.1 Transporting Method

2.1.1 Using a 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 shipping bolts and brackets before transportation, and lift
it in the posture as shown in " Fig. 2 Transporting Position ".

Eyebolt M8 (2 eyebolts)
(Delivered with the manipulator)

NOTE

Fig. 2 Transporting Position

Before turning ON the power, check to be sure that the eyebolts have been removed. The
eyebolts then must be stored for future use, in the event that the manipulator must be
moved by a crane again.

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2.1 Transporting Method

2.1.2 Using a Forklift

When using a forklift, the manipulator should be fixed on a pallet as shown in " Fig. 3 Using a
Forklift ". Insert claws under the pallet and lift it. The pallet must be strong enough to support
the manipulator. Transportation of the manipulator must be performed slowly in order to avoid
overturning or slippage.

Bolts M8 (4 bolts)

Pallet

Forklift claw entry

Fig. 3 Using a Forklift

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3 Installation

WARNING

• Install the safeguarding.

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

• Install the manipulator in a location where the manipulator’s tool or the
workpiece held by the manipulator will not reach the wall, safeguarding,
or NXC100 when the arm is fully extended.

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

• Do not start the manipulator or even turn ON the power before it is
firmly anchored.

The manipulator may overturn and cause injury or damage.

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

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

CAUTION

• Do not install or operate the manipulator that is damaged or lacks parts.

Failure to observe this caution may cause injury or damage.

• Before turning ON the power, check to be sure that the eyebolts
explained in "2.1.1 Using a Crane" are removed.

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

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3.1 Installation of Safeguarding

3.1 Installation of Safeguarding

To insure safety, be sure to install the safeguarding. It prevents unforeseen accidents with
personnel and damage to equipment. The following is quoted for your information and
guidance.

Responsibility for Safeguarding (ISO10218)

The user of a manipulator or robot system shall ensure that the safeguarding is provided and
used in accordance with Sections 6, 7, and 8 of this standard. The means and degree of
safeguarding, including any redundancies, shall correspond directly to the type and level of
hazard presented by the robot system consistent with the robot application. Safeguarding may
include but not be limited to safeguarding devices, barriers, interlock barriers, perimeter
guarding, awareness barriers, and awareness signals.

3.2 Mounting Procedures for Manipulator Base

The manipulator should be firmly mounted on a baseplate or foundation strong enough to
support the manipulator and withstand repulsion forces during acceleration and deceleration.
Refer to "Table. 1 Maximum Repulsion Forces of the Manipulator" and " Table. 2 Endurance
Torque in Operation " to construct a solid foundation with the appropriate thickness to
withstand maximum repulsion forces of the manipulator.
A manipulator base flatness must be kept at 0.5 mm or less: insufficient flatness of installation
surface may deform the manipulator shape and affect its functional abilities. Mount the
manipulator base as described in "3.2.1 When the Manipulator and Mounting Fixture are
Installed on a Baseplate" or "3.2.2 When the Manipulator is Mounted Directly on the Floor
without the Mounting Fixture".

Table. 1 Maximum Repulsion Forces of the Manipulator

Horizontal rotating maximum torque
(S-axis moving direction)

Vertical rotating maximum torque
(LU-axes moving direction)

294 Nm
(30 kgfm)

627 Nm
(64 kgfm)

Table. 2 Endurance Torque in Operation

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

Endurance torque in vertical operation
(LU-axes moving direction)

3-2

59 Nm
(6 kgfm)

194 Nm
(20 kgfm)

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3.2 Mounting Procedures for Manipulator Base

3.2.1 When the Manipulator and Mounting Fixture are

Installed on a Baseplate

For the first process, anchor the baseplate firmly to the ground. The baseplate should be rug­ged and durable to prevent shifting of the manipulator or the mounting fixture. It is recom­mended to prepare a baseplate in 25 mm in thickness, and anchor bolts in M8 or larger size.
Next, fix the manipulator base to the baseplate. The manipulator base is tapped for four
mounting holes; securely fix the manipulator base to the baseplate with four hexagon socket
head screws M8 (35 mm long is recommended) and tighten the screw to a tightening torque of

24.5 N
that they will not work loose during the operation.
See "Fig. 4 Manipulator Installation Example" for the method.

xm (2.5 kgxm). Tighten the hexagon socket head cap screws and anchor bolts firmly so

Hexagon socket head cap screw M8
(4 screws),
Tightening torque: 24.5 Nxm (2.5 kgfxm)

Manipulator base

155

50

145

78±0.1

85

+0.012

6 dia. (reference hole)

0

50±0.1

50

Baseplate

150

170

12

25 or
more

Anchor bolt (M8 or larger)
Baseplate

±0.1
88

Spring washer

Washer

Manipulator base

Baseplate

150
170

88

9 dia. mounting hole (4 places)

±0.1

Units: mm

Fig. 4 Manipulator Installation Example

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3.2 Mounting Procedures for Manipulator Base

3.2.2 When the Manipulator is Mounted Directly on the

Floor without the Mounting Fixture

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 Maximum Repulsion Forces of the Manipulator". When there is a concrete
thickness (floor) of 150 mm or more, the base of the manipulator can be fixed directly to the

floor with M8 anchor bolts. (The concrete breaking-stress should be 250 kg/cm
Before mounting the manipulator, check that the floor is level and that all cracks, etc. are
repaired. Any thickness less than 150 mm is insufficient for mounting, even if the floor is con­crete.

2

or more.)

Anchor bolts M8 (4 places)

Fig. 5 Direct Mounting on the Floor

Concrete floor

45 or more

150 or more

Units: mm

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3.3 Installation Method

3.3 Installation Method

The manipulator can be mounted in three different ways: floor-mounted (standard), wall­mounted, and ceiling-mounted types are available. For wall- and ceiling-mounted types, the
three points listed below are different from the floor-mounted types.

1. For the wall-mounted type, the S-axis specification is different from the ceiling- and
floor-mounted types. (The specification is changed before shipment.)

• The S-axis operating range for the wall-mounted type must be ±25

2. For the ceiling- and wall-mounted types, four hexagon socket head cap screws M8

2

(tensile strength: 1200 N/mm
to fix the manipulator base. Use a torque of 24.5 N

or more) (35 mm long is recommended) should be used

xm in tightening the screws.

°.

3. For the ceiling- and wall-mounted types, take appropriate measures to avoid the falling
of manipulator in case of emergency. See "Fig. 6 Precaution to Prevent the Manipula­tor from Falling" for details.

Support to prevent the manipulator from fall

NOTE

Manipulator base

Fig. 6 Precaution to Prevent the Manipulator from Falling

If the manipulator is to be wall mounted or ceiling mounted, inform Yaskawa of the matter
when placing an order. And also, make sure to contact Yaskawa representative (listed on
the back cover of this instruction manual) for a wall/ceiling installation on side.

Hexagon socket head cap screw M8 (4 places)
Tightening torque: 24.5 N
Spring washer
Washer

x

m (2.5 kgfxm)

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3.4 Location

3.4 Location

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

• Ambient temperature: 0° to +40°C (ambient temperature)

• Humidity: 20 to 80%RH (no moisture, at constant temperature)

• Free from dust, soot, or water

• Free from corrosive gases or liquids, or explosive gases

• Free from excessive impact or vibration (vibration acceleration: 4.9 m/s

• Free from large electrical noise (plasma)

• The flatness for installation is 0.5 mm or less.

2

[0.5 G] or less)

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4 Wiring

WARNING

• Ground resistance must be 100 Ω or less.

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

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

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

CAUTION

• Wiring must be performed by authorized or certified personnel.

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

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

Failure to observe this caution may result in preventing heat of the cable from being dis­charged.

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4.1 Grounding

4.1 Grounding

Follow the local regulations and electrical installation standards for grounding. The recom­mended grounding wire size is 5.5 mm
For grounding, connect the ground wire directly to the manipulator as shown in "Fig. 7
Grounding Method".

• Do not use this line in common with other ground lines or grounding electrodes for other

NOTE

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.

2

at minimum.

Bolt M6 (for grounding)
Delivered with the manipulator

Fig. 7 Grounding Method

Section A-A’

A

A’

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4.2 Manipulator Cable Connection

4.2 Manipulator Cable Connection

There are two manipulator cables; an encoder cable for detection (1BC) and power cable
(2BC). (See "Fig. 8 Manipulator Cables (1BC and 2BC)".) Connect these cables respectively
to the connectors at the manipulator connector base and the NXC100. Refer to "Fig. 9 (a)
Manipulator Cable Connectors (Manipulator Side)" and "Fig. 9 (b) Manipulator Cable
Connectors (NXC100 Side)".

4.2.1 Connection to the Manipulator

Before connecting the manipulator cables to the manipulator, verify the numbers on both the
cables and the connectors of manipulator connector base. Connect 2BC first, and then 1BC.
Insert the cables and lower each lever until it clicks.

4.2.2 Connection to the NXC100

Before connecting the manipulator cables to the NXC100, verify the numbers on both the
cables and the NXC100 connectors. Connect 2BC first to the connector X21 of NXC100, then
1BC to the connector X11 of NXC100. Insert the cables and lower each lever until it clicks.

The NXC100 Side

Encoder Cable 1BC

The NXC100 Side

The Manipulator Side

1BC

1BC

The Manipulator Side

2BC

2BC

Power Cable 2BC

Fig. 8 Manipulator Cables (1BC and 2BC)

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Fig. 9 (a) Manipulator Cable Connectors (Manipulator Side)

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2BC

1BC

3BC

Connector details

(Manipulator side)

X11

X72

X11

X21

X12

X64-X63

FAN3

X21

FAN2

X54

X53

X55

X71

X62

Connector details

PPESP PPESP

(NXC100 side)

Fig. 9 (b) Manipulator Cable Connectors (NXC100 Side)

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5 Basic Specifications

5.1 Basic Specifications

5.1 Basic Specifications

Table. 3 Basic Specifications

Item
Model

Configuration Vertically Articulated

Degree of Freedom 6

Payload 3 kg

*2

S-axis (turning)

L-axis (lower arm) +90°, -85°

U-axis (upper arm) +260°, -105°

R-axis (wrist roll) ±170°

B-axis (wrist pitch/yaw) ±120°

T-axis (wrist twist) ±360°

S-axis 3.49 rad/s, 200

L-axis 2.62 rad/s, 150
U-axis 3.32 rad/s, 190
R-axis 5.24 rad/s, 300
B-axis 5.24 rad/s, 300

T-axis 7.33 rad/s, 420
R-axis 5.39 Nm (0.55 kgfm)
B-axis 5.39 N

T-axis 2.94 N
R-axis

B-axis

T-axis

Temperature 0 to 40

Humidity 20 to 80% RH (at constant temperature)

Vibration Acceleration

Others

Range of

Motion

Maximum

Speed

Allowable
Moment

Allowable

Inertia

2

(GD

/4)

Ambient

Conditions

Repeatability

*3

*3

Approx. Mass 27 kg

Power Requirements 0.5 kVA

*1

MOTOMAN-HP3J

YR-HP3J-J00

±0.03 mm

±160°

°/s
°/s
°/s
°/s
°/s
°/s

m (0.55 kgfm)

m (0.3 kgfm)

2

m

0.1 kg

m

m

°C

2

2

2

(0.5G)

0.1 kg

0.03 kg

Less than 4.9 m/s

• Free from corrosive gas or liquid, or explosive
gas.

• Free from water, oil, or dust.

• Free from excessive electrical noise (plasma).

*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 allowable moment of inertia.

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5.2 Part Names and Working Axes

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Upper arm
(U-arm)

Lower arm
(L-arm)

U

U

R

R

L L

Rotary head
(S-head)

Base

S

S

Fig. 10 Part Names and Working Axes

5.3 Manipulator Base Dimensions

Wrist

B

T

T

B

155

50

145

A

View A

Fig. 11 Manipulator Base Dimensions

78±0.1

170

150

85

+0.012
0

6 dia. hole (reference hole)

50±0.1

50

150

9 dia. mounting hole (4 places)

±0.1

88

±0.1

88

170

Units: mm

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5.4 Dimensions and P-Point Maximum Envelope

5.4 Dimensions and P-Point Maximum Envelope

160

659

79

30

290 260

133

74
42

0

57

(*1)

531

372

389

260

337

276

229

R104

85

40

160

R188

R532

105

381

532

822

583

474

P-point maximum
envelope

193

47
18

0

(*2)

95

99.5

68

99.5

68

21

270

90

189

158

188

204

55

90

P-point

219

0

0

(*1) Shows the LU-axes working envelope within the range of S-axis motion: -40 to 40 .
(*2) Shows the LU-axes working envelope within the range of S-axis motion: -160 to 125 or 125 to 160 .

Refer to " 5.5 Special Interference Area" for details.

Fig. 12 (a) Dimensions and P-Point Maximum Envelope

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5.5 Special Interference Area

Shows the LU-axes working envelope within the range of S-axis motion: -160 to 125 or 125 to 160 .

35

35

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125

125

193

47

0

381

Shows the LU-axes working envelope within the range of S-axis motion: -40 to 40 .

158

204

U-axis does not move the S-axis is in area
of the slash part in above figure.

189

0

40

40

133

74

0

389

337

U-axis does not move the S-axis is in area
of the slash part in above figure.

0

Fig. 12 (b) Special Interference Area (LU interference)

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5.6 B-Axis Operating Range

5.6 B-Axis Operating Range

" Fig. 13 B-axis Operating Range " shows the operating range of the B-axis maintaining a
constant angle to the center of U-axis.

B-axis rotation center

U-axis rotation center

120°

120°

Wrist

U-axis rotation center

S-axis rotation center

Fig. 13 B-axis Operating Range

5.7 Alterable Operating Range

The operating range of S-axis can be altered according to the operating conditions as shown
in "Table. 4 S-Axis Operating Range". If alteration is necessary, contact your Yaskawa
representative in advance.

Table. 4 S-Axis Operating Range

Item Specifications

±160° (standard)
S-Axis
Operating
Range

±120°

±90°

±60°

±25°

NOTE

If readjustment (alteration of the S-axis operating range) is necessary, contact your
Yaskawa representative.

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6.1 Allowable Wrist Load

6 Allowable Load for Wrist Axis and Wrist

Flange

6.1 Allowable Wrist Load

The allowable wrist load is up to 3 kg. 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. 5 Allowable Moment and
Inertia ". Contact your Yaskawa representative for further information or assistance.

Table. 5 Allowable Moment and Inertia

Axis

R-axis
B-axis

T-axis

*1

( ): Gravitational unit

Moment N•m (kgf•m)

5.39 (0.55)

5.39 (0.55)

2.94 (0.3)

*1

Inertia kg•m

0.1

0.1

0.03

2

When the volume load is small, refer to the moment arm rating shown in " Fig. 14 Moment
Arm Rating ".
The allowable inertia is calculated when the moment is at the maximum. Contact your
Yaskawa representative when only load inertia, or load moment is small and inertia is large.
Also, when the load is combined as a force but a mass, contact your Yaskawa representative.

LT (mm)

200

100

3kg

100

1.5kg

200

RT-axis rotation center

L

(mm)

B

300

P-point

100

200

LT (mm)

Fig. 14 Moment Arm Rating

B-axis rotation center

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6.2 Wrist Flange

6.2 Wrist Flange

The wrist flange dimensions are shown in " Fig. 15 Wrist Flange ". In order to see the
alignment marks, it is recommended that the attachment be mounted inside the fitting. Fitting
depth of inside and outside fittings must be 5 mm or less.

Tapped hole M5 (4 places)

5 (fitting depth)

(Depth: 9) (Pitch: 0.8)

NOTE

45°

Units: mm

5 (fitting depth)

+0.013

0

20 dia.

0

-0.016

PCD31.5

40 dia.

5 dia. hole
(Depth: 7)

+0.012
0

Fig. 15 Wrist Flange

• Wash off anti-corrosive paint (yellow color) on the wrist flange surface with thinner or light
oil before mounting the tools.

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7.1 Peripheral Equipment Mount

7 System Application

7.1 Peripheral Equipment Mount

The peripheral equipment mount is on the upper arm for easier installation of the user’s
system application as shown in " Fig. 16 Installing Peripheral Equipment Mounts ". When
peripheral equipment is attached to the U-axis, the following conditions should be observed.

3718

Tapped hole M8 (3 places)
(Pitch: 1.25) (Depth: 16)

Fig. 16 Installing Peripheral Equipment Mounts

80

Units: mm

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7.2 Internal User I/O Wiring Harness and Air Lines

7.2 Internal User I/O Wiring Harness and Air Lines

Internal user I/O wiring harness (0.2 mm2 x 10 wires) and four air lines are used in the
manipulator for the drives of the peripheral devices mounted on the upper arm as shown in "
Fig. 17 Connectors for Internal User I/O Wiring Harness and Air Lines ".
The connector pins (1 to 10) are assigned as shown in " Fig. 17 Connectors for Internal User
I/O Wiring Harness and Air Lines ". Wiring must be performed by users, following the
conditions below:

• The allowable current for cables: 2.5 A or less for each cable

• The maximum pressure for the air line: 490 kPa (5 kgf/cm
(the inside diameter: 2.5 mm)

2

) or less

Connector for internal user I/O wiring harness:
HR10A-10R-12S (socket connector).
Prepare pin connector: HR10A-10P-12P*HIROSE*.

B

Details of the Connector Pin Numbers

Internal user I/O wiring harness: 0.2 mm2, 10 wires

Pins Used

1
2
3
4
5
6
7
8
9

10

9

8

7

10

12

6

5

4 Exhaust ports:
Tapped hole M5 with pipe plug

A

View A

4 Air inlets:
Tapped hole M5 with pipe plug

2BC

1BC

1

2

3

11

4

View B

Connector for internal user I/O wiring harness:
HR10A-10R-12P (pin connector).
Prepare socket connector: HR10A-10P-12S*HIROSE*.

3BC

Fig. 17 Connectors for Internal User I/O Wiring Harness and Air Lines

The same pin number (1-10) of two connectors is connected by the lead wire of single

0.2 mm

2

.

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8.1 Internal Connections

8 Electrical Equipment Specification

8.1 Internal Connections

High reliability connectors which can be easily put on and removed are used with each
connector part. For the numbers, types, and locations of connectors, see " Fig. 18 Location
Connectors " and " Table. 6 List of Connector Types ". Diagrams for internal connections
of the manipulator are shown in " Fig. 19 (a) Internal Connection Diagram " and " Fig. 19 (b)
Internal Connection Diagram ".

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

Connector base
Connector for internal user I/O wiring harness

Fig. 18 Location Connectors

Table. 6 List of Connector Types

Name Type of Connector

Connector for internal user I/O
wiring harness on connector base

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

HR10A-10R-12P

(HR10A-10P-12S: Optional)

HR10A-10R-12S

(HR10A-10P-12P: Optional)

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NXC100

1BC(10X4)

8.1 Internal Connections

1

0BT

0BAT11

BAT

2

BAT11

0BT

3

0BAT12
BAT12

4

BAT

0BT

5

0BAT21

BAT

6

BAT21

0BT

7

0BAT22

BAT

8

BAT22

1
2
3
4
5
6
7
8

1BC(10X4)

+24V

12
52

13
53

6

46

1

7

47

2

8
48

3

9

49

41

10

50

42

11

51

43

CN1-5
CN1-4

CN1-10
CN1-9

CN1-1
CN1-2

CN1-3

CN1-6
CN1-7

CN1-8

CN2-1
CN2-2

CN2-3

CN2-6
CN2-7

CN2-8

CN3-1
CN3-2

CN3-3

CN3-6
CN3-7

CN3-8

0V

+24V
0V

SPG+1
SPG-1

FG1

SPG+2
SPG-2

FG2

SPG+3
SPG-3

FG3

SPG+4
SPG-4

FG4

SPG+5
SPG-5

FG5

SPG+6
SPG-6

FG6

1
3

2
4

17

0BAT1

18

BAT1
0BAT2

19

BAT2

20
21
22
23
24
25

0BAT4

26

BAT4

27

0BAT5

28

BAT5
29
30
31
32
1

PG0V1
2

PG5V1
3

PG0V2
4

PG5V2
5

PG0V3
6

PG5V3
7

PG0V4
8

PG5V4
9

PG0V5
10

PG5V5
11

PG0V6
12

PG5V6
13
14
15
16

P
P
P

Note:
The figure below shows the internal connection diagram for MOTOMAN-HP3J.

No.1CN

No.2CN

P
P
P

P

P

1CN-1

2CN-1

DATA+1
DATA-1-2
BAT1

-3
OBT1

-4

+5V1

0V1

-2
FG1

-3

OBT
BAT

No.3CN

P

No.4CN

P

No.5CN

No.6CN

P

P
P
P

3CN-1

4CN-1

5CN-1

6CN-1

-2

-3

-4

-2

-3

-2

-3

-4

-2

-3

No.7CN

7CN-1

8CN-1

No.8CN

DATA+2
DATA-2
BAT2
OBT2
+5V2
0V2
FG2

OBT
BAT

DATA+3
DATA-3
BAT3
OBT3
+5V3
0V3
FG3

OBT
BAT

DATA+4

-2

DATA-4
BAT4

-3
OBT4

-4
+5V4
0V4

-2
FG4

-3
OBT

BAT

S-axis

PG

PG

L-axis

PG

U-axis

For lamp (Option)

PG R-axis

No.9CN

9CN-1

P
P
P

P

P

P

No.10CN

No.11CN

P

No.12CN

-2

-3

-4

10CN-1

-2

-3

11CN-1

-2 DATA-6

-3

-4

12CN-1

-2

-3

DATA+5
DATA-5
BAT5
OBT5
+5V5
0V5
FG5

OBT
BAT

DATA+6
BAT6

OBT6
+5V6
0V6
FG6

OBT
BAT

B-axis

PG

T-axis

PG

CN4-1

CN4-6

CN4-3

+24V

LB1

BC2

E

37

77

32
33

34
35

36
76

E

Fig. 19 (a) Internal Connection Diagram

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E

Base

E

2BC(6X6)

3BC

3BC-1

-2

-3

-4

-5

-6

-7

-8

-9

-10

1
2
3
4
5
6
7
8
9
10

P

P

P

P

P

3BC

1
2
3
4
5
6
7
8
9
10

3BC-1

-2

-3

-4

-5

-6

-7

-8

-9

-10

For spare (X)

2BC(6X6)

C5

D5

E5
A4

B4

A1
A2

A3
B1

B2
B3

C1
C2
C3

D1
D2

D3
E1

E2
E3

A5
A6

B6
C4

D4
E4

C6

E6
D6

CN1-1
CN1-2

CN1-3
CN1-4

CN1-5

CN2-1
CN2-2

CN2-3
CN2-4

CN2-5
CN2-6

CN3-4
CN3-5
CN3-6

CN4-1
CN4-2

CN4-3
CN4-4

CN4-5
CN4-6

CN5-1
CN5-2

CN5-3
CN5-4

CN5-5
CN5-6

CN6-1
CN6-2

CN6-3
CN6-4

CN6-5
CN6-6

E

BA1
BA2
BB1
ME1
ME2

MU1
MV1
MW1
MU2
MV2
MW2

MU3
MV3
MW3

MU4
MV4
MW4
MU5
MV5
MW5

MU6
MV6
MW6
ME3
ME4
ME5

ME6
BA3
BB4
BA4
BA5
BA6

No.14CN

No.13CN

13CN-1

14CN-1

MU1
MV1

-2
MW1

-3
ME1

-4
BA1
BB1

-2

No.16CN

No.18CN

No.15CN

15CN-1

16CN-1

No.17CN

17CN-1

18CN-1

No.20CN

MU2
MV2

-2
MW2

-3
ME2

-4
BA2
BB2

-2

MU3
MV3

-2
MW3

-3
ME3

-4
BA3
BB3

-2

No.19CN

20CN-1

19CN-1

-2

-3

-4

-2

No.22CN

No.24CN

MU4
MV4
MW4
ME4
BA4
BB4

No.21CN

No.23CN

SM

YB

SM

YB

SM

YB

21CN-1

22CN-1

23CN-1

24CN-1

S-axis

L-axis

U-axis

R-axis

SM

YB

MU5
MV5

-2
MW5

-3
ME5

-4
BA5
BB5

-2

MU6
MV6

-2
MW6

-3
ME6

-4
BA6
BB6

-2

SM

YB

SM

YB

B-axis

T-axis

PE

Fig. 19 (b) Internal Connection Diagram

8-3

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9.1 Inspection Schedule

9 Maintenance and Inspection

WARNING

• Before maintenance or inspection, be sure to turn the main power sup­ply OFF, and put up a warning sign. (ex. DO NOT TURN THE POWER ON.)

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

CAUTION

• 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 or release the brake.

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

• The battery pack must be connected before removing detection connec­tor when maintenance and inspection.

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

9.1 Inspection Schedule

Proper inspections are essential not only to assure that the mechanism will be able to function
for a long period, but also to prevent malfunctions and assure safe operation. Inspection
intervals are classified into six levels. Conduct periodical inspections according to the
inspection schedule in " Table. 7 Inspection Items ".
In " Table. 7 Inspection Items ", the inspection items are categorized by three types of
operations: operations which can be performed by personnel authorized of 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 the inspection
work.

9-1

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9.1 Inspection Schedule

38/50

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NOTE

Items

Working area
and whole exte-

c

rior of manipula­tor

LU-axis joint

d

Manipulator
base

e

mounting bolts

Cover mounting

f

screws

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

Table. 7 Inspection Items

Schedule

*4

Daily

1000

H

Cycle

6000

H

Cycle

12000

H

Cycle

24000H36000

{

{

{

{

H

Method

Visual

Visual

Wrench

Phillips
screw-

driver,

wrench

Operation

Clean the working
area if dust or spatter
is present.
Check for damage
and exterior cracks.

Check for grease

*5

leakage.

Tighten loose bolts.
Replace if necessary.

Tighten loose bolts.
Replace if necessary.

Inspection Charge

Specified

Person

{{{

{{{

{{{

{{{

Licensee

Service

Company

Connector base

g

LURBT-axis

h

timing belts

Wire harness in

i

manipulator

Battery pack in

j

manipulator

S-axis speed

k

reducer

LU-axis speed

l

reducer

{

{

{

{

{

{

{

Manual

Manual

Visual,

multimeter

Multimeter

Grease

gun

Grease

gun

Check for loose con­nectors.

Check for belt
tension and wear.

Check for conduc­tion between the
main connector of
connector base and
intermediate connec­tor with manually
shaking the wire.
Check for wear of

protective spring.

Replace.

Replace the battery
pack when the bat­tery alarm occurs or
the manipulator
drove for 36000H.

Check for malfunc­tion. (Replace if nec­essary.) Supply

*3

grease
cycle). See Par.9.2.2.

Check for malfunc­tion. (Replace if nec­essary.) Supply

*3

grease
cycle). See Par.9.2.3
and 9.2.4.

*1

*2

(6000H

(6000H

{{{

{{

{{

{

{{

{{

{{

9-2

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9.1 Inspection Schedule

Table. 7 Inspection Items

Inspection Charge

Specified

Person

Items

R-axis speed

11

reducer

BT-axis speed

12

reducer and T­axis gear

Overhaul

13

Schedule

*4

Daily

1000

H

Cycle

6000

H

Cycle

12000

H

Cycle

24000H36000

{

{

Method

H

Grease

gun

Grease

gun

Operation

Check for malfunc­tion. (Replace if nec­essary.) Supply

*3

grease

(6000H

cycle). See Par.9.2.4.

Check for malfunc­tion. (Replace if nec­essary.) Supply

*3

(6000H

grease
cycle). See Par.9.2.5.

{{

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

on the motor side for each axis, and then remove connectors on detector side for each axis from the motor.
Otherwise, the home position may be lost. (Refer to " 9.2.6 Notes for Maintenance ".)

*2 Internal cables 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. 20 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.

Licensee

Service

Company

{{

{{

Table. 8 Inspection Parts and Grease Used

No. Grease Used Inspected Parts

Harmonic Grease SK-1A S-, L-, U-, R-, B- and T-axis speed

9

10 11

,

12

,

,

reducers,
T-axis gear

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

9-3

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9.1 Inspection Schedule

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11

6

12

6

12

10

6

2

6

7

10

2

9

5

2BC

1BC

3BC

3

8

Fig. 20 Inspection Parts and Inspection Numbers

9-4

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9.2 Notes on Maintenance Procedures

9.2 Notes on Maintenance Procedures

9.2.1 Battery Pack Replacement

The battery packs are installed in the two positions indicated in " Fig. 21 (a) Battery Pack
Location ".

• Battery Pack Type: HW0470360-B

If the battery alarm occurs in the NXC100, replace the battery pack in accordance with the
following procedure:

Connector base fixing screw

Connector base

2BC

1BC

3BC

Battery pack
tied with INSULOK-tie (T50R)

Fig. 21 (a) Battery Pack Location

See the step 5.

Connector

Battery pack before replacement

Circuit board

See the step 4.

New battery pack

Fig. 21 (b) Battery Pack Connection

9-5

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9.2 Notes on Maintenance Procedures

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1. Turn the NXC100 main power supply OFF.

2. Remove the connector base fixing screws and pull out the connector base.

3. Remove the INSULOK-tie that ties the battery pack.

4. Connect the new battery pack to an unconnected connector.

5. Remove the old battery pack.

HW0483547

NOTE

6. Tie the new battery pack with INSULOK-tie, and reinstall the connector base.

NOTE

Connect the new battery pack before removing the old one so that the encoder absolute
data do not disappear.

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

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9.2 Notes on Maintenance Procedures

9.2.2 Grease Replenishment for S-axis Speed Reducer

Si: Grease inlet
Hexagon socket head plug PT1/8

2BC

1BC

S-axis speed reducer

3BC

So: Exhaust port
Hexagon socket head plug PT1/8

Fig. 22 S-axis Speed Reducer Diagram



Grease Replenishment (Refer to " Fig. 22 S-axis Speed Reducer Diagram ".)

1. Remove the hexagon socket head plug PT1/8 on the So exhaust port.

NOTE

Injecting grease with the plug on increases inner pressure and may cause damage. Never
fail to remove the plug before the grease injection.

2. Remove the hexagon socket head plug PT1/8 on the Si grease inlet.

3. Install the grease zerk PT1/8 to the Si grease inlet. (The grease zerk PT1/8 is delivered
with the manipulator.)

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

Grease type: Harmonic Grease SK-1A

Amount of grease: 10 cc

NOTE

The So exhaust port is used for air flow. Do not inject excessive grease into the Si grease
inlet.

5. Remove the grease zerk on the Si grease inlet and reinstall the hexagon socket head
plug PT1/8. Tighten the plug to a tightening torque of 4.9 N·m (0.5 kgf·m). Apply Three
Bond 1206C on the thread part of the plug.

6. Reinstall the hexagon socket head plug PT1/8 on the So exhaust port. Apply Three
Bond 1206C on the thread part of the plug.

9-7

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9.2 Notes on Maintenance Procedures

9.2.3 Grease Replenishment for L-axis Speed Reducer

Lo: Exhaust port

Plug

Cover

L-axis speed reducer

Li: Grease inlet



Hexagon socket head cap screw M6×6

Fig. 23 L-axis Speed Reducer Diagram

Grease Replenishment (Refer to " Fig. 23 L-axis Speed Reducer Diagram ".)

1. Remove the plug on the Lo exhaust port.

NOTE

Injecting grease with the plug on increases inner pressure and may cause damage. Never
fail to remove the plug before the grease injection.

2. Remove the hexagon socket head cap screw M6×6 on the Li grease inlet.

3. Install the grease zerk A-MT6×1 to the Li grease inlet. (The grease zerk A-MT6×1 is
delivered with the manipulator.)

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

Grease type: Harmonic Grease SK-1A

Amount of grease: 15 cc

NOTE

The Lo exhaust port is used for air flow. Do not inject excessive grease into the Li grease
inlet.

5. Remove the grease zerk on the Li grease inlet and reinstall the hexagon socket head
cap screw M6×6. Tighten the screw to a tightening torque of 6 N·m (0.6 kgf·m). Apply
Three Bond 1206C on the thread part of the screw.

6. Reinstall the plug on the Lo exhaust port. Apply Three Bond 1206C on the thread part
of the plug.

9-8

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9.2 Notes on Maintenance Procedures

9.2.4 Grease Replenishment for Speed Reducers of U- and

R-axes

Ro: Exhaust port
Plug

Cover

Ri: Grease inlet
Hexagon socket head cap
screw M6×6

U-axis speed reducer

R-axis speed reducer

Li: Grease inlet
Hexagon socket head
cap screw M6×6

Uo: Exhaust port
Plug

Cover

Fig. 24 UR-Axis Speed Reducer Diagram

 Grease Replenishment (Refer to " Fig. 24 UR-Axis Speed Reducer

Diagram ".)

1. Uninstall the cover to remove the plug on the Uo/Ro exhaust port.

NOTE

If grease is injected with the plug on, the grease will go inside the motor and may damage
it. Never fail to remove the plug before the grease injection.

2. Remove the hexagon socket head cap screw M6×6 on the Ui/Ri grease inlet.

3. Install the grease zerk A-MT6×1 to the Ui/Ri grease inlet. (The grease zerk A-MT6×1 is
delivered with the manipulator.)

4. Inject the grease into the Ui/Ri grease inlet using a grease gun.

Grease type: Harmonic Grease SK-1A

Amount of grease: 10 cc (Ui)

10 cc (Ri)

NOTE

The Uo/Ro exhaust port is used for air flow. Do not inject excessive grease into the Ui/Ri
grease inlet.

5. Remove the grease zerk on the Ui/Ri grease inlet and reinstall the hexagon socket
head cap screw M6×6. Tighten the screw to a tightening torque of 6 N·m (0.6 kgf·m).
Apply Three Bond 1206C on the thread part of the screw.

6. Reinstall the plug on the Uo/Ro exhaust port. Apply Three Bond 1206C on the thread
part of the plug.

9-9

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9.2 Notes on Maintenance Procedures

9.2.5 Grease Replenishment for Speed Reducers of B- and

T-axes, and T-axis Gear

T-axis speed reducer

To: Exhaust port
Plug

Bo: Exhaust port
Plug

B-axis speed reducer

Cover

Fig. 25 BT-Axis Speed Reducer and T-axis Gear Diagram

Bi: Grease inlet
Hexagon socket ehad cap screw M6×6

Ti: Grease inlet
Hexagon socket head
cap screw M6×6

 Grease Replenishment (Refer to " Fig. 25 BT-Axis Speed Reducer

and T-axis Gear Diagram ".)

1. Uninstall the cover to remove the plug on the Bo/To exhaust port.

NOTE

Injecting grease with the plug on increases inner pressure and may cause damage. Never
fail to remove the plug before the grease injection.

2. Remove the hexagon socket head cap screw M6×6 on the Bi/Ti grease inlet.

3. Install the grease zerk A-MT6×1 to the Bi/Ti grease inlet. (The grease zerk A-MT6×1 is
delivered with the manipulator.)

4. Inject the grease into the Bi/Ti grease inlet using a grease gun.

Grease type: Harmonic Grease SK-1A

Amount of grease: 10 cc (Bi)

5 cc (Ti)

NOTE

The Bo/To exhaust port is used for air flow. Do not inject excessive grease into the Bi/Ti
grease inlet.

5. Remove the grease zerk on the Bi/Ti grease inlet and reinstall the hexagon socket
head cap screw M6×6. Tighten the screw to a tightening torque of 6 N·m (0.6 kgf·m).
Apply Three Bond 1206C on the thread part of the screw.

6. Reinstall the plug on the Bo/To exhaust port. Apply Three Bond 1206C on the thread
part of the plug.

9-10

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9.2 Notes on Maintenance Procedures

9.2.6 Notes for Maintenance

 Battery Pack Connection

The connectors (crimped contact-pin) for the battery backup are installed at the end point of
the motors (marked as BAT and OBT). Connect the battery pack according to the following
procedure.

1. Connect the battery packs (HW9470932-A) with the battery backup connectors located
at the end point of the cables for the encoder. (Under this condition, remove the
encoder connector and carry out the maintenance checks).

2. After the maintenance check, verify that all the connectors are connected and remove
the battery pack.

NOTE

Wire harness
in manipulator

Do not remove the battery pack in the connector base.

Encoder

Motor

Motor cable, etc.

Power connector

a

0BT

Connect battery to encoder

to save the data before

removing conector.

CAUTION

Encoder connector

BAT

Connection

b

b

0BT

a

BAT

Battery pack
(HW9470932-A)

CAUTION label

CAUTION label (Enlarged view)

CAUTION

Connect battery to encoder
to save the data before
removing conector.

a

0BT

b

BAT

Fig. 26 Encoder Connector

9-11

b

0BT

a

BAT

a: Crimped contact-pin (pin)
b: Crimped contact-pin (socket)

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10Recommended Spare Parts

It is recommended that the following parts and components be kept in stock as spare parts for
the MOTOMAN-HP3J. The spare parts list for the MOTOMAN-HP3J is shown below.
Check the serial number and contact your Yaskawa representative for preparing lead wires for
internal wiring, etc.
Product performance can not be guaranteed when using spare parts from any company other
than Yaskawa. The spare parts are ranked as follows:

• Rank A: Expendable and frequently replaced parts

• Rank B: Parts for which replacement may be necessary as a result of frequent operation

• Rank C: Drive unit

NOTE

To replace parts in Rank B or Rank C, be sure to contact your Yaskawa representative.

Table. 9 Spare Parts for the MOTOMAN-HP3J

Rank

Parts

No.

A 1 Grease

A 2 Battery Pack

A 3 Liquid Gasket Three Bond 1206C

B 4 L-axis Timing Belt 060S3M255

B 5 U-axis Timing Belt 060S3M318

Name Type Manufacturer Qty

Harmonic Grease
SK-1A

HW0470360-B Yaskawa Electric

HW9470932-A 1 1

Harmonic Drive
System Co., Ltd.

Corporation

Three Bond
Co.,Ltd.

Mitsuboshi Belt­ing Limited

Mitsuboshi Belt­ing Limited

Qty

per

Unit

2.5 kg -

11

--

11

11

Remarks

B 6 R-axis Timing Belt 060S3M207

B 7 B-axis Timing Belt 060S3M276

B 8 T-axis Timing Belt 060S3M312

B9

B10

S-axis
Speed Reducer

L-axis
Speed Reducer

HW0385336-A

HW0385337-A

Mitsuboshi Belt­ing Limited

Mitsuboshi Belt­ing Limited

Mitsuboshi Belt­ing Limited

Yaskawa Electric
Corporation

Yaskawa Electric
Corporation

10-1

11

11

11

11

11

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Table. 9 Spare Parts for the MOTOMAN-HP3J

Rank

Parts

No.

B11

B12

B13

B14

B15

C16

C17

Name Type Manufacturer Qty

U-axis
Speed Reducer

R-axis
Speed Reducer

B-axis
Speed Reducer

T-axis
Speed Reducer

AC Servomotor for
SLU-axes

AC Servomotor for
RBT-axes

Wire Harness in
Manipulator

HW0385338-A

HW0385323-A

HW0385324-A

HW0385325-A

HW0384674-A
SGMAH-A8A2A­YR1*

HW0384690-A
SGMAH-A3A2A­YR1*

HW0172731-A

Yaskawa Electric
Corporation

Yaskawa Electric
Corporation

Yaskawa Electric
Corporation

Yaskawa Electric
Corporation

Yaskawa Electric
Corporation

Yaskawa Electric
Corporation

Yaskawa Electric
Corporation

Qty
per

Unit

11

11

11

11

With brake and

13

13

11

lead terminal
treatment

With brake and
lead terminal
treatment

Remarks

10-2

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MOTOMAN-HP3J

50/50

INSTRUCTIONS

HEAD OFFICE
2-1 Kurosaki-Shiroishi, Yahatanishi-ku, Kitakyusyu-shi, 806-0004, Japan
Phone [phone] Fax [phone]

MOTOMAN INC. HEADQUARTERS
805 Liberty Lane West Carrollton, OH 45449, U.S.A.
Phone [phone] Fax [phone]

YASKAWA MOTOMAN CANADA LTD.
3530 Laird Road, Unit 3, Mississauga, Ontario, L5L 5Z7, Canada
Phone [phone] Fax [phone]

MOTOMAN ROBOTICS EUROPE AB
Franska Vagen 1039854, Kalmar, Sweden
Phone [phone] Fax [phone]

MOTOMAN ROBOTEC GmbH
Kammerfeld strasse 1, DE-85391 Allershausen, Germany
Phone [phone] Fax [phone]

YASKAWA ELECTRIC KOREA CORPORATION
1F Samyang Bldg. 89-1, Shinchun-dong, Donk-Ku, Daegu, Korea
Phone [phone] Fax [phone]

YASKAWA ELECTRIC (SINGAPORE) PTE. LTD.
151 Lorong Chuan, #04-01, New Tech Park, Singapore 556741, Singapore
Phone [phone] Fax [phone]

YASKAWA ELECTRIC (MALAYSIA) SDN. BHD.
No.71, Jalan Bandar Rawang 2, 48000 Rawang, Selangor D.E., Malaysia
Phone [phone] Fax [phone]

YASKAWA ELECTRIC TAIWAN CORPORATION
9F, 16 Nanking E. Rd., Sec. 3, Taipei, Taiwan
Phone [phone] Fax [phone]

SHOUGANG MOTOMAN ROBOT CO., LTD.
7,Yongchang-North Road, Beijing Economic & Technological Development Area, Beijing 100076, China
Phone [phone] Fax [phone]

YASKAWA ELECTRIC CORPORATION

YASKAWA

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

C

Printed in Japan July 2006 06-07

MANUAL NO.

HW0483547

RE-MTO-A235

9.2 Notes on Maintenance Procedures

9.2.6

Notes for Maintenance

Connect the battery with reference to the following figure before removing the encoder con­nector (with WARNING label).

Motor

Encoder

0BT
BAT

Motor cable, etc.

0BT

a
b

BAT

b

0BT
BAT

a

Battery

Power connector

Internal
cable

Connect battery to encoder

to save the data bofore

removing connector.

0BT
BAT

Encoder connector

WARNING label

a: Insertion-type pin terminal (female)
b: Insertion-type pin terminal (male)

a

b

b
a

Connection Diagram

WARNING Label Enlarged View

Connect battery to encoder
to save the data bofore
removing connector.

Fig. 26 Encoder Connector Diagram

9-11

9.2 Notes on Maintenance Procedures

RE-MTO-A235

9-12

RE-MTO-A235

10

Recommended Spare Parts

It is recommended that the following parts and components be kept in stock as spare parts for
the MOTOMAN-UPJ. The spare parts list for the MOTOMAN-UPJ is shown below. Product
performance cannot be guaranteed when using spare parts from any company other than
Yaskawa. The spare parts are ranked as follows:

• Rank A: Expendable and frequently replaced parts

• Rank B: Parts for which replacement may be necessary as a result of frequent operation

• Rank C: Drive unit

NOTE

For replacing parts in Rank B or Rank C, contact your Yaskawa representative.

Table. 8 Spare Parts for the MOTOMAN-UPJ

Rank

Parts

No.

A1

A2

B3

B4

B5

B6

B7

B8

Name Type Manufacturer Qty

Grease Harmonic Grease

SK-1A

Battery HW9470917-B Yaskawa Electric

HW9470917-A For RBT-axes

L-axis Timing Belt 060S3M249 Mitsuboshi Belt-

U-axis Timing Belt 060S3M318 Mitsuboshi Belt-

R-axis Timing Belt 060S3M213 Mitsuboshi Belt-

B-axis Timing Belt 060S3M273 Mitsuboshi Belt-

T-axis Timing Belt 060S3M300 Mitsuboshi Belt-

Gear HW9381785-A Yaskawa Electric

HW9381786-A

Harmonic Drive
System Co, Ltd.

Corporation 1 1

ing Limited

ing Limited

ing Limited

ing Limited

ing Limited

Corporation 1 1

Qty

per

Unit

2.5kg -

11

11

11

11

11

Remarks

For SLU-axes

Only for YR­UPJ3-B00

B9

B10

B11

S-axis
Speed Reducer

L-axis
Speed Reducer

U-axis
Speed Reducer

HW9381718-A Yaskawa Electric

Corporation

HW9381719-A Yaskawa Electric

Corporation

HW9381720-A Yaskawa Electric

Corporation

10-1

11

11

11

RE-MTO-A235

Table. 8 Spare Parts for the MOTOMAN-UPJ

Rank

Parts

No.

B12

B13

B14

B15

C16

C17

C18

Name Type Manufacturer Qty

R-axis
Speed Reducer

B-axis
Speed Reducer

T-axis
Speed Reducer

S-, L-, and U-axis
AC Servomotors

(R-,) B-, and T-axis
AC Servomotors

Internal Cable HW0170338-A Yaskawa Electric

B- and T-axis
Internal Cable

HW9381721-A Yaskawa Electric

Corporation

HW9381726-A Yaskawa Electric

Corporation

HW9381727-A Yaskawa Electric

Corporation

HW9381714-A Yaskawa Electric

Corporation 1 3

HW9381716-A Yaskawa Electric

Corporation 1 2

Corporation

HW0270114-A Yaskawa Electric

Corporation

Qty

per

Unit

11

11

11

11

11

Only for YR­UPJ3-B00

With brake, lead
terminal treat­ment completion

With brake, lead
terminal treat­ment completion

Only for YR­UPJ3-B00

Remarks

10-2

RE-MTO-A235

11.1 S-axis Driving Unit

11

Parts List

11.1

S-axis Driving Unit

1043

1044

1046

1042

1041

1027

1051

1052

1050

10551054

1053

1026

1049

2056

1004

1012

1011

1048

1038

1014

1037

1039

1015

1047

1033

1016

1045

5002

5011

1040

5001

5010

5010

5009

5011

5007

5002

5001

1032

1033

1030

1003

1001

1002

1009

1029

1006

1005

1031

1008

1007

1013

1017

11-1

11.1 S-axis Driving Unit

No. DWG No. Name Pcs

1001 M3 × 20 Socket screw 1

1002 2H-3 Spring washer 1

1003 UE10257 Oil seal 1

1004 HW0100064-1 S head 1

1005 M3 × 30 Socket screw 12

1006 2H-3 Spring washer 12

1007 M4 × 20 Socket screw 2

1008 2H-4 Spring washer 2

1009 F6-M5MS Plug 1

1011 M6 × 10 Socket screw 1

1012 2H-6 Spring washer 1

1013 HW0100061-1 Base 1

1014 HW9381714-A Motor 1

1015 GT-SA M4 × 10 Socket screw 2

1016 HW0400655-1 Cover 1

1017 M 4×10 Cross recessed

1026 HW0400654-1 Cover 1

1027 M 4×10 Cross recessed

1029 HW9381718-A Reduction gear 1

1030 GT-SA M4 × 16 Socket screw 8

1031 HW0400653-1 M base 1

1032 HW9406341-1 Support 1

1033 M4 × 8 APS bolt 4

1037 HW9406328-2 N base 1

1038 M4 × 8 APS bolt 4

1039 M 4×10 Cross recessed

1040 HW0400657-1 Support 1

1041 GT-SA M4 × 10 Socket screw 2

1042 CD-12 Saddle 1

1043 M5 × 6 APS bolt 2

1044 M5 Washer Washer 2

1045 TA1-S8 Clamp

1046 M4 × 8 Round head

1047 T50R Insulok’tie 1

1048 HW0400657-2 Support 1

1049 GT-SA M4 × 10 Socket screw 2

1050 CD-12 Saddle 1

1051 M5 × 6 APS bolt 2

1052 M5 Washer Washer 2

1053 TA1-S8 Clamp 1

1054 M4 × 8 Round head

1055 T50R Insulok’tie 1

2056 LP-M5 Plug 1

5001 CD-15 Saddle 2

5002 M5 × 8 Round head

5007 HW9302878-1 Connector base 1

5009 TA1-S8 Clamp 2

5010 M4 × 8 Round head

5011 T50R Insulok’tie 2

head screw

head screw

head screw

screw

screw

screw

screw

RE-MTO-A235

4

4

4

1

1

4

2

11-2

RE-MTO-A235

11.2 L-axis Driving Unit

11.2

L-axis Driving Unit

2015

2058

2023

2059

2013

2014

2017

2002

2057

2016

2058

2042

2042

2029

2023

2015

2001

2042

2044

2041

2040

2031

2043

2045

2039

2028

2033

2038

2032

2030

2036

2037

2035

2034

2018

2014

2017

2013

2016

2010

2009

2020

2057

2019

2008

2022

2021

2002

2024

2025

2026

11-3

2020

2027

11.2 L-axis Driving Unit

No. DWG No. Name Pcs

2001 GT-SA M5 × 10 Socket screw 2

2002 HW9481967-A Sheet 1

2008 A-MT6 × 1 Grease nipple 1

2009 HW9482887-A Pulley 1

2010 GT-SA M4 × 12 Socket screw 1

2013 HW9482888-A Pulley 2

2014 GT-SA M4 × 12 Socket screw 2

2015 HW0200090-1 Cover 2

2016 HW9406271-1 M base 2

2017 GT-SA M4 × 12 Socket screw 4

2018 06S3M249 Belt 1

2019 HW9406283-1 Housing 1

2020 6900ZZ Bearing 2

2021 GT-SA M4 × 12 Socket screw 4

2022 GT-SA M4 × 12 Socket screw 12

2023 M 4×10 Cross recessed

head screw

2024 HW9381719-A Reduction gear 1

2025 6916DDU Bearing 1

2026 GT-SA M4 × 12 Socket screw 12

2027 6913DDU Bearing 1

2028 HW9406255-1 Housing 1

2029 HW010060-1 L arm 1

2030 GT-SA M4 × 12 Socket screw 6

2031 GT-SA M4 × 10 Socket screw 2

2032 GT-SA M4 × 10 Socket screw 2

2033 HW0400658-1 Plate 1

2034 M5 Washer 2

2035 M5 × 6 APS bolt 2

2036 CD-22 Saddle 1

2037 M4 × 8 Round head

screw

2038 T50R Insulok’tie 1

2039 TA1-S8 Clamp 1

2040 GT-SA M4 × 10 Socket screw 2

2041 HW0400659-1 Plate 1

2042 M6 × 6Bolt3

2043 M4 Washer 2

2044 CD-16 Sddle 1

2045 M4 × 8 APS bolt 2

2057 HW9381714-A Motor 2

2058 GT-SA M4 × 10 Socket screw 4

2059 06S3M318 Belt 1

12

1

RE-MTO-A235

11-4

RE-MTO-A235

11.3 Wrist Unit

11.3

Wrist Unit

2060

3056

3058

3060

3059

3068

3061

3064

3065

3063

3062

3044

2049

2048

3045

3057

3055

3020

3041

3037

3012

3021

3039
3038

3067

3013

3011

3053

3052

3043

3036

3029

2055

3034

3070

3040

3032

3035

3069

3004

3031

3042

3028

3033

3014

3027

3030

3032

3028

3067

3050

3024

3001

3003

3051

3052

3026

3030

3018

3066

3053

3010

3061

3068

3048

3019

3031

3025

3063

3062

3008

3064

3009

3022

3065

3047

3015

3049

3007

3005

3046

3006

3017

3016

3010

3054

3054

11-5

11.3 Wrist Unit

RE-MTO-A235

No. DWG No. Name Pcs

2048 HW9201033-1 Cover 1
2049 M 4×10 Cross recessed

2055 HW9101029-1 U Arm 1
2060 LP-M5 Plug 1
3001 HW9406305-1 Connector base 1
3003 M 4×10 Cross recessed

3004 GT-SA M4 × 10 Socket screw 4
3005 GT-SA M4 × 12 Socket screw 1
3006 HW9406259-1 B cover 1
3007 GT-SA M4 × 10 Socket screw 4
3008 HW9406256-1 Housing 1
3009 GT-SA M4 × 10 Socket screw 6
3010 M 4×10 Cross recessed

3011 S60 O ring 1
3012 HW9381786-A Gear 1
3013 GT-SA M3 × 10 Socket screw 6
3014 SP-0090 Sim 1
3015 HW9380739-A Bearing 1
3016 HW9406262-1 B nut 1
3017 AB2551E0 Oil seal 1
3018 GT-SA M4 × 10 Socket screw 6
3019 2H-4 Spring washer 6
3020 M4 × 20 Socket screw 1
3021 2H-4 Spring washer 1
3022 HW9302842-1 Frange 1
3024 HW9406257-1 Housing 1
3025 HW9106260-1 Housing 1
3026 HW9406266-1 B nut 1
3027 HW9381727-A Reduction gear 1
3028 6803ZZ Bearing 2
3029 HW9302841-1 Housing 1
3030 6809DDU Bearing 2
3031 AD526808 Oil seal 2
3032 6803ZZ Bearing 2
3033 HW9381726-A Reduction gear 1
3034 M4 × 20 Socket screw 6
3035 2H-4 Spring washer 6
3036 A-MT6 Grease nipple 1
3037 HW9483147-A Pulley 1
3038 M4 × 20 Socket screw 1
3039 2H-4 Spring washer 1
3040 HW9406261-A Housing 1
3041 GT-SA M4 × 10 Socket screw 4
3042 HW9406260-1 Housing 1
3043 GT-SA M4 × 10 Socket screw 6
3044 060S3M273 Belt 1
3045 HW9481967-A Seat 1
3046 HW9483146-A Pulley 1
3047 HW8481521-A Bearing 1
3048 HW9381785-A Gear 1
3049 06S3M300 Belt 1
3050 LP-M5 Plug 1
3051 HW9302840-1 Wrist base 1
3052 HW0400664-A Block 2
3053 GT-SA M4 × 16 Socket screw 4
3054 HW9201039-1 Cover 2
3055 TA1-S8 Clamp 1

head screw

head screw

head screw

No. DWG No. Name Pcs

3056 M4 × 8 Round head

4

3

10

3057 T30R Insulok’tie 1
3058 HW9406288-1 Support 1
3059 M3 × 8Socket screw2
3060 2H-4 Spring washer 1
3061 HW9406286-1 M base 2
3062 M4 × 12 Socket screw 4
3063 GT-LH M4 Washer 4
3064 HW9482888-A Pulley 2
3065 GT-SA M3 × 12 Socket screw 2
3066 HW9481967-A Seat 1
3067 HW9381716-A Motor 2
30

68 GT-SA M4 × 10 Socket screw 4
3069 LP-M5 Plug 1
3058 HW9406288-1 Support 1
3059 M3 × 8Socket screw2
3070 M6×6H set screw1

screw

1

11-6

RE-MTO-A235

11.4 U(R)-axis Driving Unit

11.4

U(R)-axis Driving Unit

4015

4008

4010

4011

4020

4004

4019

4017

4016

4022

4005

4012

4013

4021

4027

4025

4009

4028

4026

4024

4023

4006

4002

4003

4018

4029

4030

4007

4001

2007

2010

2006

2005

2009

2011

2003

2008

2012

2004

2007

2053

2051

2047

2050

2052

2046

4014

2030

2028

2027

2053

11-7

11.4 U(R)-axis Driving Unit

No. DWG No. Name Pcs

2003 GT-SA M3 × 12 Socket screw 12

2004 6913DDU Bearing 1

2005 GT-SA M4 × 12 Socket screw 8

2006 GT-SA M4 × 12 Socket screw 4

2007 6900ZZ Bearing 2

2008 A-MT6 × 1 Grease nipple 1

2009 HW9482887-A Pulley 1

2010 GT-SA M4 × 12 Socket screw 1

2011 HW9406282-1 Housing 1

2012 HW9381720-A Reduction gear 1

2027 6913DDU Bearing 1

2028 HW9406255-1 Housing 1

2030 GT-SA M4 × 12 Socket screw 6

2046 HW9302859-A Support 1

2047 GT-SA M4 × 10 Socket screw 2

2050 M5 Washer 1

2051 M5 × 8 APS bolt 1

2052 CH-16 Saddle 1

2053 T50R Insulok’tie 2

RE-MTO-A235

Following parts are applied only for YR-UPJ3-B00.

4001 GT-SA M3 × 10 Socket screw 1

4002 GT-SA M3 × 1 0 Socket screw 8

4003 HW9406275-1 B cover 1

4004 GT-SA M3 × 12 Socket screw 12

4005 GT-SA M3 ×1 0 Socket screw 6

4006 HW9406276-1 B cover 1

4007 M6 × 6 H set screw 1

4008 HW9406278-1 Washer 1

4009 HW9406285-A Pipe 1

4010 HW9482967-1 Pulley 1

4011 HW9406279-1 Frange 1

4012 M4 × 16 Socket screw 6

4013 GT-LH-4 Spring washer 6

4014 HW9101025-1 Casing 1

4015 GT-SA M3 ×1 0 Socket screw 3

4016 GT-SA M3 × 12 Socket screw 2

4017 6806LLU Bearing 1

4018 HW9482970-A Bearing 1

4019 HW9381721-A RV reduction

4020 6808LLU Bearing 1

4021 06S3M213 Belt 1

4022 GT-SA M3 × 10 Socket screw 1

4023 ST-SA M3 × 12 Socket screw 1

4024 HW9483148-A Pulley 1

4025 GT-SA M3 × 10 Socket screw 2

4026 HW9481716-A Motor 1

4027 HW9481967-B Seat 1

4028 HW9481967-A Seat 1

4029 HW9101031-1 U arm 1

4030 LP-M5 Plug 1

gear

1

11-8

MOTOMAN-UPJ

INSTRUCTIONS

HEAD OFFICE
2-1 Kurosaki-Shiroishi, Yahatanishi-ku, Kitakyusyu-shi, 806-0004, Japan
Phone [phone] Fax [phone]

MOTOMAN INC. HEADQUARTERS
805 Liberty Lane West Carrollton, OH 45449, U.S.A.
Phone [phone] Fax [phone]

YASKAWA MOTOMAN CANADA LTD.
3530 Laird Road, Unit 3, Mississauga, Ontario, L5L 5Z7, Canada
Phone [phone] Fax [phone]

MOTOMAN ROBOTICS EUROPE AB
Franska Vagen 1039854, Kalmar, Sweden
Phone [phone] Fax [phone]

MOTOMAN ROBOTEC GmbH
Kammerfeld strasse 1, DE-85391 Allershausen, Germany
Phone [phone] Fax [phone]

YASKAWA ELECTRIC KOREA CORPORATION
1F Samyang Bldg. 89-1, Shinchun-dong, Donk-Ku, Daegu, Korea
Phone [phone] Fax [phone]

YASKAWA ELECTRIC (SINGAPORE) PTE. LTD.
151 Lorong Chuan, #04-01, New Tech Park, Singapore 556741, Singapore
Phone [phone] Fax [phone]

YASKAWA ELECTRIC (MALAYSIA) SDN. BHD.
No.71, Jalan Bandar Rawang 2, 48000 Rawang, Selangor D.E., Malaysia
Phone [phone] Fax [phone]

YASKAWA ELECTRIC TAIWAN CORPORATION
9F, 16 Nanking E. Rd., Sec. 3, Taipei, Taiwan
Phone [phone] Fax [phone]

SHOUGANG MOTOMAN ROBOT CO., LTD.
7,Yongchang-North Road, Beijing Economic & Technological Development Area, Beijing 100076, China
Phone [phone] Fax [phone]

YASKAWA ELECTRIC CORPORATION

YASKAWA

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

MANUAL NO. RE-MTO-A235

C

Printed in Japan June 2006 01-5

1