Yaskawa MPL80 User Manual

MOTOMAN-MPL80

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INSTRUCTIONS

TYPE: YR-MPL0080-A00 (STANDARD SPECIFICATION)
YR-MPL0080-A01 (WITH LIMIT SWITCHES FOR S-, L-, U-AXES)

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

MOTOMAN INSTRUCTIONS

MOTOMAN-MPL80 INSTRUCTIONS
DX 100 INSTRUCTIONS
DX 100 OPERATOR’S MANUAL
DX100 MAINTENANCE MANUAL

The DX 100 operator’s manual above corresponds to specific usage.
Be sure to use the appropriate manual.

Part Number: 157283-1CD
Revision: 4

MANUAL NO.

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Copyright © 2015, Yaskawa America, Inc. All Rights Reserved.

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MANDATORY

CAUTION

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• This instruction manual is intended to explain mainly on the
mechanical part of the MOTOMAN-MPL80 for the application to the
actual operation and for proper maintenance and inspection. It
describes on safety and handling, details on specifications,
necessary items on maintenance and inspection, to explain
operating instructions and maintenance procedures. Be sure to
read and understand this instruction manual thoroughly before
installing and operating the manipulator.

• General items related to safety are listed in the Chapter 1: Safety of
the DX 100 instructions. To ensure correct and safe operation,
carefully read the DX 100 instructions before reading this manual.

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

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

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

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

WARNING

CAUTION

MANDATORY

PROHIBITED

NOTE

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Notes for Safe Operation

Read this manual carefully before installation, operation, maintenance, or
inspection of the MOTOMAN-MPL80.

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

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Indicates an imminent 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 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.

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

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

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

DANGER

• Maintenance and inspection must be performed by specified
personnel.

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

• For disassembly or repair, contact your Yaskawa representative.

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

Failure to observe these safety precautions may result in death or
serious injury from unexpected turning of the manipulator's arm.

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WARNING

TURN

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• Before operating the manipulator, check that servo power is turned
OFF pressing the emergency stop buttons on the front door of the
DX100 and the programming pendant.
When the servo power is turned OFF, the SERVO ON LED on the
programming pendant is turned OFF.

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

Figure 1: Emergency Stop Button

• Once the emergency stop button is released, clear the cell of all
items which could interfere with the operation of the manipulator.
Then turn the servo power ON.

Injury may result from unintentional or unexpected manipulator motion.

Figure 2: Release of Emergency Stop

• Observe the following precautions when performing teaching
operations within the P-point maximum envelope of the
manipulator:

– Be sure to lock out the safeguarding when going inside.

Also, display the sign that the operation is being performed
inside the safeguarding and make sure no one closes the
safeguarding.

– View the manipulator from the front whenever possible.

– Always follow the predetermined operating procedure.

– Keep in mind the emergency response measures against the

manipulator’s unexpected motion toward you.

– Ensure that you have a safe place to retreat in case of

emergency.

Improper or unintended manipulator operation may result in injury.

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

– Turning ON the power for the DX100.

– Moving the manipulator with the programming pendant.

– Running the system in the check mode.

– Performing automatic operations.

Injury may result if anyone enters the P-point maximum envelope of the
manipulator during operation. Always press an emergency stop button
immediately if there is a problem.

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

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

– Check for problems in manipulator movement.

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

• Always return the programming pendant to the hook on the cabinet
of the DX100 after use.

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

• Read and understand the Explanation of Warning Labels in the
DX100 Instructions before operating the manipulator:

Definition of Terms Used Often in This Manual

The MOTOMAN is the YASKAWA industrial robot product.

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

In this manual, the equipment is designated as follows:

Equipment Manual Designation

DX100 controller DX100

DX100 programming pendant Programming pendant

Cable between the manipulator and the
controller

Manipulator cable

Registered Trademark

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

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MOTOMAN

TYPE

PAYLOAD

ORDER NO.

SERIAL NO.

MASS

DATE

YASKAWA ELECTRIC CORPORATION JAPAN

kg

kg

WARNING

Do not enter
robot
work area.

WARNING

Moving parts
may cause
injury

Nameplate:

WARNING Label B:

WARNING Label A:

Nameplate

WARNING label A

WARNING label B

WARNING label B

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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.

Figure 3: Warning Label Locations

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Table of Contents

Table of Contents

1 Product Confirmation ...................................................................................................................... 1-1

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

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

2 Transport......................................................................................................................................... 2-1

2.1 Transport Method............................................................................................................... 2-1

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

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

2.2 Shipping Bolts and Brackets .............................................................................................. 2-3

3 Installation....................................................................................................................................... 3-1

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

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

3.2.1 Mounting Example ................................................................................................ 3-3

3.2.2 When the Manipulator is Mounted Directly on the Floor....................................... 3-4

3.3 Protection Class................................................................................................................. 3-5

3.4 Location ............................................................................................................................. 3-5

4 Wiring.............................................................................................................................................. 4-1

4.1 Grounding .......................................................................................................................... 4-1

4.2 Cable Connection .............................................................................................................. 4-2

4.2.1 Connection to the Manipulator.............................................................................. 4-2

4.2.2 Connection to the DX100...................................................................................... 4-3

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

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

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

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

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

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

5.6 Alterable Operating Range ................................................................................................ 5-5

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

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

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

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7 System Application ......................................................................................................................... 7-1

7.1 Peripheral Equipment Mounts ........................................................................................... 7-1

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

8 Electrical Equipment Specification.................................................................................................. 8-1

8.1 Location of Limit Switch ..................................................................................................... 8-1

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

9 Maintenance and Inspection ........................................................................................................... 9-1

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

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

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

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

Table of Contents

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

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

9.3.1.2 Grease Exchange ................................................................................. 9-10

9.3.2 Grease Replenishment/Exchange for L-Axis Speed Reducer............................ 9-11

9.3.2.1 Grease Replenishment.......................................................................... 9-11

9.3.2.2 Grease Exchange ................................................................................. 9-12

9.3.3 Grease Replenishment/Exchange for U-Axis Speed Reducer ........................... 9-13

9.3.3.1 Grease Replenishment.......................................................................... 9-13

9.3.3.2 Grease Exchange ................................................................................. 9-14

9.3.4 Grease Replenishment for B- and T-Axis Gears ................................................ 9-15

9.3.4.1 Grease Replenishment.......................................................................... 9-15

9.3.4.2 Grease Exchange ................................................................................. 9-16

9.3.5 Grease Replenishment for B- and T-Axis Speed Reducers and Gears ............. 9-17

9.3.5.1 Grease Replenishment.......................................................................... 9-17

9.3.5.2 Grease Exchange ................................................................................. 9-18

9.3.6 Notes for Maintenance ....................................................................................... 9-19

9.3.6.1 Battery Pack Connection....................................................................... 9-19

10 Recommended Spare Parts....................................................................................................... 10-1

11 Parts List ..................................................................................................................................... 11-1

11.1 S-Axis Unit ..................................................................................................................... 11-1

11.2 L-Axis Unit ..................................................................................................................... 11-3

11.3 U-Axis Unit..................................................................................................................... 11-5

11.4 B-,T-Axes Unit ............................................................................................................... 11-7

11.5 Wrist Unit ....................................................................................................................... 11-9

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1 Product Confirmation

1.1 Contents Confirmation

1 Product Confirmation

• Confirm that the manipulator and the DX100 have the same order
number. Special care must be taken when more than one
manipulator is to be installed.

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

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):

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• Manipulator

• DX100

• Programing Pendant

• Manipulator Cable (between the DX100 and the Manipulator)

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THE MANIPULATOR AND THE CONTROLLER
SHOULD HAVE SAME ORDER NUMBER.

ORDER NO.

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

Label (Enlarged View)

(a) DX 100 (Front View) (b) Manipulator (Side View)

ON

TRIPPED

RESET

OFF

Y

C

E

G

N

O

T

P

M

E

E

S

R

X81

PROGRAMMING PENDANT

PROPERLY.

CHECK ALL THE DOOR LOCKS

NJ3005-1

AVERAGE

PEAK

kVA

kA

INTERRUPT CURRENT

ERDR-

POWER SUPPLY

TYPE

DX100

kVA

3PHASE

NJ2960-1

60Hz

SERIAL No.

DATE

AC220V

MADE IN JAPAN

50/60HzAC200V

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1 Product Confirmation

1.2 Order Number Confirmation

1.2 Order Number Confirmation

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

Fig. 1-1: Location of Order Number Labels

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CAUTION

NOTE

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2 Transport

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2 Transport

2.1 Transport Method

• Sling applications and crane or forklift operations must be
performed by authorized personnel only.

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

• Avoid excessive vibration or shock during transport.

The system consists of precision components. Failure to observe this
caution may adversely affect performance.

2.1 Transport Method

• Check that the eyebolts are securely fastened.

• The weight of the manipulator is approximately 580 kg
including the shipping bolts and brackets. Use a wire rope
strong enough to withstand the weight.

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

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

• Avoid putting external force on the arm or motor unit when
transporting by a crane, forklift, or other equipment.
Failure to observe this instruction may result in injury.

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Shipping bracket

Hexagon socket head cap screw M12
(8 screws)

Delivered with the manipulator

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2 Transport

2.1 Transport Method

2.1.1 Using a Crane

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

Fig. 2-1: Transporting Position

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Delivered with the manipulator

Shipping bracket

Forklift claw entry

Pallet

Bolt M20 (8 bolts)

NOTE

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2 Transport

2.2 Shipping Bolts and Brackets

2.1.2 Using a Forklift

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

Fig. 2-2: Using a Forklift

2.2 Shipping Bolts and Brackets

The manipulator is provided with shipping bolts and a shipping brackets.

(See Fig. 2-1 “Transporting Position" on page 2-2.)

• The shipping bolts and bracket are painted yellow.

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

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WARNING

CAUTION

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3 Installation

3 Installation

• Install the safeguarding.

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

• Install the manipulator in a location where the tool or the workpiece
held by its fully extended arm will not reach the wall, safeguarding,
or controller.

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

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

The manipulator may overturn and cause injury or damage.

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

Failure to observe this caution may cause injury or damage.

• Before turning ON the power, check to be sure that the shipping
bolts and brackets are removed.

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

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3 Installation

3.1 Installation of the Safeguarding

3.1 Installation of the Safeguarding

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

Responsibility for Safeguarding (ISO10218)

The user of a manipulator or robot system shall ensure that 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.

Construct a solid foundation with the appropriate thickness to withstand
maximum repulsion forces of the manipulator referring to Table 3-1

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

A baseplate flatness must be kept at 0.5 mm or less: insufficient flatness
of installation surface may deform the manipulator shape and affect its
functional abilities.

Mount the manipulator base as instructed in section 3.2.1 “Mounting

Example” on page 3-3 or section 3.2.2 “When the Manipulator is Mounted
Directly on the Floor” on page 3-4.

Table 3-1:

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

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

Maximum Repulsion Forces of the Manipulator at Emergency Stop

24500 N•m
(2500 kgf•m)

45080 N•m
(4600 kgf•m)

Table 3-2: Endurance Torque in Operation

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

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

6125 N•m
(625 kgf•m)

11270 N•m
(1150 kgf•m)

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50

30

Flatness:

0.5mm or less

Hexagon head screw
M20 (8 screws)

Manipulator base

Spring washer

Washer

Baseplate

Anchor bolt M20 or more

Baseplate

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3 Installation

3.2 Mounting Procedures for Manipulator Base

3.2.1 Mounting Example

For the first process, anchor the baseplate firmly to the ground. The
baseplate should be rugged and durable to prevent shifting of the
manipulator or the mounting fixture. It is recommend to prepare a
baseplate of 50 mm or more thick, and anchor bolts of M20 or larger size.

Next, fix the manipulator base to the baseplate. The manipulator base is
tapped for eight mounting holes; securely fix the manipulator base to the
baseplate with hexagon head screws M20 (70 mm long is recommended).

Tighten the hexagon head screws and anchor bolts firmly so that they will
not work loose during the operation.

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

Fig. 3-1: Mounting the Manipulator Baseplate

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600

900

800

720

385

320

300300

400

230

Bolt A

Tapped hole M20 (8 holes)

Bolt B

Tapped hole M24 (4holes) (Base B)

28dia. (4 holes) (Base A)

28dia. (4 holes) (Base B)

Base B

Base A

Bolt A: Bolt M20 X 70 mm (8 bolts),Spring Washer, Flat Washer

Tightening bolts or bases are prepared by the customer.

FL

Leveling is required

32

36250

350

200

100

100

200

JA Base bolt
M24 X315mm

Weld after adjusting
the installation

10

Manipulator base

Units: mm

Bolt B: Bolt M24 X 70 mm (4 bolts),Spring Washer, Flat Washer

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3 Installation

3.2 Mounting Procedures for Manipulator Base

3.2.2 When the Manipulator is Mounted Directly on the Floor

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 a rough standard, when there is a
concrete thickness (floor) is 200 mm or more, the manipulator base can
be fixed directly to the floor with M 20 anchor bolts. Before mounting the
manipulator, however, check that the floor is level and that all cracks, etc.
are repaired. Any thickness less than 200 mm is insufficient for mounting,
even if the floor is concrete.

Fig. 3-2: Direct Mounting on the Floor

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3 Installation

3.3 Protection Class

3.3 Protection Class

The protection class at the main part conforms to IP54 and that of wrist
part is IP67.

3.4 Location

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

• Ambient Temperature: 0° to +45°C

• Humidity: 20 to 80%RH (non-condensing)

• Free from dust, soot, oil, or water

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

• Free from excessive vibration (4.9 m/s

• Free from large electrical noise (plasma)

2

[0.5G] or less)

• The flatness for installation is 0.5 mm or less

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WARNING

CAUTION

NOTE

A

5.5mm or more

2

Delivered with the manipulator

Bolt M8 (for grounding)

View A

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4 Wiring

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4 Wiring

4.1 Grounding

• Ground resistance must be 100 Ω or less.

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

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

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

• Wiring must be performed by authorized or certified personnel.

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

4.1 Grounding

Follow the local regulations and electrical installation standards for
grounding. A wire of 5.5 mm

Refer to Fig. 4-1 “Grounding Method” to connect the ground line directly
to the manipulator.

Fig. 4-1: Grounding Method

2

or more is recommended.

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

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

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4 Wiring

4.2 Cable Connection

4.2 Cable Connection

Two manipulator cables are delivered with the manipulator; an encoder
cable (1BC) and a power cable (2BC). (Refer to Fig. 4-2 “Manipulator
Cables" on page 4-3.)

Connect these cables to the manipulator base connectors and to the
DX100. Refer to Fig. 4-3(a) "Manipulator Cable Connectors (Manipulator

Side)" on page 4-4" and Fig. 4-3(b) "Manipulator Cable Connectors
(DX100 Side)" on page 4-4.

4.2.1 Connection to the Manipulator

Before connecting cables to the manipulator, verify the numbers on both
manipulator cables and the connectors on the connector base of the
manipulator. When connecting, adjust the cable connector positions to
the main key positions of the manipulator, and insert cables in the order of
2BC, then 1BC. After inserting the cables, depress the lever until it clicks.

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molexmolexmolex molexmolexmolex

2BC

X11

1BC

1BC

X21

2BC

X11

1BC

X21

2BC

The DX100 side

The Manipulator side

Encoder cable

Power cable

The DX100 side

The Manipulator side

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4 Wiring

4.2 Cable Connection

4.2.2 Connection to the DX100

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

Fig. 4-2: Manipulator Cables

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X11

X21

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4 Wiring

4.2 Cable Connection

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

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

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5 Basic Specifications

5.1 Basic Specifications

5 Basic Specifications

5.1 Basic Specifications

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Table 5-1: Basic Specifications

Item Model MOTOMAN-MPL80

Structure Vertically Articulated

Degree of Freedom 5

Payload 80 kg

Repeatability

Range of Motion

Maximum Speed S-Axis 2.97rad/s, 170°/s

*2)

3)

1)

±0.07 mm

S-Axis (turning) ±180°

L-Axis (lower arm) +135°, -90°

U-Axis (upper arm) +251°, -170°

B-Axis (wrist pitch/yaw) ±15°

T-Axis (wrist twist) ±360°

L-Axis 2.97rad/s, 170°/s

U-Axis 2.97rad/s, 170°/s

4)

B-Axis 2.97rad/s, 170°/s

T-Axis 6.11 rad/s, 350°/s

Allowable Moment

Allowable Inertia

2

/4)

(GD

Approx. Mass 550 kg

Ambient Conditions Temperature 0° to 45°C

Power Capacity 4.0 kVA

1 SI units are used in this table. However, gravitational unit is used in ( ).
2 Conformed to ISO9283
3 The range of motion of type:MPL0080-A01 is limited with the limit switch before shipment.
4 The range of motion of the B-axis indicates the angle to the ground. With certain postures, however, motion may

be limited by the relative angle between the B-axis and the upper arm. Refer to section 5.5 “B-Axis Operating
Range” on page 5-4.

5 Refer to section 6.1 “Allowable Wrist Load” on page 6-1 for details on the allowable inertia.

5)

B-Axis 78.4 N•m (8 kgf•m)

T-Axis 20.5N•m (2.1 kgf•m)

B-Axis 16 kg•m

T-Axis 6.1 kg•m

Humidity 20 to 80% RH at constant temperature

Vibration Acceleration Less than 4.9 m/s

Others Free from corrosive gas or liquid, or explosive gas or

liquid.
Free from water, oil, or dust.
Free from excessive electrical noise (plasma).

2

2

2

(0.5G)

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T-

B-

T+

B+

U-

U+

L-

L+

S-

S+

Wrist

Wrist flange

Lower arm
L-arm

Upper arm
U-arm

Rotary head
S-head

Manipulator base

30

A

153

455

608

455

±

0.1

195

385

320

±0.1

195

±0.1

195

±0.1

230

230±0.1

22 dia.(8 holes)

View A

+0.018
0

12 dia. (2 holes)

230

400

195

±0.1

Base dimensions

25 of 69

MPL80

5 Basic Specifications

5.2 Part Names and Working Axes

5.2 Part Names and Working Axes

Fig. 5-1: Part Names and Working Axes

Fig. 5-2: Baseplate Dimensions

5.3 Baseplate Dimensions

5-2

HW0485739

MPL80

3291

2170

1300

925

312

112 1

623

2192

543

471248

131

2061

57

175

1025

145

1807

187540 870 210

105 105

6

A

P-point

276

343

253

234

234

R377

R543

R2061

View A

P-point
maximum
envelope

Units: mm

26 of 69

5 Basic Specifications

5.4 Dimensions and P-Point Maximum Envelope

5.4 Dimensions and P-Point Maximum Envelope

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

157283-1CD

5-3

HW0485739

157283-1CD

15°

B-axis rotation center

Wrist flange

15°

15°

15°

15°

55°

(*1)

U-axis rotation center

15°

15°

15°

15°

S-axis rotation center

L-axis rotation center

55°

Upper arm

(U-arm)

(*1)

1515°15°

1515°15°

15°

15°

1515°15°

27 of 69

MPL80

5 Basic Specifications

5.5 B-Axis Operating Range

5.5 B-Axis Operating Range

The operating range of the B-axis maintaining a constant angle to the
center of U-axis is shown in Fig. 5-4 “B-Axis Operating Range”.

By “B-axis adjustable motion function”, the B-axis maintains the same
posture to the ground regardless of the L- or U-axis angle.

The operating range is ±15° (0 degree is defined as the angle when the
wrist flange is horizontal and facing to the ground.) When the B-axis
position exceeds this limit, ”Special Soft Limit” occurs.

Note: In relation with interference with the upper arm, the range of motion
can be limited.

Fig. 5-4: B-Axis Operating Range

5-4

HW0485739

MPL80

28 of 69

5 Basic Specifications

5.6 Alterable Operating Range

5.6 Alterable Operating Range

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

Table 5-2: S-Axis Operating Range

Item Specifications

S-Axis Operating
Range

157283-1CD

±180°(standard)
±165°
±150°
±135°
±120°
± 105°
± 90°
± 75°
± 60°
± 45°
± 30°
± 15°

5-5

HW0485739

157283-1CD

800 600 400

20kg

1200

1000

800

600

400

800600400

LT(mm)

10kg

40kg

60kg

80kg

LB(mm)

LT(mm)

T- and R-axes
center of rotation

B-axis center of rotation

29 of 69

MPL80

6 Allowable Load for Wrist Axis and Wrist Flange

6.1 Allowable Wrist Load

6 Allowable Load for Wrist Axis and Wrist Flange

6.1 Allowable Wrist Load

The allowable wrist load is 80 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 6-1 "Allowable Wrist Load". Contact your Yaskawa representative
for further information or assistance.

Table 6-1: Allowable Wrist Load

Axis Moment N•m (kgf•m)

B-Axis 78.4 (8) 16

T-Axis 20.5 (2.1) 6

1 ( ): Gravitational unit

1)

GD
kg•m

2

/4 Total Moment of Inertia

2

When the volume load is small, refer to the moment arm rating shown in
Fig. 6-1 “Moment Arm Rating”.

The allowable total moment of inertia is calculated when the moment is at
the maximum. Contact your Yaskawa representative beforehand when
only the moment of inertia is created, or when the load moment is small
while the moment of inertia is large. Also, when the load mass is
combined with an outside force, contact your Yaskawa representative
beforehand.

Fig. 6-1: Moment Arm Rating

6-1

HW0485739

MPL80

P.C.D.80

42

40

Unit: mm

6

6

10

axis

Tapped hole M8

8 dia

Alignment mark

6 dia.

+0.012
0

50 dia.

0

-0.025

(depth: 10mm)

(depth:14 mm) (pitch:1.25) (6 holes)

(depth: 14mm)

+0.015
0

100 dia.

0

-0.022

NOTE

30 of 69

Fig. 6-2: Wrist Flange

157283-1CD

6 Allowable Load for Wrist Axis and Wrist Flange

6.2 Wrist Flange

6.2 Wrist Flange

The wrist flange dimensions are shown in Fig. 6-2 “Wrist Flange”. 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.

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

6-2

HW0485739

157283-1CD

611.5

200

100

100

57

223.5

40

105

105

223.5

40

105

105

100

100

200

50

Tapped hole M8 (4 holes)
(pitch: 1.25) (depth: 16)

Tapped hole M8 (4 holes)

(pitch: 1.25) (depth: 16)

Tapped hole M12 (4 holes)
(pitch: 1.75) (depth: 20)

A

B

C

31 of 69

MPL80

7 System Application

7.1 Peripheral Equipment Mounts

7 System Application

7.1 Peripheral Equipment Mounts

The peripheral equipment mounts are provided on the U-axis (upper arm)
and S-axis (rotary head) as shown in Fig. 7-1 “Installing Peripheral
Equipment” for easier installation of the users’ system applications. The
following conditions should be observed to attach or install peripheral
equipment.

Fig. 7-1: Installing Peripheral Equipment

Table 7-1: Conditions for Installation

Section Application Note

A Cable processing 80 kg max. for attaching load mass including

wrist load.

B Cable processing and

valve load

10 kg max.

N•m (5 kgf•m) max. for increased

49

moment amount of upper arm

C Others 30 kg max.

7-1

HW0485739

MPL80

View A

Connector for Internal User I/O Wiring Harness

Pins used

Internal user I/O wiring harness :

0.5 mm

2

, 23 wires

AIR

1BC

2BC

8

4

9

6517

23

14

19

20

15

17

11 121813

21 22 23

10

16

P

P

P

P

P

P

P

P

P

P

P

1

6

5

3
4

2

7
8
9
10

15

14

13

12

11

20

19

17
18

16

22
23

21

Tapped hole PT3/8
with a pipe plug

Air inlet

Connector for internal user I/O wiring
harness: JL05-2A24-28PC (with a cap)

Prepare pin connector: JL05-6A24-28S

A

B

Connector for internal user I/O wiring
harness: JL05-2A24-28SC (with a cap)

Prepare pin connector: JL05-6A24-28S

View B

Air inlet
Tapped hole PT3/8

with a pipe plug

32 of 69

157283-1CD

7 System Application

7.2 Internal User I/O Wiring Harness and Air Line

7.2 Internal User I/O Wiring Harness and Air Line

Internal user I/O wiring harness (0.5 mm2 x 23 wires), and an air line are
incorporated in the manipulator for the drive of peripheral device mounted
on the upper arm as shown in Fig. 7-2 “Connectors for Internal User I/O
Wiring Harness and Air Line" on page 7-2.

The connector pins 1 to 23 are assigned as shown in Fig. 7-2. Wiring must
be performed by users.

The allowable current for internal user
I/O wiring harness

5.1A or less for each wire
(The total current value for pins 1 to 23
must be 34.5A or less.)

The maximum pressure for the air line 490 kPa (5 kgf/cm

(The air line inside diameter: 8.0 mm.)

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

2

) or less

The same numbered pins (1 to 23) of the two connectors are connected
with a single lead wire of 0.5 mm

2

.

7-2

HW0485739

157283-1CD

33 of 69

MPL80

8 Electrical Equipment Specification

8.1 Location of Limit Switch

8 Electrical Equipment Specification

8.1 Location of Limit Switch

The limit switches are optional. See Fig. 8-1 “Location of Limit Switches”.
The overrun limit switches (the S- and L-axis overrun limit switches and
the LU-axes interference limit switch) are mounted only if the manipulator
type is : YR-MPL0080-A01.

Fig. 8-1: Location of Limit Switches

L-and U-axes interference limit switch
(YR-MPL0080-A01 with limit switch)

S-axis overrun limit switch

L-axis overrun limit switch
(YR-MPL0080-A01 with limit swich)

8-1

HW0485739

MPL80

1BC

2BC

Connector for internal
user I/O wiring harness

Connector for internal
user I/O wiring harness

L-and U-axes interference limit switch
(YR-MPL0080-A01 with limit switch)

S-axis overrun limit switch

L-axis overrun limit switch
(YR-MPL0080-A01

with limit switch)

34 of 69

8 Electrical Equipment Specification

8.2 Internal Connections

8.2 Internal Connections

Highly reliable connectors are equipped on each connection part of the
manipulator to enable easy removal and installation for maintenance and
inspection. For the number and location of connectors, see Fig. 8-2

“Location and Numbers of Connectors” and Table 8-1 "List of Connector
Types".

Diagrams for internal connections of the manipulator are shown in Fig.
8-3(a) "Internal Connection Diagram" on page 8-3 and Fig. 8-3(b) "Internal
Connection Diagram" on page 8-4 .

Fig. 8-2: Location and Numbers of Connectors

157283-1CD

Table 8-1: List of Connector Types

Name Type of Connector

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

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

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

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

8-2

HW0485739

DX100

Board for encoder power

1.For the limit switch specification, the connection of the section A B are changed as follows:

<Notes>

S-axis overrun L.S.

Connected to

A1

L-axis overrun L.S.

A2

Connected to

L and U-axes interference L.S.

A3

Connected to

S-axis overrun L.S.

Connected to

B1

L-axis overrun L.S.

B2Connected to

L and U-axes interference L.S.

B3

Connected to

SLU-axes with Limit Switch Specification

S-axis with Limit Switch Specification

S-axis overrun L.S.

Connected to

B1

S-axis overrun L.S.

Connected to

A1

DC/DC

SP23

23

23

P

22

SP22

SP21

21

22

21

P

20

SP20

SP19

19

20

19

P

P

P

P

P

P

S1(24-28)

No.8CN(24-28)

3

2

1

SP1
SP2
SP3

SP6

7
8
9

SP7
SP8

6

5

SP5

SP4

4

13
14
15
16

12

11

SP12

SP13
SP14
SP15

SP11

SP10

18

SP18

SP17

17

SP16

10

SP9

P

P

P

1
2

6

8

7

4
5

3

12

13

15

14

10
11

18

17

16

9

LC1

LD1

LD1

+24V

LD1

LD2

LB1

LB2

LA1

LB1

P

0V

P

P

CN4-9

CN4-4
CN4-5

P

AWG23

AWG23
AWG23

CN4-4
CN4-5

CN2-10

CN2-9

CN2-5

CN2-4

CN3-4
CN3-5

AWG23

AWG23
AWG23

AWG23

AWG23

AWG23

CN3-10

AWG23

AWG23

CN3-9

CN2-10

CN3-4
CN3-5

CN2-4
CN2-5
CN2-9

+24V
LD1

CN3-9
CN3-10

CN4-9

CN4-10

AWG23

0V

CN4-10

S-AXIS

PG

PG

U-AXIS

PG

BAT
OBT
+5V
0V

DATA-5

-9

-6

-5

-4

-2

DATA+5

B-AXIS

DATA+6

BAT

DATA-6

OBT

-2

PG

+5V

FG6

0V

BAT
OBT

-10

-4

-9

-6

-5

T-AXIS

FG5-10

BAT

OBT

L-AXIS

PG

0BAT2

BAT1

0BAT1
18
19

17

0BAT3

BAT3

21

24
25

22
23

BAT2

20

0BAT5

0BAT6

BAT6

BAT5

27

29
30

28

31

PG0V3

PG0V2

PG5V2

PG5V1

PG0V1

5

2
3
4

1

32

26

1CN-1

No.1CN

-2

DATA-1

DATA+1

S

P

-4

-9

-10

-5

-6

0V

+5V

FG1

BAT
OBT

No.2CN
2CN-1

-6

-2

DATA-2

DATA+2

BAT

BAT

OBT

P

P

L

P

No.18CN

PG5V6

PG0V6

PG5V5

PG0V5

8

12

11

10

9

7

16

15

14

13

-3

-4

-2

-1

No.19CN

-1

PG5V1
PG0V1

0BAT1

BAT2

BAT1

PG5V3

6

0BAT12

BAT11

0BAT11

2
3

1

PK R BAT

0BT

0BT

0BAT21

50BT

BAT12

PK R BAT 4

0BAT22
BAT22

7

1

8PKR

0BT
BAT

7

4
5
6

3

2

BAT21

PK R BAT 6

X

3

1

-3

No.24CN

-1 +24V
0V

4

2

-2-4+24V
0V

1BC(10 4)

0V

+24V

CN1-5
CN1-4

P

AWG23

AWG23

SPG-1

SPG+1

0V

+24V

CN1-2

CN1-1

CN1-9

CN1-10

P

P

AWG23

AWG23

AWG23

AWG23

FG1

CN1-3

SPG-2

SPG+2

CN1-7

CN1-6

P AWG23

AWG23

CN1-5

0V

+24V

CN1-10

CN1-1

CN1-9

0V

SPG-1

SPG+1

+24V

CN1-4

CN1-3

FG1

CN1-6
CN1-7

SPG-2

SPG+2

CN1-2

8

-10

-4

-9 0V

BAT

OBT

FG2

+5V

-2

-5

-6

3CN-1

No.3CN

DATA-3

DATA+3

OBT

BAT

P

U

P

P

-9

-10

0V

OBT
BAT

FG3

P

-4 +5V

-4

-3

No.20CN

-2

-1

-4

-3

PG5V3
PG0V3

0BAT3

PG0V2

PG5V2

BAT3

B

P

P

P

T

P

P

P

No.22CN

-4

-2

-3

-1

No.23CN

-2

-3

-4

-1

PG5V6
PG0V6

0BAT6

BAT6

PG0V5

0BAT5
PG5V5

BAT5

FG2

CN1-8

SPG-3

SPG+3

CN2-2

CN2-1

P

AWG23
AWG23

FG3

CN2-3

CN2-7

CN2-6

P

AWG23
AWG23

CN1-8

FG2

CN2-2

CN2-1

SPG-3

SPG+3

CN2-3

FG3

CN2-6
CN2-7

CN3-1

CN2-8

AWG23

FG5

SPG-5

CN3-3

CN3-2

P

AWG23

SPG+5

SPG+6
SPG-6

CN3-6
CN3-7

P

AWG23
AWG23

FG6

CN3-8

CN2-8

CN3-2

FG5

SPG-5

CN3-1

SPG+5

CN3-6

SPG-6

SPG+6

CN3-8

FG6

CN3-7

CN3-3

BC1
BC2

SS1

E

MANIPULATOR CasingBase

E

LB1

+24V

CN4-6

P

AWG23

AWG23

CN4-1

SS2

BC2

SS2

CN4-3

CN4-7

CN4-2

P

AWG23

AWG23
AWG23

CN4-8

P

AWG23

CN4-6

CN4-1

LB1

+24V

CN4-7

CN4-2

BC2

SS2

CN4-8

CN4-3

E

-2

0BAT2 P

-5 OBT

6CN-1

No.6CN

5CN-1

No.5CN

LC3

LD3

LA3

LB3

LA1

LC1

LA3

LB3

LB2
LB1

LB1

LA1

LC3

LD3

LD2

LD1

LD1

LC1

LD1

LD1

LC1

LB1

LB1

LA1

LD1

LC2

LD2

LD2

LD1

LC1

LB1

LA2

LB2

LB2

LB1

LA1

LC2
LD2

LD2

LD1

LB1
LB2

LB2

LA2

FOR LAMP(OPTION)

B1

A1

B3

A3

B2

A2

35 of 69

157283-1CD

MPL80

8 Electrical Equipment Specification

8.1 Internal Connections

Fig. 8-3(a): Internal Connection Diagram

8-3

HW0485739

MPL80

YB

SM

B-AXIS

SM

YB

T-AXIS

13CN-3

No.13CN

MU5

-2

-1

-5

-4

-PE

MV5
MW5

BB5

BA5

ME5

-2

14CN-3

No.14CN

MU6
MV6

-1

-4

-5

-PE

MW6

BA6
BB6

ME6

EE

2BC

2BC(8X4+12X2)

PE

ME6

BB1

BA1

BA3

BA6

BA5

BB5

BA2

ME5

ME3

ME2

ME2

ME1

ME1

MW5

MV5

MU5

MU6

MW6

MV6

MV2
MV2
MW2

MU3
MV3

MW2

MU1

MV1
MV1
MW1

MU1

MU2
MU2

MW1

MW3

ME6

BB1

BA1

BA3

BA6

BA5

BB5

BA2

CN6-9
CN6-10

CN6-12

CN6-11

CN6-2

CN6-1

CN6-4

CN6-7

CN6-8

CN6-6

CN6-5

CN6-3

ME5

ME3

ME2

ME2

ME1

ME1

CN5-5

CN5-8

CN5-7

CN5-6

CN5-4

CN5-3

CN5-2

CN5-1

CN4-2

CN4-1

CN4-6
CN4-7

CN4-3

CN4-5

CN4-4

CN4-8

MW5

MV5

MU5

MU6

MW6

MV6

CN3-1
CN3-2

CN3-5

CN3-4

CN3-7

CN3-8

CN3-6

CN3-3

CN5-5

CN5-8

CN5-7

CN5-6

CN5-4

CN5-3

CN5-2

CN2-8

CN2-7

CN2-8

CN2-7

MV2
MV2
MW2

MU3
MV3

MW2

CN2-1

CN2-3

CN2-2

CN2-5
CN2-6

CN2-4

CN1-8

CN1-7

CN1-6

CN1-5

CN1-4

CN1-3

CN1-2

CN1-8

CN1-7

CN1-6

CN1-5

CN1-4

CN1-3

CN1-2

CN6-9
CN6-10

CN6-12

CN6-11

S-AXISSM

YB

L-AXIS

YB

SM

U-AXISSM

YB

-C

No.9CN

9CN-A

-B
MW1

MU1
MV1

-1

-D

-2

BA1

ME1

BB1

CN1-1

MU1

MV1
MV1
MW1

MU1

MU2
MU2

MW1

CN1-1

CN2-1

CN2-3

CN2-2

10CN-A

No.10CN

MU2

-2

-C

-1

-D

BB2

MW2

BA2

ME2

MV2-B

-C

-B

No.11CN
11CN-A

MW3

MV3

MU3

-2

-1 BA3
BB3

ME3-D

MW3

CN2-5
CN2-6

CN2-4

CN3-1
CN3-2

CN3-5

CN3-4

CN4-2

CN3-7

CN4-1

CN3-8

CN3-6

CN3-3

CN4-6
CN4-7

CN4-3

CN4-5

CN4-4

CN4-8

CN5-1

CN6-2

CN6-1

CN6-4

CN6-7

CN6-8

CN6-6

CN6-5

CN6-3

36 of 69

157283-1CD

8 Electrical Equipment Specification

8.1 Internal Connections

Fig. 8-3(b): Internal Connection Diagram

8-4

HW0485739

157283-1CD

DANGER

WARNING

CAUTION

NOTE

37 of 69

MPL80

9 Maintenance and Inspection

9.1 Inspection Schedule

9 Maintenance and Inspection

• Maintenance and inspection must be performed by specified
personnel.

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

• For disassembly or repair, contact your Yaskawa representative.

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

Failure to observe these safety precautions may result in death or
serious injury from unexpected turning of the manipulator's arm.

• 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.

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

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

9.1 Inspection Schedule

Proper inspections are essential not only to assure that the mechanism
will be able to function for a long period, but also to prevent malfunctions
and assure safe operation. Inspection intervals are classified into six
levels as shown in Table 9-1 "Inspection Items" on page 9-2.

In Table 9-1 "Inspection Items" on page 9-2, the inspection items are
classified into three types of operation: operations which can be
performed by personnel authorized by the user, operations to be
performed by trained personnel, and operations to be performed by
service company personnel. Only specified personnel shall perform the
inspection work.000

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

• The inspection may be conducted at shorter intervals if the
manipulator is used very frequently for the application
such as handling; in this case, contact your Yaskawa
representative.

9-1

HW0485739

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

38 of 69

1)

Items

Schedule Method Operation Inspection

MPL80 9.1 Inspection Schedule

Charge

1 Alignment mark

2 External lead
3 Working area and

manipulator

4 S, L, U, B, T-axes motor

9-2

5 Baseplate mounting bolts

6 Cover mounting screws

7 S, L, U, B, T-axes motor

connector

8 Connector base

9 Wire harness in

manipulator

HW0485739

10 Limit switches and dogs

(S,L,U-axes)

11 Battery pack in

manipulator

12 S-axis speed reducer

Daily

•

•

•

•

1000HCycle

•

•

•

•

6000HCycle

12000HCycle

•

•

••

24000HCycle

36000HCycle

Visual Check alignment mark accordance at the home position.

Check for damage.
Visual Check for damage and deterioration of leads.
Visual Clean the work area if dust or spatter is present. Check for damage

and outside cracks.
Visual Check for grease leakage.
Spanner

Wrench
Screwdriver,

Wrench
Manual Tighten loose bolts.

Manual Check for loose connectors.

Visual Multimeter Check for conduction between the main connecter of base

•

Screwdriver,
Wrench,
Multimeter

•

Grease Gun Check for malfunction. (Replace if necessary.)

Tighten loose bolts. Replace if necessary.

Tighten loose bolts. Replace if necessary.

and intermediate connector with manually shaking the wire. Check

for wear of protective spring

Replace it 24000H intervals.

Tighten loose bolts. Replace if necessary.

Replace the battery pack when the battery alarm occurs or the

manipulator drove for 36000H.

Supply grease (6000H cycle)5)

Replace grease. (12000H cycle) 5)See section 9.3.1 on page 9-8.

2)

3)

4)

Specified

Personnel

Licensee

Service

Company

•••

•••

•••

•••

•••

•••

•••

•••

••

•

••

••

••

9 Maintenance and Inspection

157283-1CD

9-3

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

1)

Items

13 LU-axes speed reducers

14 B,T-axes speed reducers

B,T-axes gears

15 Overhaul

1 Inspection No. correspond to the numbers in Fig. 9-1 “Inspection Items" on page 9-4.
2 The occurrence of a grease leakage indicates the possibility that grease has seeped into the motor. This can cause a motor breakdown. Contact your Yaskawa

representative.

3 When checking for conduction with multimeter, connect the battery to “BAT” and “OBT” of connectors on the motor side for each axis, and then remove

connectors on detector side for each axis from the motor. Otherwise, the home position may be lost. (Refer to section 9.3.6 on page 9-19.)

4 The grease might leak out from the air breather or the internal pressure might rise in case the manipulator is used very frequently for the application such as

handling.

5 For the grease, refer to Table 9-2 "Inspection Parts and Grease Used" on page 9-5.

Schedule Method Operation Inspection

Charge

Daily

1000HCycle

6000HCycle

12000HCycle

24000HCycle

••

••

36000HCycle

Grease Gun Check for malfunction. (Replace if necessary.)

Supply grease (6000H cycle)5).

Replace grease (12000H cycle)5). See section 9.3.2 on page 9-11,

section 9.3.3 on page 9-13.
Grease Gun Check for malfunction. (Replace if necessary.)

Supply grease(6000H cycle)5).

Replace grease(12000H cycle)

5)

. See section 9.3.5 on page 9-17.

4)

4)

Specified

Personnel

Licensee

••

••

••

Service

157283-1CD

MPL80 9.1 Inspection Schedule

Company

9 Maintenance and Inspection

HW0485739

Fig. 9-1: Inspection Items

6

7

2

1

8

10

L-axis

15

1

B-axis

6

1

14

R-axis

1

U-axis

11

14

6

5

6

16

1

T-axis

6

6

4

13

6

1

9

12

S-axis

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MPL80 9.1 Inspection Schedule

9 Maintenance and Inspection

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9 Maintenance and Inspection

9.1 Inspection Schedule

Table 9-2: Inspection Parts and Grease Used

No. Grease Used Inspected Parts

13,14,15,16 Molywhite RE

No.00

The numbers in the above table correspond to the numbers in Table 9-1
"Inspection Items" on page 9-2.

Speed reducers for all axes
B,T-axes gears

9-5

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MPL80

AIR

1BC

2BC

Top View

Backside View

Connector base

Battery pack (HW0470360-A)

Cross head APS bolt M6
(Length:12)(8 bolts)

Cross head APS bolt M4
(Length:8)(4 bolts)

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9 Maintenance and Inspection

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 position shown in Fig. 9-2 “Battery
Location”.

• Battery Type: HW0470360-A

Fig. 9-2: Battery Location

9-6

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See procedure 5

Connector

Battery pack before replacement

See procedure 4

New battery pack

Circuit Board

(Type: SGDR-EFBA02A)

NOTE

NOTE

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Fig. 9-3: Battery Connection

9 Maintenance and Inspection

9.2 Notes on Maintenance Procedures

1. Turn OFF the DX100 main power supply.

2. Remove the plate fixing screws and the plate on the connector base,
then

pull the battery pack out to replace it with the new one.

3. Remove the battery pack from the battery holder.

4. Connect the new battery pack to the unoccupied connectors on the
circuit boa

5. Remove the old battery pack from the circuit board.

6. Mount the new battery pack on the battery holder.

7. Reinstall the plate.

rd.

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

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

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NOTE

Grease exhaust port

Air breather

S-axis speed reducer

Grease inlet

Hexagon socket
head plug PT1/4

Air breather

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9 Maintenance and Inspection

9.3 Notes on Grease Replenishment/Exchange Procedures

9.3 Notes on Grease Replenishment/Exchange Procedures

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

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

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

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

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

9.3.1 Grease Replenishment/Exchange for S-Axis Speed Reducer

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

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NOTE

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9.3.1.1 Grease Replenishment

9 Maintenance and Inspection

9.3 Notes on Grease Replenishment/Exchange Procedures

(Refer to Fig. 9-4 “S-Axis Speed Reducer Diagram" on page 9-8.)

1. Remove the hexagon socket head plug PT1/4 from the grease inlet
and the hexagon socket head air breather from the grease exhaust
port.

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

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

– Grease type: Molywhite RE No. 00

• If grease is injected with the air breather on, grease will
leak inside the motor and may cause a damage. Make
sure to remove the air breather before the grease
injection.

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

–

Amount of grease: 520 cc
(1040 cc for 1st supply)

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

– Grease injection rate: 8 g/s or less

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

5. Wipe the discharged grease with a cloth and reinstall the air breather
up

ward.
Before installing the air breather, apply
thread part of each plug.

6. Remove the grease zerk from the grease inlet and reinstall the
he

xagon socket head plug PT1/4.
Before installing the plug, apply Three Bond
of each plug, then tighten the plug with a tightening torque of 12 N•m
(1.2 kgf•m).

Three Bond 1206C on the

1206C on the thread part

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NOTE

NOTE

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9.3.1.2 Grease Exchange

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9 Maintenance and Inspection

9.3 Notes on Grease Replenishment/Exchange Procedures

(Refer to Fig. 9-4 “S-Axis Speed Reducer Diagram" on page 9-8.)

1. Remove the hexagon socket head plug PT1/4 from the grease inlet
and the hexagon socket head air breather from the grease exhaust
port

.

• If grease is injected with the air breather, the grease will
leak inside the motor and may cause a damage. Make
sure to remove the air breather before the grease
injection.

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

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

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

– Grease type: Molywhite RE No. 00

–

Amount of grease: approx. 2600 cc

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

– Grease injection rate: 8 g/s or less

4. The grease exchange is complete when new grease appears from the
e

xhaust port. (The new grease can be distinguished from the old

grease by color.)

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

6. Wipe the discharged grease with a clo
upward.
Before installing the air breather
thread part of each plug.

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

7. Remove the grease zerk from the grease inlet and reinstall the

exagon socket head plug PT1/4.

h
Before installing the plug, apply Three Bond 1206C
of each plug, then tighten the plug with a tightening torque of 12 N•m
(1.2 kgf•m).

th and reinstall the air breather

, apply Three Bond 1206C on the

on the thread part

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Grease exhaust port

Hexagon socket head
plug PT3/8

Grease inlet

Hexagon socket

head plug PT1/8

L-axis speed reducer

NOTE

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9 Maintenance and Inspection

9.3 Notes on Grease Replenishment/Exchange Procedures

9.3.2 Grease Replenishment/Exchange for L-Axis Speed Reducer

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

9.3.2.1 Grease Replenishment

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

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

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

3. Remove the hexagon socket head plug PT1/8 from the grease inlet.

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

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

4. Install the grease zerk PT1/8 to the grease inlet. (The grease zerk is
d

elivered with the manipulator.)

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

– Grease type: Molywhite RE No. 00

–

Amount of grease: 250 cc
(500 cc for 1st supply)

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

– Grease injection rate: 8 g/s or less

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

7. Wipe the discharged grease with a cloth and reinstall the hexagon
so

cket head plug PT3/8 to the exhaust port.

Before installing the plugs, apply Three

Bond 1206C on the thread part
of each plug, then tighten the plug with a tightening torque of 23 N•m
(2.3 kgf•m).

8. Remove the grease zerk from the grease inlet and reinstall the
xagon socket head plug PT1/8 to the grease inlet.

he
Before installing the plug, apply Three Bond

1206C on the thread part
of each plug, then tighten the plug with a tightening torque of 4.9 N•m
(0.5 kgf•m).

9-11

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NOTE

NOTE

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9.3.2.2 Grease Exchange

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9 Maintenance and Inspection

9.3 Notes on Grease Replenishment/Exchange Procedures

(Refer to Fig. 9-5 “L-Axis Speed Reducer Diagram" on page 9-11.)

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

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

3. Remove the hexagon socket head plug PT1/8 from the grease inlet.

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

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

4. Install the grease zerk PT1/8 to the gr
(The grease zerk is delivered with the manipulator.)

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

– Grease type: Molywhite RE No. 00

–

Amount of grease: approx. 1650 cc

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

– Grease injection rate: 8 g/s or less

6. The grease discharge is complete when new grease appears from the
e

xhaust port. The new grease can be distinguished from the old

grease by color.

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

8. Wipe the discharged grease with a clo
socket head plug PT3/8 to the exhaust port.
Before installing the plugs, apply Three Bond 1206C on the thread part

f each plug, then tighten the plug with a tightening torque of 23 N•m

o
(2.3 kgf•m).

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

ease inlet.

th and reinstall the hexagon

9. Remove the grease zerk from the grease inlet and reinstall the

exagon socket head plug PT1/8 to the grease inlet.

h
Before installing the plug, apply Three Bond 1206C
of each plug, then tighten the plug with a tightening torque of 4.9 N•m
(0.5 kgf•m).

on the thread part

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U-arm

NOTE

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9 Maintenance and Inspection

9.3 Notes on Grease Replenishment/Exchange Procedures

9.3.3 Grease Replenishment/Exchange for U-Axis Speed Reducer

Fig. 9-6: U-Arm Posture

Fig. 9-7: U-Axis Speed Reducer Diagram

Grease inlet

Hexagon socket head
plug PT1/8

9.3.3.1 Grease Replenishment

(Refer to Fig. 9-7 “U-Axis Speed Reducer Diagram”.)

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

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

3. Remove the hexagon socket head plug PT1/8 from the grease inlet.

4. Install the grease zerk PT1/8 to the grease inlet. (The grease zerk is
d

U-axis speed reducer

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

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

elivered with the manipulator.)

Grease exhaust port

Hexagon socket head
plug PT3/8

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

– Grease type: Molywhite RE No. 00

– Amount of grease: 140 cc

(280 cc for 1st supply)

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

– Grease injection rate: 8 g/s or less

9-13

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NOTE

NOTE

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9 Maintenance and Inspection

9.3 Notes on Grease Replenishment/Exchange Procedures

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

9.3.3.2 Grease Exchange

7. Wipe the discharged grease with a clo
socket head plug PT3/8 to the exhaust port.
Three Bond 1206C on the thread part of each plug, then tighten the

lug with a tightening torque of 23 N•m (2.3 kgf•m)

p

8. Remove the grease zerk from the grease inlet and reinstall the
h

exagon socket head plug PT1/8.
Before installing the plug, apply Three Bond 1206C
of each plug, then tighten the plug with a tightening torque of 4.9 N•m
(0.5 kgf•m)

Refer to Fig. 9-7 “U-Axis Speed Reducer Diagram" on page 9-13.)

(

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

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

haust port.

3. Remove the hexagon socket head plug PT1/8 from the grease inlet.

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

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

th and reinstall the hexagon

on the thread part

4. Install the grease zerk PT1/8 to the gr
delivered with the manipulator.)

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

– Grease type: Molywhite RE No. 00

–

Amount of grease: approx.700 cc

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

– Grease injection rate: 8 g/s or less

6. The grease discharge is complete when new grease appears from the
ex

haust port. The new grease can be distinguished from the old

grease by color.

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

8. Wipe the discharged grease with a clo
socket head plug PT3/8 to the exhaust port.
Before installing the plug, apply Three Bond 1206C
of each plug, then tighten the plug with a tightening torque of 23 N•m
(2.3 kgf•m).

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

ease inlet. (The grease zerk is

th and reinstall the hexagon

on the thread part

9. Remove the grease zerk from the grease inlet and reinstall the

exagon socket head plug PT1/8.

h
Before installing the plug, apply Three Bond 1206C
of each plug, then tighten the plug with a tightening torque of 4.9 N•m
(0.5 kgf•m).

on the thread part

9-14

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NOTE

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9 Maintenance and Inspection

9.3 Notes on Grease Replenishment/Exchange Procedures

9.3.4 Grease Replenishment for B- and T-Axis Gears

Fig. 9-8: B- and T-Axis Gears Diagram

9.3.4.1 Grease Replenishment

(Refer to Fig. 9-8 “B- and T-Axis Gears Diagram”.)

Exhaust port

Hexagon socket head
plug PT3/8

U-arm

Grease inlet

Hexagon socket head
plug PT1/8

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

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

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

2. Remove the hexagon socket head plug PT1/8.

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

– Grease type: Molywhite RE No. 00

–

Amount of grease: approx.700 cc
(1400 cc for 1st supply)

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

– Grease injection rate: 8 g/s or less

4. The grease discharge is complete when new grease appears from the
exha

ust port. The new grease can be distinguished from the old

grease by color.

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

6. Wipe the discharged grease with a cloth and reinstall the hexagon
so

cket head plug PT3/8 to the exhaust port.

Before installing the plug, apply Three Bond

1206C on the thread part
of each plug, then tighten the plug with a tightening torque of 23 N•m
(2.3 kgf•m).

7. Remove the grease zerk from the grease inlet and reinstall the
xagon socket head plug PT1/8.

he
Before installing the plug, apply Three Bond

1206C on the thread part
of each plug, then tighten the plug with a tightening torque of 4.9 N•m
(0.5 kgf•m).

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NOTE

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9.3.4.2 Grease Exchange

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9 Maintenance and Inspection

9.3 Notes on Grease Replenishment/Exchange Procedures

(Refer to Fig. 9-8 “B- and T-Axis Gears Diagram" on page 9-15.)

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

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

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

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

3. Install the grease zerk PT1/8 to the gr
delivered with the manipulator.)

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

– Grease type: Molywhite RE No. 00

–

Amount of grease: approx.3500 cc

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

– Grease injection rate: 8 g/s or less

5. The grease discharge is complete when new grease appears from the
ex

haust port. The new grease can be distinguished from the old

grease by color.

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

7. Wipe the discharged grease with a clo
socket head plug PT3/8 to the exhaust port.
Before installing the plug, apply Three Bond 1206C
of each plug, then tighten the plug with a tightening torque of 23 N•m
(2.3 kgf•m).

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

ease inlet. (The grease zerk is

th and reinstall the hexagon

on the thread part

8. Remove the grease zerk from the grease inlet and reinstall the

exagon socket head plug PT1/8.

h
Before installing the plug, apply Three Bond 1206C
of each plug, then tighten the plug with a tightening torque of 4.9 N•m
(0.5 kgf•m).

on the thread part

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Grease inlet
Hexagon socket head
plug PT1/8

T-axis speed reducer, gear

Exhaust port
Hexagon socket head
plug PT1/8

B-axis speed reducer, gear

NOTE

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9 Maintenance and Inspection

9.3 Notes on Grease Replenishment/Exchange Procedures

9.3.5 Grease Replenishment for B- and T-Axis Speed Reducers and Gears

Fig. 9-9: B- and T-Axis Speed Reducers and Gears Diagram

9.3.5.1 Grease Replenishment

(Refer to Fig. 9-9 “B- and T-Axis Speed Reducers and Gears Diagram”.)

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

2. Remove the hexagon socket head plug PT1/8.

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

4. The grease discharge is complete when new grease appears from the

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

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

– Grease type: Molywhite RE No. 00

–

Amount of grease: approx.300 cc
(600 cc for 1st supply)

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

– Grease injection rate: 8 g/s or less

exha

ust port. The new grease can be distinguished from the old

grease by color.

5. Move the B-axes for a few minutes to dischar

6. Wipe the discharged grease with a cloth and reinstall the hexagon
so

cket head plug PT1/8 to the exhaust port.

Before installing the plug, apply Three Bond

ge the excess grease.

1206C on the thread part
of each plug, then tighten the plug with a tightening torque of 4.9 N•m
(0.5 kgf•m).

7. Remove the grease zerk from the grease inlet and reinstall the
xagon socket head plug PT1/8.

he
Before installing the plug, apply Three Bond
of each plug, then tighten the plug with a tightening torque of 4.9 N•m
(0.5 kgf•m).

1206C on the thread part

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NOTE

NOTE

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9.3.5.2 Grease Exchange

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9 Maintenance and Inspection

9.3 Notes on Grease Replenishment/Exchange Procedures

(Refer to Fig. 9-9 “B- and T-Axis Speed Reducers and Gears Diagram" on
page 9-17.)

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

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

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

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

3. Install the grease zerk PT1/8 to the gr
delivered with the manipulator.)

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

– Grease type: Molywhite RE No. 00

–

Amount of grease: approx.1500 cc

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

– Grease injection rate: 8 g/s or less

5. The grease discharge is complete when new grease appears from the
ex

haust port. The new grease can be distinguished from the old

grease by color.

6. Move the B-axes for a few minutes to discharge the excess grease.

7. Wipe the discharged grease with a clo
socket head plug PT1/8 to the exhaust port.
Before installing the plug, apply Three Bond 1206C
of each plug, then tighten the plug with a tightening torque of 4.9 N•m
(0.5 kgf•m).

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

ease inlet. (The grease zerk is

th and reinstall the hexagon

on the thread part

8. Remove the grease zerk from the grease inlet and reinstall the

exagon socket head plug PT1/8.

h
Before installing the plug, apply Three Bond 1206C
of each plug, then tighten the plug with a tightening torque of 4.9 N•m
(0.5 kgf•m).

on the thread part

9-18

HW0485739

157283-1CD

NOTE

b

a

a

b

0BT

BAT

BAT*

0BT*

Motor

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

Connector for motor encoder

Power connector

Connector for battery backup

Battery pack: HW9470932-A

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MPL80

9 Maintenance and Inspection

9.3 Notes on Grease Replenishment/Exchange Procedures

9.3.6 Notes for Maintenance

When performing maintenance such as replacement of a wire harness in
the manipulator, the encoder connector may be necessary to be removed.
In this case, be sure to connect the battery pack to the battery backup
connector before removing the encoder connector.

Removing the encoder connector without connecting the battery pack
leads to disappearance of the encoder absolute data.

For the battery pack connection, refer to Fig. 9-10 “Battery Pack
Connection”.

9.3.6.1 Battery Pack Connection

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

1. Remove the cap attached to the battery backup connector of the

2. Connect the battery packs (HW9470932-A) with the battery backup

motors.

connectors (BAT and OBT are marked) located at the end point of the
cables for the encoder. (Under this condition, remove the encoder
connector and carry out the maintenance checks.)

3. Confirm all connectors connected after the maintenance check, and
remove the battery

packs. Install the caps attached to the battery

backup connectors of the motors.

Do not remove the battery pack in the connector base.

Fig. 9-10: Battery Pack Connection

9-19

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NOTE

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10 Recommended Spare Parts

10 Recommended Spare Parts

It is recommended to keep the parts and components in the following table
in stock as spare parts for the MOTOMAN-MPL80. 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

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

Table 10-1: Spare Parts for YR-MPL0080-A00, -A01 (Sheet 1 of 2)

157283-1CD

Rank Parts

A1Grease

A 2 Liquid Gasket Three Bond 1206C Three Bond Co.,

A 3 Battery Pack HW9470932-A Yaskawa 1 1 For internal wire

A 4 Battery Pack HW0470360-A Yaskawa 1 1

B 5 S-Axis

B 6 S-Axis Input Gear HW0313741-1 Yaskawa 1 1

B7L-Axis

B 8 L-Axis Input Gear HW9482771-A Yaskawa 1 1

B 9 U-Axis

B 10 U-Axis Input Gear HW0313740-1 Yaskawa 1 1

B 11 B-Axis

B 12 T-Axis

C 13 S-Axis

C 14 L-Axis

C 15 U-Axis

C16B-, T-Axes

Name Type Manufacturer Qty Qty

No.

Yaskawa 16 kg - For speed reducers

Ltd.

Yaskawa 1 1

Yaskawa 1 1

Yaskawa 1 1

Yaskawa 1 2

Speed Reducer

Speed Reducer

Speed Reducer

Speed Reducer

Speed Reducer

AC Servomotor

AC Servomotor

AC Servomotor

AC Servomotor

Molywhite RE No. 00

HW0387752-A Yaskawa 1 1

HW1382898-A Yaskawa 1 1 For the manipulator

HW09381465-B Yaskawa 1 1

HW0387753-A Yaskawa 1 1

HW0387737-B Yaskawa 1 1

HW0389043-A Yaskawa 1 1

SGMRV-30ANA-YR11
HW0388669-A

SGMRV-37ANA-YR11
HW0388670-A

SGMRV-13ANA-YR11
HW0388666-A

SGMRV-09ANA-YR11
HW0388665-A

Remarks

per

Unit

in each axis

--

harness
replacement

assembled after
Apr.2, 2014

10-1

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MPL80

10 Recommended Spare Parts

Table 10-1: Spare Parts for YR-MPL0080-A00, -A01 (Sheet 2 of 2)

Rank Parts

C 17 Internal Wire

C 18 Connector Base HW0374528-B Yaskawa 1 1

C 19 Circuit Board SGDR-EFBA02A Yaskawa 1 1

Name Type Manufacturer Qty Qty

No.

HW0175247-A Yaskawa 1 1

Harness

Remarks

per

Unit

10-2

HW0485739

MPL80

1019

1001

1002

1003

1004

1005

1007

1009

1008

1010

1011

1013

1014

1016

1018

1020

1017

1021

1022

1025

1026

1028

1023

1024

1012

1030

1033

1029

1032
1031

1035

58 of 69

11 Parts List

Fig. 11-1: S-Axis Unit

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11 Parts List

11.1 S-Axis Unit

11.1 S-Axis Unit

11-1

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MPL80

11 Parts List

11.1 S-Axis Unit

Table 11-1: S-Axis Unit

No. DWG No. Name Pcs

1001 HW0387752-A Speed reducer 1

HW1382898-A
(For the manipulator
assembled after Apr.2, 2014)

1002 SGMRV-30ANA-YR1* Motor 1

1003 HW9404486-1 Shaft 1

1004 HW0400405-1 Stopper 1

1005 6310 Bearing 1

1007 M8X45 Socket screw 1

1008 2H-8 Spring washer 1

1009 HW0102237-2 S-head 1

1010 M12X45 Socket screw 15

M12X45
(For the manipulator
assembled after Apr.2, 2014)

1011 2H-12 Spring washer 15

2H-12
(For the manipulator
assembled after Apr.2, 2014)

1012 C-30-SG-22A Grommet 1

1013 M12X55 Socket screw 3

1014 2H-12 Spring washer 3

1016 STW-50 Retaining Ring-C type 1

1017 M8X100 Socket screw 1

1018 2H-8 Spring washer 1

1019 PT3/8(STAINLESS) Plug 1

1020 MSTH10-25 Dowel pin 1

1021 M12X55 Socket screw 12

1022 2H-12 Spring washer 12

1023 HW9405875-1 Collar 1

1024 M20X40 Socket screw 1

1025 HW0102236-1 Base 1

1026 KQ2L10-01S Elbow 1

1028 NB-1075-0.43 Tube 1

1029 HW0314010-1 M-base 1

1030 Y507212.5 Oil seal 1

1031 M6X20 Socket screw 2

1032 2H-6 Spring washer 2

1033 HW0313741-1 Gear 1

1034 PT1/8(STAINLESS) Plug 1

1035 M12X35

(For the manipulator
assembled after Apr.2, 2014)

Speed reducer 1

Socket screw 16

Spring washer 16

GT-SA bolt 2

11-2

HW0485739

MPL80

2002

2005

2016

2004

2003

2026
2009
2008

2006

2007

2026

2027

2027

2027

2011

2013

2014

2015

2010

2019

2020

1009

2001

2021

2022

2024

2023

2018

2025

2025

2012

2017

60 of 69

Fig. 11-2: L-Axis Unit

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11 Parts List

11.2 L-Axis Unit

11.2 L-Axis Unit

11-3

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11 Parts List

11.2 L-Axis Unit

Table 11-2: L-Axis Unit

No. DWG No. Name Pcs

2001 SGMRV-37ANA-YR1* Motor 1

2002 HW0102425-1 L-arm 1

2003 M12X55 Socket screw 16

2004 SW-2H-12 Spring washer 16

2005 HW9381465-B Speed reducer 1

2006 M10X40 Socket screw 18

2007 2H-10 Spring washer 18

2008 M16X45 Socket screw 6

2009 2H-16 Spring washer 6

2010 HW9481343-A Shaft 1

2011 HW9482771-A Gear 1

2012 HW9405902-1 Pipe 1

2013 M8X130 Socket screw 1

2014 2H-8 Spring washer 1

2015 M8 Washer 1

2016 G270 O-ring 1

2017 EZ0094-A0 Air breather 1

2018 HW0314011-1 M-base 1

2019 HW0312815-2 Gear 1

2020 HW9482447-A Oil seal 1

2021 M12X65 Socket screw 4

2022 2H-12 Spring washer 4

2023 M6X30 Socket screw 2

2024 2H-6 Spring washer 2

2025 EZ5002A0 Cap 3

2026 PT3/8(STAINLESS) Plug 2

2027 PT1/8(STAINLESS) Plug 4

1009 HW0102237-4 S-head 1

11-4

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MPL80

2002

3014

3015

3028

3023

3024

3007

3027

3017

3022

3001

3016

3021

3026

3025

3018

3008

3009

3011

3010

3005

3006

3020

3019

3002

3004

3003

3012

3015

62 of 69

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11 Parts List

11.3 U-Axis Unit

11.3 U-Axis Unit

Fig. 11-3: U-Axis Unit

11-5

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MPL80

11 Parts List

11.3 U-Axis Unit

Table 11-3: U-Axis Unit

No. DWG No. Name Pcs

3001 SGMRV-13ANA-YR1* Motor 1

3002 HW0413914-1 Stopper 1

3003 M6X55 Socket screw 1

3004 2H-6 Spring washer 1

3005 M8X55 Socket screw 4

3006 2H-8 Spring washer 4

3007 HW0387753-A Speed reducer 1

3008 HW0313740-1 Gear 1

3009 HW8411125-3 Washer 1

3010 M6X115 Socket screw 1

3011 2H-6 Spring washer 1

3012 M12X30 Socket screw 12

3013 2H-12 Spring washer 12

3014 M10X30 Socket screw 6

3015 2H-10 Spring washer 6

3016 HW9405257-1 Collar 1

3017 HW0102239-2 Casing 1

3018 Y426012.5 Oil seal 1

3019 M6X30 Socket screw 2

3020 2H-6 Spring washer 2

3021 HW0314012-1 M-base 1

3022 G195 O-ring 1

3023 M10X40 Socket screw 16

3024 2H-10 Spring washer 16

3025 TSH6-01M Union 2

3026 UB-0640-0.1C Tube 2

3027 PT1/8(STAINLESS) Plug 1

3028 PT3/8(STAINLESS) Plug 1

2002 HW0102425-1 L-arm 1

11-6

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MPL80

4029

4030

4001

B axis

T axis

4003

4004

4005

4007

4008

4010

4012

4013

4014

4016

4017

4019

4021

4022

4023

4024

4025

4026

4027

4028

4031

4031

4031

4033

4035

4034

4048

4036

4037

4037

4039

4038

4040

4041

4044

4045

3017

4007

4020

4002

4046

4047

4046

4047

4002

4049
4050

4042

4043

4006

64 of 69

11.4 B-,T-Axes Unit

Fig. 11-4: B-,T-Axes Unit

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11 Parts List

11.4 B-,T-Axes Unit

11-7

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MPL80

11 Parts List

11.4 B-,T-Axes Unit

Table 11-4: B-,T-Axes Unit

No.

4001 HW0387754-A Speed reducer 1
4002 SGMRV-09ANA-YR1* Motor 2
4003 AC1306-G00X6 Oil seal 1
4004 TC20367*FKM* Oil seal 1
4005 HW0415265-1 Spacer 1
4006 HW0415352-1 Cover 1
4007 HR32005XJ Bearing 2
4008 HR32909J Bearing 1
4010 HW0313628-1 Gear 1
4012 HW0313629-1 Gear 1
4013 HW0312826-1 Gear 1
4014 HW0404196-8 Washer 1
4016 MSTH8-20 Dowel pin 1
4017 HW0312834-1 Shaft 1
4019 HW0312831-1 Gear 1
4020 HW0312833-1 Shaft 1
4021 HW0312835-1 Shaft 1
4022 HW0312838-1 Flange 1
4023 MSTH6-15 Dowel pin 1
4024 HW0200768-1 Shaft 1
4025 HW0312837-1 Housing 1
4026 HW9405662-1 Washer 1
4027 HW0312825-1 Gear 1
4028 HW0412720-1 B nut 1
4029 PT1/8 (STAINLESS) Plug 2
4030 PT3/8 (STAINLESS) Plug 1
4031 M5X16 GT-SA bolt 14
4033 M4X6 H set screw 1
4034 M6X25 Socket screw 1
4035 2H-6 Spring washer 1
4036 M8X25 Socket screw 18
4037 2H-8 Spring washer 19
4038 M6X20 Socket screw 1
4039 2H-6 Spring washer 1
4040 M6X25 Socket screw 6
4041 2H-6 Spring washer 6
4042 M8X18 Socket screw 3
4043 2H-8 Spring washer 3
4044 M6X35 GT-SA bolt 16
4045 M8X30 GT-SA bolt 8
4046 M8X25 Socket screw 7
4047 2H-8 Spring washer 7
4048 M8X20 Socket screw 1
4049 M4X6 Socket screw 1
4050 2H-4 Spring washer 1
3017 HW0102239-2 Casing 1

型式

Name

Pcs.

11-8

HW0485739

MPL80

5001

5002

5003

5004

5006

5007

5008

5009

5010

5013

5014

5047

5048

5053

5054

5055

5056

5057

5058

5060

5075

5082

5089

5093

5094

5113

5015

5016

5027

5028

5029

5032

5033

5034

5035

5036

5037

5039

5039

5040

5041

5044

5046

5022

5095

5096

5104

5103

5108
5107

3017

5091

5090

5049

5099

5092

5092

5030

5038

5097

5098

5045

5068

5092

5017

5012

5043

5109

5059

5092

5031

5042

5093

5094

5105

5106

5035

5102

5100

5039

5005

5005

5039

5115

5114

5011

5115

5115

5112

5111

5110

66 of 69

Fig. 11-5: Wrist Unit

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11 Parts List

11.5 Wrist Unit

11.5 Wrist Unit

11-9

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MPL80

11 Parts List

11.5 Wrist Unit

Table 11-5: Wrist Unit

No. DWG No. Name Pcs

5001 HW0387737-B Speed reducer 1

5002 HW0389043-A Speed reducer 1

5003 HW9405880-1 B-cover 1

5004 HW9405445-1 B nut 1

5005 HW9405881-1 B nut 2

5006 HW9405882-1 B nut 1

5007 S34 O ring 1

5008 AE3092E2 Oil seal 1

5009 SC15247F585 Oil seal 1

5010 SC39528F585 Oil seal 1

5011 HW9405883-1 Collar 1

5012 HW9381667-A Gear 1

5013 HW9381668-A Gear 1

5014 HW9381669-A Gear 1

5015 HW9381672-A Gear 1

5016 WR60 Circlip 1

5017 HW9405888-* Shim *

5022 HW9405885-* Shim *

5027 HW9482772-A Gear 1

5028 HW9482765-A Shaft 1

5029 HW9381675-A Shaft 1

5030 RTW42 Retaining Ring 1

5031 STW-25 Retaining Ring-C type 1

5032 ISTW40 Retaining Ring 1

5033 HW9405891-1 Housing 1

5034 PT3/8 Plug 2

5035 PT1/8 (STAINLESS) Plug 3

5036 HW9405892-1 Flange 1

5037 HW9481234-A Bearing 1

5038 6004LBD2PX24V1 Bearing 1

5039 HW9480086-A Bearing 4

5040 6912DU Bearing 1

5041 6808LLU Bearing 2

5042 6905 Bearing 1

5043 HW9405901-1 Washer 1

5044 BG3000-15X19 Ring 1

5045 HW0312827-1 Gear 1

5046 HW0312828-1 Gear 1

5047 HW0313631-1 Gear 1

5048 HW0313631-1 Gear 1

5049 HW0201297-A Shaft 1

5053 HW1300244-1 Flange 1

5054 HW0314705-1 Flange 1

11-10

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11 Parts List

11.5 Wrist Unit

Table 11-5: Wrist Unit

No. DWG No. Name Pcs

5055 HW9302630-3 Housing 1

5056 HW0102233-1 U-arm 1

5057 HW0102491-1 Wrist 1

5058 HW0201226-1 Cover 1

5059 HW0414884-1 Cover 1

5060 HW0412694-* Shim *

5068 HW0412683-* Shim *

5075 HW0412695-* Shim *

5082 HW0412696-* Shim *

5089 HW9404651-1 Washer 1

5090 M8X85 Socket screw 12

5091 2H-8 Spring washer 12

5092 M4X12 GT-SA bolt 17

5093 M5X16 Socket screw 10

5094 2H-5 Spring washer 10

5095 M5X35 Socket screw 6

5096 2H-5 Spring washer 6

5097 M4X25 Socket screw 6

5098 2H-4 Spring washer 6

5099 M4X6 H set screw 1

5100 M8X18 GT-SA bolt 8

5102 M6X30 GT-SA bolt 10

5103 M6X20 Socket screw 1

5104 2H-6 Spring washer 1

5105 M6X25 Socket screw 16

5106 2H-6 Spring washer 16

5107 M8X25 Socket screw 12

5108 2H-8 Spring washer 12

5109 M6X16 Socket screw 1

5110 2H-6 Spring washer 1

5111 M8X20 Socket screw 16

5112 2H-8 Spring washer 16

5113 M4X14 Socket screw 4

5114 2H-4 Spring washer 4

5115 M5X7 Magic screw 6

3017 HW0102239-2 Casing 1

11-11

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69 of 69

INSTRUCTIONS

HEAD OFFICE
2-1 Kurosakishiroishi, Yahatanishi-ku, Kitakyushu 806-0004, Japan
Phone [phone] Fax [phone]

YASKAWA America Inc. (Motoman Robotics Division)
100 Automation Way, Miamisburg, OH 45342, U.S.A.
Phone [phone] Fax [phone]

YASKAWA Europe GmbHRobotics Divsion )
Yaskawastrasse 1, 85391 Allershausen, Germany
Phone [phone] Fax [phone]

YASKAWA Nordic AB
Bredbandet 1 vån. 3 varvsholmen 392 30 Kalmar, Sweden
Phone [phone] Fax [phone]

YASKAWA Electric (China) Co., Ltd.
22/F One Corporate Avenue No.222, Hubin Road, Huangpu District, Shanghai 200021, China
Phone [phone] Fax 㧗86-21-5385-3299

YASKAWA SHOUGANG ROBOT Co. Ltd.
No7 Yongchang North Road, Beijing E&T Development AreaChina 100176
Phone

[phone]

Fax

[phone]

YASKAWA India Private Ltd. (Robotics Division)
#426, Udyog Vihar, Phase- IV,Gurgaon, Haryana, India

YASKAWA Electric Korea Co., Ltd
9F, KyoboSecuritiesBldg., 26-4, Yeouido-dong,Yeongdeungpo-gu, Seoul 150-737, Korea
Phone [phone] Fax [phone]

YASKAWA Electric Taiwan Corporation
12F, No.207, Sec. 3, Beishin Rd., Shindian District, New Taipei City 23143, Taiwan

YASKAWA Electric (Singapore) PTE Ltd.
151 Lorong Chuan, #04-02A, New Tech Park, Singapore 556741
Phone [phone] Fax [phone]

YASKAWA Electric (Thailand) Co., Ltd.
252/125-126 27th Floor, Tower B Muang Thai-Phatra Complex Building,
Rachadaphisek Road㧘Huaykwang, Bangkok 10320, Thailand
Phone

[phone]

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

Fax [phone]Phone [phone]

Fax [phone]Phone [phone]

Fax

[phone]

Fax [phone]Phone [phone]

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

MANUAL NO.

HW0485739

4