Instructions - Motoman...– Check for problems in manipulator movement. – Check for damage to...

MOTOMAN-EP4000DINSTRUCTIONSTYPE: YR-EP4000D-*6* (PARALLEL LINK HAND SPECIFICATION)TYPE: YR-EP4000D-*7* (FIXED HAND SPECIFICATION) YR-EP4000D-*72 (SPECIAL FLANGE SPECIFICATION)

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

Part Number: 163305-1CDRevision: 1

MOTOMAN INSTRUCTIONSMOTOMAN-EP4000D INSTRUCTIONSDX100 INSTRUCTIONSDX100 OPERATOR’S MANUALDX100 MAINTENANCE MANUAL

The DX100 operator’s manual above corresponds to specific usage. Be sure to use the appropriate manual.

MANUAL NO.

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EP4000D

MANDATORY• This instruction manual is intended to explain mainly on the

mechanical part of the MOTOMAN-EP4000D for the application to the actual operation and for proper maintenance and inspection. It describes on safety and handling, details on specifications, necessary items on maintenance and inspection, to explain operating instructions and maintenance procedures. Be sure to read and understand this instruction manual thoroughly before installing and operating the manipulator.

• General items related to safety are listed in Chapter 1: Safety of the DX100 Instructions. To ensure correct and safe operation, carefully read the DX100 Instructions before reading this manual.

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

or shields removed for clarity. Be sure all covers and shields are replaced before operating this product.

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

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

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

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

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Notes for Safe OperationRead this manual carefully before installation, operation, maintenance, or inspection of the DX100.

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

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

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

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

CAUTIONIndicates 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.

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

PROHIBITEDMust never be performed.

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

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EP4000D

WARNING• 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

TURN

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

– 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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EP4000D

Definition of Terms Used Often in This ManualThe MOTOMAN is the YASKAWA industrial robot product.

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

In this manual, the equipment is designated as follows:

CAUTION• Perform the following inspection procedures prior to conducting

manipulator teaching. If problems are found, repair them immediately, and be sure that all other necessary processing has been performed.

– Check for problems in manipulator movement.

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

• Always return the programming pendant to the hook on the cabinet of the 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:

Equipment Manual Designation

DX100 Controller DX100

DX100 Programming Pendant Programming Pendant

Cable between the manipulator and the controller

Manipulator cable

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Explanation of Warning LabelsThe 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 Location

Nameplate

WARNINGDo not enterrobot work area.

WARNINGMoving partsmay causeinjury

WARNING Label B:

WARNING Label A:

A B7BC

1BC 2BC 3BC 4BC 5BC 6BC

Nameplate

WARNING label A

WARNING label A

WARNING label B

WARNING label B

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EP4000D Table of Contents

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

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

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

2 Transporting.................................................................................................................................... 2-1

2.1 Transporting Method.......................................................................................................... 2-1

2.1.1 Using a Crane ...................................................................................................... 2-1

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

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

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

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

3.2.1 Manipulator Base Mount....................................................................................... 3-3

3.2.2 Location ................................................................................................................ 3-4

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

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

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

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

4.2.2 Connection to the DX100 ..................................................................................... 4-2

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

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

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

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

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

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

5.6 Alterable Operating Range ................................................................................................ 5-4

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

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

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

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

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

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

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

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Table of Contents

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8.1 Position 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 and Exchange Procedures ........................................... 9-7

9.3.1 Grease Replenishment and Exchange for S-Axis Speed Reducer and Gear ......9-79.3.1.1 Grease Replenishment............................................................................ 9-89.3.1.2 Grease Exchange....................................................................................9-8

9.3.2 Grease Replenishment and Exchange for L-Axis Speed Reducer.....................9-109.3.2.1 Grease Replenishment.......................................................................... 9-109.3.2.2 Grease Exchange..................................................................................9-11

9.3.3 Grease Replenishment and Exchange for U-Axis Speed Reducer ....................9-129.3.3.1 Grease Replenishment.......................................................................... 9-129.3.3.2 Grease Exchange..................................................................................9-13

9.3.4 Grease Replenishment and Exchange for R-, B-, and T-Axis Gear ...................9-149.3.4.1 Grease Replenishment.......................................................................... 9-149.3.4.2 Grease Exchange..................................................................................9-15

9.3.5 Grease Replenishment and Exchange for R-Axis Speed Reducer ....................9-169.3.5.1 Grease Replenishment.......................................................................... 9-169.3.5.2 Grease Exchange..................................................................................9-17

9.3.6 Grease Replenishment and Exchange for B-Axis Speed Reducer and Gear ....9-189.3.6.1 Grease Replenishment.......................................................................... 9-189.3.6.2 Grease Exchange..................................................................................9-19

9.3.7 Grease Replenishment and Exchange for T-Axis Speed Reducer and Gear.....9-209.3.7.1 Grease Replenishment.......................................................................... 9-209.3.7.2 Grease Exchange..................................................................................9-21

9.3.8 Grease Replenishment for L-Axis Cross Roller Bearing.....................................9-22

9.3.9 Grease Replenishment for Tapered Roller Bearing in the Link Part...................9-23

9.3.10 Grease Replenishment for Balancer Link Part .................................................9-24

9.3.11 Notes for Maintenance......................................................................................9-26

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

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EP4000D Table of Contents

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

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

11.2 L- and U-Axis Unit.......................................................................................................... 11-5

11.1 Balancer Unit ................................................................................................................. 11-9

11.4 R-, B-, and T-Axis Unit................................................................................................. 11-11

11.5 Shaft Unit ..................................................................................................................... 11-13

11.6 U-Arm Unit ................................................................................................................... 11-16

11.7 Wrist Unit ..................................................................................................................... 11-19

11.8 Link Unit....................................................................................................................... 11-23

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1 Product Confirmation1.1 Contents Confirmation

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1 Product Confirmation

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

• DX100

• Programming pendant

• Manipulator cables (6 cables, between the DX100 and the manipulator)

CAUTION• 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.

NOTE

Connectors for manipulator cables are located on different positions depending on manipulator types.

Manipulator cableconnector

The left side of the front

The back side

The right side of the front


EP4000D-K**

EP4000D-J** EP4000D-L**

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EP4000D 1 Product Confirmation1.2 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

THE MANIPULATOR AND THE CONTROLLERSHOULD HAVE SAME ORDER NUMBER.

ORDER NO.

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

Label (Enlarged View)

(a) DX100 (Front View) (b) Manipulator (Top View)

PROGRAMMING PENDANT

YCEG N

OT P

ME

E

S

R

ON

TRIP

PEDRESET

OFF

DX100

NJ2960-1MADE IN JAPAN

ORDER NO.NJ1529

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2 Transporting2.1 Transporting Method

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2 Transporting

2.1 Transporting Method

2.1.1 Using a Crane

As a rule, the manipulator should be lifted by a crane with a four-leg bridle sling using the attached eyebolts when removing it from the package and moving it.

Be sure the manipulator is lifted in the posture as shown in Fig. 2-1 Transporting Position on page 2-2.

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 transporting.

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

NOTE

• Check that the eyebolts are securely fastened.

• The mass of the manipulator is approximately 3200 kg including the shipping bolts and brackets. 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.

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

• Avoid external force on the arm or motor unit when transporting. Use caution when using transporting equipment other than a crane or forklift, as injury may occur.

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EP4000D 2 Transporting2.1 Transporting Method

Fig. 2-1: Transporting Position

A B7BC


A B7BC


3

C

2

1

A

B

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2 Transporting2.2 Shipping Bolts and Brackets

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2.2 Shipping Bolts and Brackets

The manipulator is provided with shipping bolts and brackets as illustrated at , , and . (Refer to Fig. 2-1 Transporting Position on page 2-2.)

• The shipping bolts and brackets illustrated at , , and are painted in yellow.

• Followings are the details of the shipping bolts and brackets fixing bolts.

Table 2-1: Shipping Bracket Fixing Bolts

Bolt Position Bolt Type Pcs.

A Hexagon socket head cap screw: M12 (length: 30 mm) (Tensile strength: 1200 N/mm2 or more)

3

B Hexagon nut: M12 2

C Hexagon nut: M12 2

NOTEBefore turning ON the power, check to be sure that the shipping bolts and brackets have been 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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EP4000D 3 Installation

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 DX100 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.

CAUTION• Do not install or operate a manipulator that is damaged or lacking in

parts.

Failure to observe this caution may cause injury or damage.

• Before turning ON the power, check to be sure that the shipping bolts and brackets explained in Fig. 2-1 Transporting Position on page 2-2 are removed.

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

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3 Installation3.1 Installation of Safeguarding

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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 (ISO 10218)

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 BaseThe 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 as shown in Table 3-1 Maximum Repulsion Forces of the Manipulator on page 3-3.

During installation, if the flatness is not right, the manipulator shape may be deformed and its functional ability may be compromised. The flatness for baseplate must be kept at 0.5 mm or less. Fix the manipulator base as described in Section 3.2.1 “Manipulator Base Mount” on page 3-3.

NOTE

Connectors for manipulator cables are located on different positions depending on manipulator types.

Confirm the correct position of the manipulator cable before Installing the manipulator.


The left side of the front

The back side

The right side of the front


EP4000D-K**

EP4000D-J** EP4000D-L**

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EP4000D 3 Installation3.2 Mounting Procedures for Manipulator Base

3.2.1 Manipulator Base Mount

Design and construct the manipulator base mount so that it can bear the torque shown in Table 3-1 Maximum Repulsion Forces of the Manipulator and Table 3-2 Maximum Torque during Acceleration and Deceleration. The vibration in the manipulator base must be 4.9 m/s2 (0.5G) or less when the manipulator is individually operated.

The manipulator base has 12 mounting holes. Mount the manipulator base firmly by using the hexagon socket head cap screws M24 (tensile strength: 1000 N/mm2 or more, recommended length: 90 mm).

Fig. 3-1: Manipulator Base Mount

Table 3-1: Maximum Repulsion Forces of the Manipulator

Maximum horizontal rotating torque(S-axis moving direction)

88200 N•m (9000 kgf•m)

Maximum vertical rotating torque(LU-axis moving direction)

137340 N•m (14000 kgf•m)

Table 3-2: Maximum Torque during Acceleration and Deceleration

Maximum horizontal torque(S-axis moving direction)

44145 N•m(4500 kgf•m)

Maximum vertical torque(LU-axis moving direction)

68670 N•m(7000 kgf•m)

Hexagon socket head cap screw M24 (length: 90 mm)

1

2 Torque

Torque

Spring washer

Washer

Manipulator base

Manipulator base mount

45

Unit: mm

A B7BC


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3 Installation3.2 Mounting Procedures for Manipulator Base

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3.2.2 Location

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

• Ambient temperature: 0 to +45C

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

• Free from exposure to water, oil, or dust

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

• Free from large electrical noise (plasma)

• Shock or vibration from the press must be 9.8 m/s2 (1.0G) or less.

• Free from excessive shock or vibration: 4.9 m/s2 (0.5G) or less when the manipulator is operated individually (with no vibration from other equipment such as the press). (Excessive vibration affects the mechanism.)

• The flatness for installation is 0.5 mm or less.

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EP4000D 4 Wiring

4 Wiring

WARNING• Ground resistance must be 100 or less.

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

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

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

CAUTION• Wiring must be performed by authorized or certified personnel.

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

• Do not cover the cable with heat insulating material, and avoid multiple cabling when laying manipulator cables from the manipulator to the DX100.

Failure to observe this caution may result in burn caused by cable heat emission failure.

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4 Wiring4.1 Grounding

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4.1 Grounding

Follow electrical installation standards and wiring regulations for grounding. A ground wire of 8.0 mm2 or more is recommended.

Refer to Fig. 4-1 Grounding Method on page 4-2 to connect the ground line directly to the manipulator.

Fig. 4-1: Grounding Method

4.2 Manipulator Cable Connection

6 manipulator cables are delivered with the manipulator; an encoder cable (1BC) and power cables (2BC to 6BC). 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 Connection (DX100 Side) on page 4-4.

4.2.1 Connection to the Manipulator

Before connecting the cables to the manipulator, verify the numbers on both the 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, 3BC, 4BC, 5BC, 6BC, and 1BC. After inserting the cables, depress the lever until it clicks.

4.2.2 Connection to the DX100

Before connecting the cables to the DX100, verify the numbers on both the cables and the connectors on the DX100. When connecting, adjust the cable connector positions to the main key positions of the DX100 connectors, and insert cables in the order of X21, X22, X23, X24, X25, and X11, and depress each lever low until it clicks.

NOTE

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

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

Bolt M8 (for grounding)Delivered with the manipulator

View A

AA B

7BC


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EP4000D 4 Wiring4.2 Manipulator Cable Connection

Fig. 4-2: Manipulator Cables

CAUTION• Do not cover the cable with heat insulating material, and avoid

multiple cabling when laying manipulator cables from the manipulator to the DX100.

Failure to observe this caution may result in burn caused by cable heat emission failure.

Encoder cable

Power cable

Power cable

Power cable

Power cable

Power cable

X11

X21

X22

X23

X24

X25

1BC

6BC

4BC

5BC

3BC

2BC

X25 6BC

X24 5BC

X23 4BC

X22 3BC

X21 2BC

X11 1BC

1BC

Manipulator sideDX100 side

2BC

3BC

4BC

5BC

6BC

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4 Wiring4.2 Manipulator Cable Connection

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

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

A B7BC


A B7BC


Main key position

X22X21

X11

X23

X24

X25

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EP4000D 5 Basic Specifications5.1 Basic Specifications

5 Basic Specifications

5.1 Basic SpecificationsTable 5-1: Basic Specifications1)

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

Item ModelMOTOMAN-EP4000D-*6* MOTOMAN-EP4000D-*7*

MOTOMAN-EP4000D-*72

Configuration Vertically Articulated

Degree of Freedom 6

Payload 100 kg2)

2 Payload at the parallel link hand flange part

200 kg

Repeatability3)

3 Conforms to ISO9283

±0.5 mm

Motion Range S-Axis (turning) -150+150

L-Axis (lower arm) -122+25

U-Axis (upper arm) -70+53

R-Axis (wrist roll) -360+360

B-Axis (wrist pitch/yaw) -120+85 -120+120

T-Axis (wrist twist) -70+70 -360+360

Maximum Speed S-Axis 1.57 rad/s, 90/s

L-Axis 1.57 rad/s, 90/s

U-Axis 1.57 rad/s, 90/s

R-Axis 0.62 rad/s, 35.5/s 1.40 rad/s, 80/s

B-Axis 1.40 rad/s, 80/s

T-Axis 2.79 rad/s, 160/s

Mass 3100 kg

Ambient Conditions Temperature 0 to 45C

Humidity 20 to 80% RH (non-condensing)

Vibration Acceleration Less than 9.8 m/s2 (1.0G)

Others Free from corrosive gas or liquid, or explosive gas or liquidFree from water, oil, or dustFree from excessive electrical noise (plasma)

Power Capacity 22 kVA

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5 Basic Specifications5.2 Part Names and Working Axes

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5.2 Part Names and Working Axes

Fig. 5-1: Part Names and Working Axes

5.3 Manipulator Base Dimensions

Fig. 5-2: Manipulator Base Dimensions

Rotary head(S-head)

Lower arm(L-arm)

Manipulator base

Upper arm(U-arm)

Wrist

Wrist flange

A B7BC


R+

U+

R-

B+ B-

T-

U-

L- S-

T+

L+

S+

28 dia. holes(12 holes)

12 dia. reamed hole+0.018 0

12 dia. reamed hole+0.018 0

A B7BC


475

640

640

860

45

70

860

760

760A 350±0.2

410±

0.2

350±0.2

410±

0.2

Unit: mm

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EP4000D 5 Basic Specifications5.4 Dimensions and P-Point Maximum Envelope

5.4 Dimensions and P-Point Maximum Envelope

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

P-p

oint

P-po

int m

axim

um en

velop

e

Ser

vo O

N la

mp

(red

)(o

ptio

nal)

152

300

1681

380

44 110

A

R35

05 803

2110

R1033

250

550

122°

1100

210

150°

150°

755

53°

527

2135

25°

70°

3505

3878

1803

542

1823

255

740

588

555

467

690

261 0

373

1874

53°

View

A

2500 (with the lamp)2480 (without the lamp)

70 dia.(lamp dia.)

Tapp

ed h

ole

M10

(pitc

h: 1

.5)

(dep

th: 2

5)(4

hol

es)

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5 Basic Specifications5.5 B-Axis Operating Range

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5.5 B-Axis Operating Range

The B-axis operates keeping the constant angle to the center of U-arm as shown in Fig.5-4 B-Axis Operating Range.

Fig. 5-4: B-Axis Operating Range

5.6 Alterable Operating Range

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

U-axis rotation center

B-axis rotation center

S-axis rotation center

L-axis rotation center

120°120°

Table 5-2: S-Axis Operating Range

Item Specifications

S-Axis Operating Range -150° - +150° (standard)-120° - +120° -90° - + 90° -60° - + 60° -30° - + 30°

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EP4000D 6 Allowable Load for Wrist Axis and Wrist Flange6.1 Allowable Wrist Load

6 Allowable Load for Wrist Axis and Wrist Flange

6.1 Allowable Wrist Load

The allowable wrist load including the mass of the gripper is 200 kg.

This section explains the allowable values and conditions.

As shown in Table 6-1 Moment and Total Moment of Inertiabelow, there are limitations in moment and moment of inertia: fulfill the requirement in the table when operating the manipulator.

Table 6-1: Moment and Total Moment of Inertia1)

1 Allowable wrist load is based on an assumption that the robot is handling aworkpiece horizontally by keeping its wrist flange downwards.

Axis Moment N•m (kgf•m) 2)

2 ( ): Gravitational unit

GD2/4 Total Moment of Inertia kg•m2

R-axis 1274 (130) 84.5

B-axis 2156 (220) 330

T-axis 0 (0) 80

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6 Allowable Load for Wrist Axis and Wrist Flange6.2 Wrist Flange

163305-1CD

EP4000D

6.2 Wrist Flange

The wrist flange dimensions are shown in Fig. 6-1 Wrist Flange on page 6-2. 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 8 mm or less.

Fig. 6-1: Wrist Flange

(255

from

P-p

oint)

(227

from

P-p

oint)

T-axis flange (movable side)B-axis flange (fixed side)

8 dia. (2 holes) (depth: 8)+0.015 0

8 dia. (2 holes) (depth: 8)+0.015 0

40 dia.0-0.016

170 dia. 0-0.025

236 dia. 0-0.029

Tapped hole M10 (3 holes)(depth: 15) (pitch: 1.5)

Tapped hole M10 (8 holes) (depth: 18) (pitch: 1.75)Tapped hole M8 (6 holes)(depth: 15) (pitch: 1.25)


8

85

214

55°

55°

45°

55°

25°

55°

30°

60° 30°

30°

30°

30°

30°60°

30°

30°

45°

PCD58

PCD212

12.5°

12.5

°

-*7* (Fixed hand specification)-*6* (Parallel link hand specification)

PCD100PCD126

-*72 (Special flange specification)

Units: mm

8 dia. (2 holes) (depth: 8)

+0.015 0

8 dia. (2 holes)(depth: 8)

+0.015 0





55°30°

30°

30°

55°

45°

12.5

°

12.5°

60°

45°

45°

15°

25°

30°

30°

30°

30°

55°75°

55°

60°

60°

45°

218

PCD58

PCD212

PCD100PCD126

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

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163305-1CD

EP4000D 7 System Application7.1 Peripheral Equipment Mounts

7 System Application

7.1 Peripheral Equipment Mounts

When peripheral equipment is attached to the U-arm, the following conditions described in Table 7-1 Conditions for Installationand Fig.7-1 Installing Peripheral Equipmentshould be observed.

Fig. 7-1: Installing Peripheral Equipment

A B7BC


100

794.

5

16.5

160

100

60

Unit: mm

1495

.5

140

94

B

A

Tapped hole M8 (2 holes) (2 places)(depth: 15) (pitch: 1.25)

Tapped hole M8 (2 holes) (2 places)(depth: 15) (pitch: 1.25)

Table 7-1: Conditions for Installation

Application Note

A Cabling Up to 200 kg including the peripheral equipment mass attached to the wrist unit

B Cabling and valve, etc. mounting

Up to 10 kgUp to 25 N•m (2.5 kgf•m) for moment increase amount of upper arm

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7 System Application7.2 Internal User I/O Wiring Harness and Air Lines

163305-1CD

EP4000D

7.2 Internal User I/O Wiring Harness and Air Lines

Internal user I/O wiring harness (0.5 mm2 34 wires) and two air lines are incorporated in the manipulator for the drive of peripheral devices mounted on the upper arm as shown in Fig.7-2 Connectors for Internal I/O Wiring Harness and Air Lines.

The connector pins are assigned as shown in Fig.7-2 Connectors for Internal I/O Wiring Harness and Air Lines.

Wiring must be performed by users.

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

The allowable current for internal user I/O wiring harness

6.6 A or less for each wire(The total current value for pins 1 to 34 must be 60 A or less.)

The maximum pressure for the air line

490 kPa (5 kgf/cm2) or less(The air line inside diameter:8 mm dia.)

Connector for internal user I/O wiring harness:JL05-2A28-21PC (pin connector with a cap)Prepare socket connector JL05-6A28-21S.

Air inlet BTapped hole PT3/8 with a pipe plug

Air inlet ATapped hole PT3/8 with a pipe plug

Exhaust port A (air flow)Tapped hole PT3/8 with a pipe plug

Exhaust port B (air flow)Tapped hole PT3/8 with a pipe plug

Connector for internal userI/O wiring harness:JL05-2A28-21SC (socket connector with a cap)Prepare pin connector:JL05-6A28-21P.

A B7BC


3433323130292827262524

2726 28252423

222019 21181716

12

45

3

67

3 42

11

141312

109

1615

8

1

15

9

3231

36

14

87

13

33

21

2322

1918

20

10

29 30

34

5

11

6

35

12

17

7BCAIR1 AIR2

AIR

1A

IR2

AIR

1A

IR2

0.5 mm2 , 34 pins

Pin details for internal user I/O wiring harness

Pins used

Internal user I/O wiring harness

7-2

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163305-1CD

EP4000D 8 Electrical Equipment Specification8.1 Position of Limit Switch

8 Electrical Equipment Specification

8.1 Position of Limit Switch

• “YR-EP4000D-**0”Equipped with an overrun limit switch for the S-axis. Refer to Fig.8-1(a Location of Limit Switches for the location.

• “YR-EP4000D-**1”Equipped with overrun limit switches for the S- and L-axes, and an interference limit switch for the L- and U-axes. Refer to Fig.8-1(a Location of Limit Switches for the locations.

Fig. 8-1(a): Location of Limit Switches

• The L-axis overrun limit switch and the L- and U-axis interference limit switch electrically restrict the ranges of each subject axis motion by adjusting the dog position. The mechanical stopper is effective at the P-point maximum envelope, and its position cannot be changed.

• The power supply to the manipulator will be cut off once the limit switch is activated, resulting in an emergency stop of the manipulator. Refer to “8.9 Overrun/Tool Shock Sensor Releasing” in “DX100 INSTRUCTIONS” to release the manipulator from the overrun status.

• The limit switches are set at the P-point maximum envelope before the shipment.

• Adjustable range of the L-axis overrun limit switchAs shown in Fig. 8-1(b) L-axis Overrun Limit Switch Adjustable Range on page 8-2, L-axis is adjustable within the range between 26° to the plus (+) direction and 123° to the minus (-) direction. However, the least adjustable range of motion is 16°. The L-axis can be set at any degrees within the above mentioned range as long as it is set at 16° or more.

L-axis overrun limit switchonly for YR-EP4000D-**1

L- and U-axis interference limit switchonly for YR-EP4000D-**1

S-axis overrun limit switch

NOTEIn the case of re-adjusting the operating range of each subject axis, it is also required to change the dog location and limit values in software. Contact your Yaskawa representative if re-adjustment is required.

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8 Electrical Equipment Specification8.2 Internal Connections

163305-1CD

EP4000D

Fig. 8-1(b): L-axis Overrun Limit Switch Adjustable Range

• Adjustable range of the L-U-axis interference limit switchThe limit switch for the L- and U-axis interference is designed to check the interference angle between the L- and U-axes. Set the interference angle between the L- and U-axes within the range from 19° to 161° as shown in Fig.8-1(c L- and U-axis Interference Limit Switch Adjustable Range.

Fig. 8-1(c): L- and U-axis Interference Limit Switch Adjustable Range

8.2 Internal Connections

Diagrams for internal connections of the manipulator are shown in Fig. 8-2(a) Internal Connection Diagram on page 8-3 and Fig. 8-2(b) Internal Connection Diagram on page 8-4.

A B7BC


123°

123°

26°

16° o

rmo

re

Less than16°

L-axis rotation center

L-arm

<Example>

plus (

+) si

de

minus (-) side

Minus (-) sidenot adjustable

Plus (+) sideadjustable

26°

A B7BC


19°

161°

U-arm

U-axis rotation center

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HW1480584 32/87

8 Electrical Equipment SpecificationUP400RD 8.2 Internal Connections

HW1480584

HW1480584

Fig. 8-2(a): Internal Connection Diagram

S-, L-, and U-axes Limit Switch Specification

Note:1. This internal connection diagram is for MOTOMAN-EP4000D.2. The limit switch specification has the different connections at parts.A B

LC3LD4

LC2LD2

LC5LC5LC3LD4

LD2LD1

LD1

LC1LD1

LC2LD2LD2

LD1LC1

L AND U-AXIS INTERFERENCE L.S.

L-AXIS OVERRUN L.S.

S-AXIS OVERRUN L.S.

LA3LB4

LA2LB2

LA5LA5LA3LB4

LB2LB1

LB1

LA1LB1

LA2LB2LB2

LB1LA1

L AND U-AXIS INTERFERENCE L.S.

L-AXIS OVERRUN L.S.

S-AXIS OVERRUN L.S.

DX1001BC(10P x 4)

Connected to

Connected to

Connected to

B3

B2

B1

-G-H-S-T-D

-J

-G-H-S-T-D

-J

0BAT6BAT6

PG5V6

TN

PG0V6

0BAT5BAT5

PG5V5

BN

PG0V5

R

0BAT4

PG0V4PG5V4

BAT4N

U

0BAT3

PG0V3PG5V3

BAT3N

L

0BAT2

PG0V2PG5V2

BAT2N

S

0BAT1BAT1

PG5V1PG0V1

-1-2-3-4

No.19CN

X

0V+24V

0V+24V

No.22CN

-2-4

-1-3

-6-5-4-9

-6-5-4-9

-6-5-4-9

-G-H-S-T

S-AXISPGDATA-1DATA+1

-D

0V

BATOBT+5V

1CN-CNo.1CN

0BAT2

0BAT3BAT2

BAT3

BAT11819

2122

20

0BAT4

0BAT5

0BAT6BAT5

BAT4

2425

2829

2726

23

17 0BAT1BAT0BTBAT

P

P 4

23

BAT110BAT12BAT12

0BT

0BTBATP

BATP 6

87

5 0BAT21

BAT220BAT22BAT21

K

K

K

K

R

R

R

R

0BAT1110BT

BAT6

PG0V2PG5V1PG0V1

3031

32132

PG0V3

PG0V5

PG0V4PG5V4

PG5V35

9

78

6

4 PG5V2

P

P

P

PG5V6PG0V6

1211

16151413

10 PG5V5

12

543

876

1BC(10P x 4)

31

42

0V+24V

0V+24V

SPG-1SPG+1

P

P

P

CN1-5

CN1-2CN1-1

CN1-9CN1-10

CN1-4

L-AXISPG

U-AXISPG

DATA+2

FG1

BATOBT

-J

2CN-CNo.2CN

BAT

0VFG2

+5VOBT

DATA-2

DATA-3DATA+3

BAT

BAT3CN-CNo.3CN

OBT

0VFG3

OBT

+5V

OBT

R-AXISPG

B-AXISPG

DATA+4DATA-4-2

OBTBAT

4CN-1No.4CN

-10OBTBAT

FG40V+5V

DATA+5DATA-5-2

0V

BATOBT+5V

5CN-1

DATA+6

-10OBTBAT

FG5

6CN-1No.6CN

No.5CN

BAT

P

P

P

P

P

P

FG1

P

P

P

P

P

P

T-AXISPG

-10

BAT

0V

OBT+5V

FG6

BATOBT

P

P

P -2 DATA-6

CN1-3

CN1-5CN1-4

CN1-10CN1-9

0V

0V+24V

+24V

CN1-1CN1-2 SPG-1

SPG+1

CN1-3 FG1

Connected to

Connected to

Connected to

A3

A2

A1

LD2LD1

LD2LC2

LB2LB1

LB2LA2

LD1LD2

LD4LC3 OVERRUN L.S.

AL2AL2

2-L-AXISFOR FAN

AL3

ALM

AL2AL2 AL1 AL2AL3 AL2AL2AL1 AL1

ALM

AL1AL2

LB1LB2

LB4LA3

BC2BC1

23456

89

10

7

1

1213141516

18

192021

17

222324252627282930

31

11

3334

32

E

E7BC(28-21)

OVERRUN L.S.

S-AXISALM

FOR FAN

FOR LAMP(OPTION)

AL1AL2

CASINGOR

B3

A3B2

A2

B1

A1

33/87

8-3

EEEEEEE

P CN4-7CN4-2CN4-2

CN4-7

AL1AL2

P CN3-10CN3-9CN3-9

CN3-10

+24VB2

CN4-3P CN4-8

CN4-3 +24V

CN4-8 BC2

P CN2-5CN2-4CN2-4

CN2-5

+24VLD1

+24VCN4-4SS2P CN4-5

CN4-4 +24V

CN4-5 SS2

0VCN4-10CN4-10 0V

P CN4-6CN4-1CN4-1

CN4-6

+24VLB1

E

-1-2-3

No.24C

-4

-1-2-3

No.23C

-4

-4-3-2-1No.22C

-4-3-2-1No.21C

-4-3-2-1No.20C

SPG+2

FG2

SPG-2P CN1-7CN1-6

CN1-8

SPG-3SPG+3

FG3

P

CN2-3

CN2-2CN2-1

SPG+4SPG-4

FG4

P CN2-7CN2-6

CN2-8

SPG-5SPG+5

SPG+6

FG5

P

CN3-6

CN3-3

CN3-2CN3-1

FG6CN3-8

SPG-6P CN3-7

CN1-6 SPG+2

CN1-7

CN1-8 FG2

SPG-2

CN2-1CN2-2 SPG-3

SPG+3

CN2-3 FG3

CN2-6CN2-7

SPG+4SPG-4

CN2-8 FG4

CN3-1CN3-2

SPG+5SPG-5

CN3-6

CN3-3

SPG+6

FG5

CN3-7

CN3-8 FG6

SPG-6

LC1LD1

LA1LB1

LD1 S-AXISLC1LD1

+24V

LB1

+24V

S-AXIS

7BC-34

247BC-2325

282726

32

3029

7BC-257BC-24

7BC-277BC-26

7BC-307BC-297BC-28

7BC-327BC-33

7BC-313334

31

E MANIPULAT

LA1LB1

SS2SS1

B2B1

EE EE

EEBASE

SP1SP2

+24V

+24V

B2

BC2

AL1AL2

EE7BC(28-21)

21

43

5

11109

78

6

1312

16

1415

1819

2120

17

7BC-27BC-1

7BC-47BC-3

7BC-9

7BC-11

7BC-77BC-8

7BC-6

7BC-10

7BC-5

7BC-137BC-12

7BC-187BC-197BC-207BC-21

7BC-167BC-17

7BC-147BC-15

23227BC-22

8 Electrical Equipment SpecificationEP4000D 8.2 Internal Connections

HW1480584

HW1480584

Fig. 8-2(b): Internal Connection Diagram

No.16CN

YBBB5BA5

-2CN16-1

No.18CN

MV6MU6

-B

No.17CN

-C

CN17-A

BB6

ME6

BA6

MW6

-2CN18-1

-D

No.14CN

E

CN1-1CN1-2CN1-3CN1-4CN1-5CN1-6CN3-1

CN3-2CN3-3

CN5-1

CN3-4CN3-5CN3-6

CN5-2CN5-3CN5-4CN5-5

3BC(6X4)

ME1

Type A

MW1MW1MW1MW1MW1MW1MW1MW1MW1

ME1ME1ME1ME1ME1ME1ME1

E

CN1-6CN3-1

CN1-2

CN1-4CN1-3

CN1-1

CN1-5

CN3-2CN3-3

CN3-4CN3-5CN3-6

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

CN5-1

MV1

MU1

MV1MV1MV1MV1MV1MV1MV1MV1

MU1MU1MU1MU1MU1MU1MU1MU1

2BC(6X3)

AC1AC2

AC1AC2

AC1AC2 AC2

AC1

AC1AC2

AC1AC2

L-AXISFAN

L-AXISFANAC2AC1

YB

YB

No.8CN

YB

SM B-AXISME5MW5MV5MU5

-D

-B-C

No.15CNCN15-A

YB

SM R-AXISMV4MU4

-B

No.13CN

-C

CN13-A

BB4

ME4

BA4

MW4

-2CN14-1

-D

SM T-AXIS

YB

ME1ME1ME1ME1ME1ME1ME1


CN3-6CN3-5CN3-4

CN3-3CN3-2CN3-1CN1-6CN1-5CN1-4CN1-3CN1-2

MW1MW1MW1MW1MW1MW1MW1MW1MW1

3BC(6X4) Type A

MU1MU1MU1MU1MU1MU1MU1MU1

MV1MV1MV1MV1MV1MV1MV1MV1

CN5-1


CN3-6CN3-5CN3-4

CN3-3CN3-2

E

ME1

CN5-1

SM S-AXIS

SM U-AXIS

SM L-AXIS

CN7-ANo.7CN

-D-C-B

ME1

MV1MW1

MU1

FAN S-AXIS

FOR FANAC2AC1

EType BType B

MU1

MV1

CN1-5

CN1-1

CN1-3CN1-4

CN1-2

CN3-1CN1-6

2BC(6X3)

CN1-1

34/87

8-4

AC2AC1 AC1

AC2

6BC(8X5)


CN2-1CN2-2CN2-3CN2-4CN2-5CN2-6CN2-7CN2-8

CN6-1CN6-2

CN5-2CN5-1

CN4-2CN4-3CN4-4CN4-5CN4-6CN4-7

CN6-3CN4-8

CN6-6CN6-5

CN5-4

CN6-4

CN5-3

CN4-1

AC1AC2

EType A

MV6

MU6MV6

MU6

BA6

BB4BA4

MU4

ME5ME5

ME2ME5

BA5

MU5MV5

MU5

MU5MU5

MV5

MW5MV5MV5

MW5

MW5MW5

MV4MW4ME4

E

CN1-3

CN1-5CN1-4

5BC(8X4)

CN1-1CN1-2

CN2-8CN3-1

CN2-1

CN2-3CN2-2

CN2-6CN2-5

CN2-7

CN2-4

CN1-7CN1-8

CN1-6

ME3

MU3

MW3

MV3

Type B

MU3MU3

MU3MU3MV3

MV3MV3MV3

MW3MW3MW3MW3

ME3

CN3-4CN3-3

CN4-1BA3

ME3ME3

CN3-2ME3

E4BC(8X4)

CN1-1

CN1-6CN1-7

CN1-5

CN1-3CN1-4

CN1-2

CN2-4

CN4-3CN4-2CN4-1



CN6-1CN4-4

MW2

ME2

ME2ME2

BA2ME2

ME2

MW2MW2MW2

MU2

MV2

MW2

MV2MV2

MV2

MV2

MU2MU2MU2MU2

Type A

CN5-6CN6-1

CN6-2

ME1BA1BB1

-BCN12-ANo.12CN

BA3BB3

CN10-A-B

No.10CNBA2BB2

CN8-A BA1-B BB1

CN6-4

CN6-2CN6-1

CN4-8CN6-3

CN4-7CN4-6CN4-5CN4-4CN4-3CN4-2CN4-1CN2-8CN2-7CN2-6CN2-5CN2-4CN2-3

ME4MW4MV4

MW5MW5

MV5

MW5

MV5

MU5MU5

MU5

MV5

BA5

ME5

ME5ME5

CN1-3CN1-2CN1-1 MU4

CN2-2CN2-1

BA4BB4

CN1-4

CN5-1

CN5-3CN5-4

CN5-2

BA6

MU6

MW6MV6

ME6

Type A6BC(8X5)

ME3ME3ME3ME3

MW3MW3MW3MW3

MV3MV3MV3

MV3MU3MU3

E

MU3MU3

Type B

CN1-2CN1-1

5BC(8X4)

MV3

MW3

CN1-8CN1-7CN1-6

CN1-4CN1-5

CN2-4

CN2-7

CN2-5CN2-6

CN2-2CN2-3

CN2-1

CN1-3 MU3

BA3CN4-1

CN3-3CN3-4

CN3-1CN3-2

CN2-8 ME3

BB1BA1ME1

CN6-2CN6-1CN5-6

CN9-A-B

No.9CNMU2MV2

-D ME2

CN11-A

-D-C-B

No.11CN

ME3

MV3MW3

MU3

MW2-C

EType A

MU2MU2MU2MU2

MV2

MV2

MV2MV2

MW2

MV2

MU2CN1-2

CN1-4CN1-3

CN1-5


CN1-6

CN1-1

4BC(8X4)

MW2MW2MW2

ME2

ME2BA2

ME2ME2

ME2

CN2-5CN2-6CN2-7CN2-8CN4-1CN4-2CN4-3CN4-4CN6-1

E

CN2-4 MW2

AC2AC1CN6-5

CN6-6

163305-1CD

EP4000D 9 Maintenance and Inspection9.1 Inspection Schedule

9 Maintenance and Inspection

9.1 Inspection ScheduleProper 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 displayed in six levels. Conduct periodical inspections according to the inspection schedule in Table 9-1 Inspection Items on page 9-2.

In Table 9-1, the inspection items are classified into three types of operation: 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 inspection work.

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, and do not 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.

NOTE

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

• For axes which are used very frequently (in handling applications, etc.), it is recommended that inspections be conducted at shorter Intervals. Contact your Yaskawa representative.

• Replace the S-, L-, and U-axis speed reducers at the second inspection (in 10000-hour cycle) as preventive maintenance.

9-1

HW1480584 35/87

9 M

aintenance and InspectionE

P4000D9.1

Inspection Schedule

9-2

163305-1CD

HW

1480584

Inspection Charge

Sp

ecif

ied

P

erso

nL

ice

ns

ee

Ser

vic

e C

om

pa

ny

dance and damage at the home position. • • •ioration of leads. • • •r spatter is present.ior cracks. • • •

• • • if necessary. • • • if necessary. • • •nd tighten if necessary. • • •

• • • for wear. • • for wear. • •s, and tighten if necessary. •n the main connector of connector base ually shaking the wire.

spring.5)

ycle).

• •

eness. • •

36/87

Table 9-1: Inspection Items (Sheet 1 of 3)

Items1) Schedule Method Operation

Dai

ly

50

0 H

Cy

cle

20

00H

Cyc

le

1s

t in

sp

ec

tio

n6

000

H

2n

d i

nsp

ec

tio

n

10

000

H2

nd

in

spe

cti

on

18

000

H

1 Alignment mark • Visual Check alignment mark accor2 External lead • Visual Check for damage and deter3 Working area and

manipulator • Visual Clean the work area if dust oCheck for damage and exter

4 LU-axis motor • Visual Check for grease leakage.2)

5 Manipulator base mounting bolts • Wrench Tighten loose bolts. Replace

6 Cover mounting screws • Screwdriver,

wrenchTighten loose bolts. Replace

7 S-, L-, U-, R-, B-, and T-axismotor connectors • Manual Check for loose connectors a

8 ConnectorBase • Manual Check for loose connectors.

9 Internal wiring harness in S-axis • Visual Remove the cover and check

10 Protective spring for internal wiring harness • Visual Remove the cover and check

Apply grease.11 L-axis balancer • Visual,

grease gunCheck for loose nuts or shaftSupply grease. 3)

12 Wire harness in manipulator 4) • Multimeter Check for conduction betwee

and each connector with manCheck for wear of protective Replace the wire (18000 H c

13 Limit switch dog (S-axis) • Screwdriver, wrench, multimeter

Check for dirt, damage, loosTighten if necessary. Check the operation.

9 M


P4000D9.1

Inspection Schedule

9-3

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1 • •

1 • •

1 by moving the L- and U-axes back • •

1 attery alarm occurs or the • •1 ecessary.)

Section 9.3.1 on page 9-7.e Section 9.3.1 on page 9-7.

• •

1 ecessary.) Section 9.3.2 on page 9-10 and

e Section 9.3.2 on page 9-10 and

• •

2 ecessary.) Section 9.3.4 on page 9-14. e Section 9.3.4 on page 9-14.

•

2 ecessary.) Section 9.3.5 on page 9-16. e Section 9.3.5 on page 9-16.

•

2 ecessary.) Section 9.3.6 on page 9-18 and

e Section 9.3.6 on page 9-18 and

•

T

I Inspection Charge

Sp

ecif

ied

P

erso

nL

icen

see

Ser

vice

Co

mp

an

y

37/87

4 Limit switch (L-axis) • Screwdriver, wrench, multimeter

Check for dirt, damage, looseness. Tighten if necessary. Check the operation.

5 L- and U-axis interferencelimit switch • Screwdriver,

wrench, multimeter

Check for dirt, damage, looseness. Tighten if necessary. Check the operation.

6 L- and U-axis arm connection parts • Visual,

manualCheck for a backlash of the bearing and forth, and up and down. Supply grease.

7 Battery pack in manipulator • Multimeter Replace the battery pack when the bmanipulator drove for 36000 H.

8 S-axis speed reducer • Grease gun Check for malfunction. (Replace if nSupply grease3) (2000H cycle). SeeReplace grease3) (6000H cycle). Se

9 L- and U-axis speed reducers • Grease gun Check for malfunction. (Replace if n

Supply grease3)(2000H cycle). SeeSection 9.3.3 on page 9-12.Replace grease3) (6000H cycle). SeSection 9.3.3 on page 9-12.

0 R-, B-, and T-axis gear • Grease gun Check for malfunction. (Replace if nSupply grease3) (2000H cycle). SeeReplace grease3) (6000H cycle). Se

1 R-axis speed reducer • Grease gun Check for malfunction. (Replace if nSupply grease3) (2000H cycle). SeeReplace grease3) (6000H cycle). Se

2 B- and T-axis speed reducersand gears

• Grease gun Check for malfunction. (Replace if nSupply grease3) (2000H cycle). SeeSection 9.3.7 on page 9-20. Replace grease3) (6000H cycle). SeSection 9.3.7 on page 9-20.

able 9-1: Inspection Items (Sheet 2 of 3)

tems1) Schedule Method Operation

Dai

ly

50

0 H

Cy

cle

20

00H

Cy

cle

1s

t in

sp

ec

tio

n6

000

H

2n

d in

sp

ec

tio

n

10

000

H2

nd

ins

pe

cti

on

18

000

H

9 M


P4000D9.1

Inspection Schedule

9-4

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lace if necessary.) e). See Section 9.3.8 on page 9-22. le). See Section 9.3.8 on page 9-22.

•

••

page 9-5.r. This can cause a motor breakdown. Contact your

nnectors on the motor side for each axis, and thenn may be lost. (Refer to Section 9.3.11 “Notes for

Table 9-1: Inspection Items (Sheet 3 of 3)

Inspection Charge

Sp

eci

fie

d

Per

son

Lic

ens

ee

Ser

vice

Co

mp

an

y

38/87

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

23 L-axis cross roller bearing • Grease gun Check for malfunction. (RepSupply grease3) (2000H cyclReplace grease3)(6000H cyc

24 S-, L-, and U-axes overhaul •25 R-, B-, and T-axes overhaul •1 Inspection No. correspond to the numbers in Fig. 9-1 Inspection Parts and Inspection Numbers on 2 The occurrence of a grease leakage indicates the possibility that grease has seeped into the moto

Yaskawa representative.3 For the grease, refer to Table 9-2 Inspection Parts and Grease Used on page 9-4.4 The internal wiring harness is to be replaced at 18000H inspection (at overhaul).5 When checking for conduction with multimeter, connect the battery pack to “BAT” and “OBT” of co

remove connectors on detector side for each axis from the motor. Otherwise, the home positioMaintenance” on page 9-26.)

Table 9-2: Inspection Parts and Grease Used

No. Grease Used Inspected Parts

18,19, 20, 21, 22 Molywhite RE No.00 All axis speed reducers B- and T-axis gears

11, 16, 23 Alvania EP Grease 2 L-axis cross roller bearing Tapered roller bearing in the link partL-axis balancer

Items1) Schedule Method Operation

Dai

ly

500

H C

yc

le

200

0H C

ycl

e

1st

ins

pec

tio

n60

00

H

2nd

ins

pec

tio

n

100

00 H

2nd

ins

pec

tio

n

180

00 H

9 M


P4000D9.1

Inspection Schedule

9-5

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Fig.

pecification .

6

39/87

9-1: Inspection Parts and Inspection Numbers

This figure shows the standard smanipulator in the nome position

A B7BC


16

7

AIR

2A

IR1

11

2

1

1

8

7219

1

6

2

152319

47

16

17

10

9 1310 12

22

21

18

14

6 1

5

4

7

1

20

L-axis

S-axis

R-axis

B-axis

U-axis

9 Maintenance and Inspection9.2 Notes on Maintenance Procedures

163305-1CD

EP4000D

9.2 Notes on Maintenance Procedures

9.2.1 Battery Pack Replacement

Battery packs are located as illustrated in Fig.9-2 Battery Pack Location. If the battery alarm occurs in the DX100, replace the battery packs according to the following procedure:

Fig. 9-2: Battery Pack Location

Fig. 9-3: Battery Connection

1. Turn OFF the DX100 main power supply.

2. Remove the plate fixing screws and the plate from the connector base, and pull the battery pack out to replace it with a new battery pack.

3. Remove the battery pack from the battery holder.

4. Connect the new battery pack to the unoccupied connector on the board.

5. Remove the old battery pack from the board.

6. Mount the new battery pack to the holder.

7. Reinstall the plate.

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

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

PlateCross head APS bolt M4 (4 bolts) (length: 10 mm)

Connector base

A B7BC


See procedure 5

Connector

Board See procedure 4

Battery pack before replacement

New battery pack(HW0470360-A)

9-6

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EP4000D 9 Maintenance and Inspection9.3 Notes on Grease Replenishment and Exchange Procedures

9.3 Notes on Grease Replenishment and Exchange Procedures

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

9.3.1 Grease Replenishment and Exchange for S-Axis Speed Reducer and Gear

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

NOTE

• If grease is added without removing the plug/screw 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/screw.

• 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 the hose on the grease inlet with grease beforehand to prevent air from leaking into the speed reducer.

S-axis gear unit

Grease exhaust portHexagon socket head plug PT1/8

Grease inletHexagon socket head plug PT1/4

S-axis speed reducer

A B7BC


9-7

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9 Maintenance and Inspection9.3 Notes on Grease Replenishment and Exchange Procedures

163305-1CD

EP4000D

9.3.1.1 Grease Replenishment

(Refer to Fig.9-4 S-Axis Speed Reducer and Gear Diagram.)

1. Remove the plugs from the grease inlet and the grease exhaust port.

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

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

– Grease type: Molywhite RE No.00

– Amount of grease: approx. 2340 cc(4680 cc for 1st supply)

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

– Grease injection rate: 8 g/s or less

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

5. Wipe the discharged grease with a cloth, and reinstall the plugs to the grease inlet and the grease exhaust port. Before installing the plugs, apply ThreeBond 1206C on the thread parts of the plugs, then tighten them with a tightening torque of 4.9 N•m (0.5 kgf•m).

9.3.1.2 Grease Exchange

(Refer to Fig. 9-4 S-Axis Speed Reducer and Gear Diagram on page 9-7.)





– Amount of grease: approx. 11700 cc



NOTE

• 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.


NOTEIf the plug is installed while grease is being exhausted, grease will leak inside the motor and may cause a damage. Ensure that grease has been completely exhausted before installing the plug.

NOTE



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4. The grease exchange is completed when new grease appears in the grease exhaust port. (The new grease can be distinguished from the old grease by color.)

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



9-9

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EP4000D

9.3.2 Grease Replenishment and Exchange for L-Axis Speed Reducer

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


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

1. Tilt the L-arm as illustrated in Figure 9-5.

2. Remove the plug from the grease exhaust port.






L-axis speed reducer

Grease exhaust portHexagon socket head plug PT1/8

Grease inletGrease zerk A-PT1/8

NOTE



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

5. Wipe the discharged grease with a cloth, and reinstall the plug to the grease exhaust port. Before installing the plug, apply ThreeBond 1206C on the thread part of the plug, then tighten it with a tightening torque of 4.9 N•m (0.5 kgf•m).


(Refer to Fig. 9-5 L-Axis Speed Reducer Diagram on page 9-10.)

1. Tilt the L-arm as illustrated in Fig. 9-5 on page 9-10.








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



NOTE




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EP4000D

9.3.3 Grease Replenishment and Exchange for U-Axis Speed Reducer

Fig. 9-6: U-Axis Speed Reducer Diagram


(Refer to Fig.9-6 U-Axis Speed Reducer Diagram.)

1. Tilt the L-arm as illustrated in Figure 9-6.







Grease exhaust portHexagon socket head plug PT1/8U-axis speed reducer

Grease inlet Grease zerk A-PT1/8

A B7BC


Section A-A

AA

NOTE



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



(Refer to Fig. 9-6 U-Axis Speed Reducer Diagram on page 9-12.)

1. Tilt the L-arm as illustrated in Fig. 9-6 on page 9-12.








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



NOTE




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EP4000D

9.3.4 Grease Replenishment and Exchange for R-, B-, and T-Axis Gear

Fig. 9-7: R-, B-, and T-Axis Gear Diagram


(Refer to Fig.9-7 R-, B-, and T-Axis Gear Diagram.)







3. Move the R-, B-, and T-axes for a few minutes to discharge excess grease.


Grease exhaust port Hexagon socket head plug PT1/8

AIR

2A

IR1

NOTE



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(Refer to Fig. 9-7 R-, B-, and T-Axis Gear Diagram on page 9-14.)








4. Move the R-, B-, and T-axes for a few minutes to discharge excess grease.



NOTE




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EP4000D

9.3.5 Grease Replenishment and Exchange for R-Axis Speed Reducer

Fig. 9-8: R-Axis Speed Reducer Diagram


(Refer to Fig.9-8 R-Axis Speed Reducer Diagram.)







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


R-axis speed reducer



NOTE




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(Refer to Fig. 9-8 R-Axis Speed Reducer Diagram on page 9-16.)








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


NOTE




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EP4000D

9.3.6 Grease Replenishment and Exchange for B-Axis Speed Reducer and Gear

Fig. 9-9: B-Axis Speed Reducer and Gear Diagram


(Refer to Fig.9-9 B-Axis Speed Reducer and Gear Diagram.)








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



B-axis speed reducer


NOTE




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(Refer to Fig. 9-9 B-Axis Speed Reducer and Gear Diagram on page 9-18.)









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


NOTE




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EP4000D

9.3.7 Grease Replenishment and Exchange for T-Axis Speed Reducer and Gear

Fig. 9-10: T-Axis Speed Reducer and Gear Diagram


(Refer to Fig.9-10 T-Axis Speed Reducer and Gear Diagram.)

1. Remove the plug from the grease inlet and the screw from the grease exhaust port.







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


Grease exhaust port Hexagon socket set screw M5 (length: 6 mm)

T-axis speed reducer

NOTE



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163305-1CD


5. Wipe the discharged grease with a cloth, and reinstall the plug to the grease inlet and the screw to the grease exhaust port. Before installing the plug and the screw, apply ThreeBond 1206C on the thread parts of the plug and the screw, then tighten them with a tightening torque of 4.9 N•m (0.5 kgf•m).


(Refer to Fig. 9-10 T-Axis Speed Reducer and Gear Diagram on page 9-20.)

1. Remove the plug from the grease inlet and the screw from the grease exhaust port.








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

6. Wipe the discharged grease with a cloth, and reinstall the plug to the grease inlet and the screw to the grease exhaust port. Before installing the plug and the screw, apply ThreeBond 1206C on the thread parts of the plug and the screw, then tighten them with a tightening torque of 4.9 N•m (0.5 kgf•m).


NOTE




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EP4000D

9.3.8 Grease Replenishment for L-Axis Cross Roller Bearing

Fig. 9-11: L-Axis Cross Roller Bearing Diagram

1. Remove the plug from the exhaust port. (Refer to Fig.9-11 L-Axis Cross Roller Bearing Diagram.)


– Grease type: Alvania EP grease 2


3. Reinstall the plug to the exhaust port. Before installing the plug, apply ThreeBond 1206C on the thread part of the plug, then tighten it with a tightening torque of 4.9 N•m (0.5 kgf•m).

L-axis cross roller bearing

L-arm

Exhaust port Hexagon socket head plug PT1/8


NOTE The exhaust port is used for air flow. Do not inject excess grease into the grease inlets.

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9.3.9 Grease Replenishment for Tapered Roller Bearing in the Link Part

Fig. 9-12: Link Part Diagram

1. Remove the plug from the exhaust port. (3 exhaust ports for each side, 6 exhaust ports in total) Refer to Fig.9-12 Link Part Diagram.




3. Reinstall the plug to the exhaust port. Before installing the plug, apply ThreeBond 1206C on the thread part of the plug, then tighten it with a tightening torque of 4.9 N•m (0.5 kgf•m).

Exhaust portHexagon socket head plug PT1/8 (2 plugs)



This figure shows one side of the manipulator.There are three other link parts on the other side; tapered roller bearings, grease inlets and exhaust portsare similarly located.Perform the same grease replenishment for the other side.

Grease inletGrease zerk A-PT1/8 (2 zerks)



Tapered roller bearing(2 bearings)

Tapered roller bearing (2 bearings)

Tapered roller bearing(2 bearings)


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EP4000D

9.3.10 Grease Replenishment for Balancer Link Part

Fig. 9-13: Balancer Link Part

1. For the side of the manipulator, remove the screw from the exhaust port. For the top of the manipulator, remove the plug from the exhaust port (2 places). (Refer to Fig.9-13 Balancer Link Part.)

Exhaust port Hexagon socket head plug PT1/8 (2 plugs)

Exhaust port Hexagon socket head cap screw M6(2 screws) (length: 6 mm)

Grease inlet Grease zerk A-PT1/8

Grease inlet Grease zerk A-PT1/8 (2 zerks)

The tapered roller bearings, grease inlets, and exhaust ports are also located on the other side of the manipulator like this side. Perform the same grease replenishment for the other side.

Needle bearing

Tapered roller bearing (2 bearings)

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3. For the side of the manipulator, reinstall the screw to the exhaust port. For the top of the manipulator, reinstall the plug to the exhaust port (2 places). Apply ThreeBond 1206C on the thread part of the screw and plug, then tighten them with a tightening torque of 4.9 N•m (0.5 kgf•m).


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EP4000D

9.3.11 Notes for Maintenance

The connectors for the battery pack connection are attached to the main body of motors. Connect the battery pack according to the following procedure.

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

2. Connect the battery pack (HW9470917-A) for motors to the battery backup connector. (With the battery pack connected to the battery backup connector, remove the encoder connector and perform the maintenance.)

3. After the maintenance, confirm that all connectors are connected and then remove the battery pack connection cable for the motor and battery pack.

4. Reinstall the attached cap to the battery backup connector of the motor.

Fig. 9-14: Battery Pack Connection for Motor

NOTE

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 con-nect 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. 9-14 Battery Pack Connection for Motor on page 9-26.

NOTE Do not remove the battery pack in the connector base.

ab0BT

BAT

Motor

Connector for battery backup

Battery pack (HW9470917-A)

Power connectorEncoder connector

b

a

BAT*0BT*

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

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EP4000D 10 Recommended Spare Parts

10 Recommended Spare Parts

It is recommended that the following parts and components be kept in stock as spare parts for the MOTOMAN-EP4000D.

For preparing lead wires for wire harness in the manipulator, etc., check the serial number and contact your Yaskawa representative.

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, contact your Yaskawa representative.

Table 10-1: Spare Parts for the MOTOMAN-EP4000D (Sheet 1 of 2)

Rank PartsNo.

Name Type Manufacturer Qty. Qty.perUnit

Remarks

A 1 Battery pack HW9470917-A Yaskawa 1 1

A 2 Battery pack HW0470360-A Yaskawa 1 1

A 3 Liquid gasket ThreeBond 1206C ThreeBond Co., Ltd.

1 1

A 4 Grease Molywhite RE No. 00 Yaskawa 16 kg - For all speed reducersand wrist units

A 5 Grease Alvania EP Grease 2 Showa Shell Sekiyu K.K.

16 kg - For tapered roller bearing

B 6 S-axis speed reducer

HW0280730-A Yaskawa 1 1

B 7 S-axis input gear

HW0308653-1 Yaskawa 1 1

B 8 L- and U-axis speed reducers


B 9 L- and U-axis input gears

HW0302975-1 Yaskawa 1 2

B 10 R-axis speed reducer

HW0380393-B Yaskawa 1 1

B 11 B-axis speed reducer


B 12 T-axis speed reducer

HW0380794-B Yaskawa 1 1

B 13 Wrist unit HW0170875-A Yaskawa 1 1 -*6*, -*7*

B 14 Wrist unit HW0170875-D Yaskawa 1 1 -*72

C 15 AC servomotor for S-axis

HW0385741-A(SGMGH-1AA2A-YR3*)

Yaskawa 1 1

C 16 AC servomotors for L- and U-axes

HW0385742-A(SGMGH-75A2A-YR3*)

Yaskawa 1 2

10-1

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10 Recommended Spare Parts

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EP4000D

C 17 AC servomotors for R- and T-axes

HW0388667-A(SGMRV-13ANA-YR2*)

Yaskawa 1 2

C 18 AC servomotors for B-axis

HW0388671-A(SGMRV-44ANA-YR2*)

Yaskawa 1 1

C 19 Wire harness in manipulator


C 20 Connector base unit


C 21 Cooling fan HW9370631-E Yaskawa 1 3 With lead termination

Table 10-1: Spare Parts for the MOTOMAN-EP4000D (Sheet 2 of 2)

Rank PartsNo.

Name Type Manufacturer Qty. Qty.perUnit

Remarks

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163305-1CD

EP4000D 11 Parts List11.1 S-Axis Unit

11 Parts List

11.1 S-Axis Unit

Fig. 11-1: S-Axis Unit

1044

1023

11021103

1003

1039

1005

10111013

1022

10431042

1087

1090

1091

1004

1088

10831084

1089

1045

106910681067

1070

1014

1076

1075

11-1

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11 Parts List11.1 S-Axis Unit

163305-1CD

EP4000D

Fig. 11-2: S-Axis Unit

1057

1028

1019

1060

1021

1063

101810541055

1033

1036

1105

1066

10781092

1002

1026

1077

1001

1024

10801079

1017

1016

1056

1056

1056

10251062

1062

1007

1020

1047

1006

10081030

1027

1029

1032

1052

1015

1087

1031

10121009

1064

1063

1065

1061

1058

1059

1056

10821081

10861085

1048

1010

1012

10501051

1034

1035

1037

1038

11-2

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EP4000D 11 Parts List11.1 S-Axis Unit

Table 11-1: S-Axis Unit (Sheet 1 of 2)

No. DWG No. Name Pcs.

1001 G80 O-ring 1

1002 G70 O-ring 2

1003 G145 O-ring 1

1004 ARP568-387 O-ring 1

1005 HW0303047-1 Pipe 1

1006 HW0309348-1 Pipe 1

1007 HW0309350-1 Pipe 1

1008 S115 O-ring 1

1009 M4X12 Socket screw 3



1012 2H-4 Spring washer 7


1014 HW0310921-1 Stopper 2

1015 HW0302632-1 Gear 1

1016 HW0302633-1 Gear 1

1017 HW0302634-1 Gear 1

1018 HW0308669-1 Gear 1

1019 HW0308653-1 Shaft 1

1020 HW0309349-1 Flange 1

1021 HW0308670-1 Housing 1

1022 HW0402970-1 Cover 1

1023 HW0402971-1 Cover 1

1024 HW0403001-1 Holder 1

1025 HW0403002-1 B-nut 1

1026 HW0403003-1 B-cover 2

1027 HW9405049-1 B-holder 1

1028 HW0403005-1 Fly wheel 1

1029 HW9481231-A Bearing 1



1032 HW9405052-1 B-holder 1

1033 HW0100319-1 Gear case A 1



1036 HW0100320-1 Gear case B 1



1039 HW0280730-A Speed reducer 1



1044 HW0100317-1 Base 1

1045 M5X10 GT-SA bolt 6

1047 TC13016014 Oil seal 1

11-3

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11 Parts List11.1 S-Axis Unit

163305-1CD

EP4000D






1055 M12 Washer 2

1056 HR33207J Bearing 4

1057 SGMGH-1AA2A-YR3* Motor 1





1062 M6X8 Set screw with a ball 2




1066 PT3/8 Plug 1



1069 HW9404486-1 Shaft 1

1070 HW0410165-2 Stopper 1













1087 HW0100315-1 S-head 1



1090 KQ2S10-01S Union 1

1091 NB-1075-1.1 Tube 1

1092 HW0403009-* Shim -



1105 MSTH8-20 Pin 1

Table 11-1: S-Axis Unit (Sheet 2 of 2)


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EP4000D 11 Parts List11.2 L- and U-Axis Unit

11.2 L- and U-Axis Unit

Fig. 11-3: L- and U-Axis Unit

1087

2026

2031

2063

20292030

2003

20582059

2025

20672066

20272028

20082002

20092017

2017

2005

2005

20012062

2062

2015

2015

2001

2016

2016

2061

20562057

2061

2060

2044

2019

2019

2060

20562057

2044

2036

2068

2075

2074

20352034

20322033

2047

2065

3014

3001

11-5

HW1480584 67/87

11 Parts List11.2 L- and U-Axis Unit

163305-1CD

EP4000D

Fig. 11-4: L- and U-Axis Unit

2026

2047

2049

2012

2050

2004

2006

2006

20532054

2052

2010

2069

2071

2070

2038

20422041

2048

1087

2048

20102043

2043

2039

2072

2040

2073

2011

2022

2022

2037

2013

2013

2055

2055

2023

20232024

2014

20142024

2007

2007

2051

2051

2054

2045

2044

2044

2052

2046

2045

20492050

2046

2053

11-6

HW1480584 68/87

163305-1CD

EP4000D 11 Parts List11.2 L- and U-Axis Unit

Table 11-2: L- and U-Axis Unit (Sheet 1 of 2)



2002 NA6912 Needle bearing 1

2003 G135 O-ring 1

2004 GS355 O-ring 1

2005 S105 O-ring 2

2006 G370 O-ring 2

2007 STW-14 Retaining ring C-type 2

2008 WR60 Circlip 1

2009 AR85 Circlip 1

2010 HW0306092-1 M-base 2

2011 HW0308252-1 Shaft 1

2012 HW0306093-1 B-cover 1

2013 HW0302975-1 Gear 2

2014 HW0402974-1 Shaft 2

2015 HW0402972-1 Shaft 2

2016 HW9405699-5 B-cover 2

2017 HW9405195-* Shim -


2022 HW9404323-1 Collar 2

2023 HW9482386-A Bolt 2

2024 HW0408806-4 Washer 2

2025 HW9302054-1 Shaft 1

2026 HW0100316-1 L-arm 1





2031 HW0200328-1 Flange 1





2036 HW0100318-1 Link B 1

2037 RB25040UUCC0S Cross roller bearing 1

2038 VB 265 280 7 Oil seal 1





2043 EZ3193A0 Cap 2

2044 PT1/8 Grease zerk 4

2045 TSH6-01M Union 2

2046 UB-0640-0.1C Tube 2

2047 PT1/8 Plug 3

11-7

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11 Parts List11.2 L- and U-Axis Unit

163305-1CD

EP4000D




2051 SGMGH-75A2A-YR3* Motor 2

2052 Y567812.5 Oil seal 2



2055 HW9481716-1 Shaft 2







2062 KE901107 Oil seal 2

2063 VB60X78X7 Oil seal 1

2065 VB75X95X6 Oil seal 1



2068 HW0200327-1 Counter weight 1

2069 VB280.5X328.5X11 Oil seal 1


2071 PT1/8 Plug 1





1087 HW0100315-1 S-head 1

3001 HW0100197-1 Case 1

3014 HW9405057-1 Clevis 1

Table 11-2: L- and U-Axis Unit (Sheet 2 of 2)


11-8

HW1480584 70/87

163305-1CD

EP4000D 11 Parts List11.1 Balancer Unit

11.1 Balancer Unit

Fig. 11-5: Balancer Unit

1087

2026

2031

30013011

3008

3004

30023020

3018

3003

3018

3017

3016

3015

3013

3013

3006

3010

3019

3014

3005

3012

3012

11-9

HW1480584 71/87

11 Parts List11.1 Balancer Unit

163305-1CD

EP4000D

Table 11-3: Balancer Unit


3001 HW0100197-1 Case 1

3002 HW0301603-1 Rod 1

3003 HW0301604-1 Flange 1

3004 HW0401112-1 Flange 1

3005 HW0200213-1 Flange 1



3010 FD3187A0 Dust seal 1

3011 EZ2228B0 Cap 1

3012 IRTW-75 Retaining ring 2

3013 SOB607440 OILES bearing 2

3014 HW9405057-1 Clevis 1

3015 HW0481933-A Coil spring 1




3019 PT1/8 Plug 3


1087 HW0100315-1 S-head 1

2026 HW0100316-1 L-arm 1

2031 HW0200328-1 Flange 1

11-10

HW1480584 72/87

163305-1CD

EP4000D 11 Parts List11.4 R-, B-, and T-Axis Unit

11.4 R-, B-, and T-Axis Unit

Fig. 11-6: R-, B-, and T-Axis Unit

R-axis

T-axis

B-axis

5026

4031

4024

4035

4011

4008

4003

4025

4014

40334032

40294028

40234022

4016

4012

4015

40184021

40204009

4019

4013

4017

4007

4007

4010

4004

4030

4030

4002

4013

4001

4001

40274026

4039

2026

40374036

4038

11-11

HW1480584 73/87

11 Parts List11.4 R-, B-, and T-Axis Unit

163305-1CD

EP4000D

Table 11-4: R-, B-, and T-Axis Unit


4001 SGMRV-13ANA-YR2* Motor 2

4002 HW0302536-1 Flange 1

4003 HW0302542-1 Flange 1

4004 HW0302547-1 Flange 1

4007 HW0401506-1 Plate 2

4008 HW0402951-1 Plate 1

4009 HW0402952-3 Collar 1

4010 HW0302588-1 Gear 1

4011 HW0302591-1 Gear 1

4012 HW0302595-1 Gear 1

4013 G115 O-ring 2

4014 G145 O-ring 1





4019 TAFI506825 Needle bearing 1


4021 ISTW-50 Retaining ring 1



4024 SGMRV-44ANA-YR2* Motor 1

4025 Y507212.5 Oil seal 1





4030 Y507212.5 Oil seal 2

4031 HW0100321-1 M-base 1




4036 PT1/8 Plug 1

4037 HW9405487-1 Cover 1

4038 HW9482435-A Packing 1

4039 M5X16 APS bolt 4

2026 HW0100316-1 L-arm 1

5026 HW0100310-1 Casing 1

11-12

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163305-1CD

EP4000D 11 Parts List11.5 Shaft Unit

11.5 Shaft Unit

Fig. 11-7: Shaft Unit

5026

5021

5018

50165015 5017

4031

50385039

5004

5029

5030

5040

50255024

50235022

50205014

5034

5031

5011

5003

50095035

5001

5036503750105044

5032

5033

50445041

5005

5013

50425043

5002

50275028

5019

50455046

5012

11-13

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11 Parts List11.5 Shaft Unit

163305-1CD

EP4000D

Table 11-5: Shaft Unit (Sheet 1 of 2)


5001 HW0100173-1 Housing 1

5002 HW0302537-1 Spacer 1

5003 HW0302538-A Shaft 1

5004 HW0302543-A Shaft 1

5005 HW0302583-A Shaft 1

5009 HW0401505-1 B-nut 1

5010 HW0401508-1 Plate 1

5011 HW0302589-1 Gear 1

5012 HW0302592-1 Gear 1

5013 HW0302596-1 Gear 1




5017 6922DDU Bearing 1

5018 HW0302539-1 Spacer 1



5021 HW0100313-1 U-arm A 1



5024 MSTH8-20 Pin 1

5025 G170 O-ring 1

5026 HW0100310-1 Casing 1




5030 SC115X145X14 Oil seal 1

5031 SC75X100X13 Oil seal 1



5034 HR32016XJ Bearing 1

5035 M4X6 Hexagon socket set screw

1





5040 GS210 O-ring 1





11-14

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163305-1CD

EP4000D 11 Parts List11.5 Shaft Unit



4031 HW0100321-1 M-base 1

Table 11-5: Shaft Unit (Sheet 2 of 2)


11-15

HW1480584 77/87

11 Parts List11.6 U-Arm Unit

163305-1CD

EP4000D

11.6 U-Arm Unit

Fig. 11-8: U-Arm Unit

5021

6043604560446048

6049

6006

60426041

6001

6022

6021

6015

6034

6010

6038

6011

6036

6035

6014

6025

6003

6002

60466047

6004

6032

6017

6039

60326037

6040

6033

60246050

6023

60316030

60276026

60296028

603560136005

6016

6012

6051

11-16

HW1480584 78/87

163305-1CD

EP4000D 11 Parts List11.6 U-Arm Unit

Table 11-6: U-Arm Unit (Sheet 1 of 2)


6001 AS568-272 O-ring 1

6002 G150 O-ring 1


6004 MSTH8-20 Pin 1


6006 HW0302540-A Shaft 1

6010 HW0302581-1 Shaft 1

6011 HW0302541-1 Housing 1

6012 HW0300925-2 Spacer 1

6013 HW0402952-2 Collar 1

6014 HW0302590-1 Gear 1

6015 HW0380393-B Speed reducer 1

6016 6908LLU Bearing 1

6017 HW0302584-A Shaft 1













6033 IRTW42 Retaining ring 1

6034 6813LLU Bearing 1




6038 HW0100314-1 U-arm B 1

6039 HW0302545-A Shaft 1




6043 HW0302544-1 Shaft 1







11-17

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11 Parts List11.6 U-Arm Unit

163305-1CD

EP4000D

6050 PT1/8 Plug 1


5021 HW0100313-1 U-arm A 1

Table 11-6: U-Arm Unit (Sheet 2 of 2)


11-18

HW1480584 80/87

163305-1CD

EP4000D 11 Parts List11.7 Wrist Unit

11.7 Wrist Unit

Fig. 11-9: Wrist Unit

7045

7118

7011

7040

71007104

70687069

7105

7123

7092

70917090

70997103

7093

7059

706170607062

7002

7003

*7004

7007

7001

70067005

7008

7010 712771267009

7125

70167017

70167023

7012

7024

7013

7042

7041

70397039

7031

70387033

70377015

7015

7025

7014

7101

7117

7089

7102

7026

6012

711971207121

7056

7047

7044

7048

7049

7043

7113

71087106

7046

7029

7124

7088

7081

7080

7087

70797078

70287027

7075 7077707270747073

70577058

70547055

71107109

7116

71127111

7107

71157114

7076

70717070

70307032

7122

HW0302576-1 YR-EP4000D-*6*, YR-EP4000D-*7*HW0302576-2 YR-EP4000D-*72

*7004

11-19

HW1480584 81/87

11 Parts List11.7 Wrist Unit

163305-1CD

EP4000D

Table 11-7: Wrist Unit (Sheet 1 of 3)


7001 M5X6 Hexagon socket set screw 1

7002 ARP568-263 O-ring 1

7003 HW0380794-B Speed reducer 1

7004 HW0302576-1 Flange 1



7007 HW0301782-2 Spacer 1

7008 HW0302575-1 Flange 1



7011 HW0302601-1 Gear 1

7012 HW0401514-1 B-nut 1


7014 HW0200329-1 Cover 1



7017 HW0403390-* Shim -

7023 HW0402965-1 Housing 1


7025 PT1/8 Plug 1

7026 HW0302600-1 Gear 1



7029 6911 Bearing 1

7030 RTW80 Retaining ring 1

7031 HW0302599-1 Gear 1

7032 AE3290E3 Oil seal 1

7033 HW9403622-* Shim -

7037 HW0402964-1 Housing 1

7038 S60 O-ring 1


7040 HW0302598-1 Gear 1


7042 HW0402963-1 B-nut 1

7043 HW0302582-1 Shaft 1

7044 HW0302546-1 Housing 1

7045 HW0100311-1 Wrist 1

7046 HW0100312-1 Wrist base 1

7047 HW0481446-A Bearing 1

7048 G95 O-ring 1

7049 HW0402955-* Shim -



7056 HW0402954-1 B-holder 1

11-20

HW1480584 82/87

163305-1CD

EP4000D 11 Parts List11.7 Wrist Unit



7059 HW0302602-1 Gear 1


7061 6006 Bearing 1

7062 HW0402206-* Shim -





7072 HW0402962-1 Cover 1



7075 HW0402960-1 B-nut 1




7079 HW0402959-1 B-holder 1

7080 HW0402958-1 Housing 1

7081 HW0402961-* Shim -

7087 HW0481447-A Bearing 1

7088 HW0302597-1 Gear 1

7089 AS568-272 O-ring 1



7092 PT1/8 Plug 1

7093 HW0402968-* Shim -

7099 HW0302594-1 Gear 1


7101 HW0302457-1 Cover 1


7103 6009 Bearing 1




7107 6911 Bearing 1

7108 RTW45 Retaining ring 1




7112 AC2847-F3-FKM Oil seal 1

7113 HW0302593-1 Gear 1



7116 HW0402956-1 Shaft 1



11-21

HW1480584 83/87

11 Parts List11.7 Wrist Unit

163305-1CD

EP4000D



7119 HW0402953-1 B-holder 1



7122 EZ5036A0 Cap 2

7123 HW0402957-1 Plate 1

7124 G140 O-ring 1

7125 LPT10-20 Pin 4



6012 HW0300925-2 Spacer 1



11-22

HW1480584 84/87

163305-1CD

EP4000D 11 Parts List11.8 Link Unit

11.8 Link Unit

Fig. 11-10: Link Unit

2026

2036

8022 8015

8044

8005

80238024

80168002

8035

80348013

8030

80278033

80338027

8014

80028012

80298028

8030

8015

8027

8033

80028005

80328031

8030

80368037

80368037

5026

8005

80318032

80168002 8026

80258013

8030

8039

80338027

8014

8042

8042

8043

8004

8004

80388001

80018006

8003

80418040

80418040

8022

8038

8003

8039

8043

8022

11-23

HW1480584 85/87

11 Parts List11.8 Link Unit

163305-1CD

EP4000D

Table 11-8: Link Unit


8001 G125 O-ring 2

8002 G90 O-ring 4

8003 HW0402975-1 B-holder 2

8004 HW0402976-1 Shaft 2

8005 HW0402978-1 B-holder 3

8006 HW0402977-* Shim -

8012 HW0402979-1 B-holder 1

8013 HW0402980-1 Plate 2

8014 HW0402981-1 Collar 2

8015 HW0402982-1 Shaft 2

8016 HW0402983-* Shim -






8027 VC70X95X7 Oil seal 4



8030 PT1/8 Plug 4








8038 33017U Bearing 2

8039 PT1/8 Plug 2



8042 VC95X115X9 Oil seal 2


8044 HW0302631-2 Link A 1

2026 HW0100316-1 L-arm 1

5026 HW0100310-1 Casing 1

11-24

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MOTOMAN-EP4000DINSTRUCTIONS

4HW1480584MANUAL NO.

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

87/87

Instructions - Motoman...– Check for problems in manipulator movement. – Check for damage to...

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Transcript of Instructions - Motoman...– Check for problems in manipulator movement. – Check for damage to...