149200-1 Manipulador Manual

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Part Number: 149200-1

Release Date: February 5, 2004
Document Version: 2
Document Status: Final
Motoman, Incorporated
805 Liberty Lane
West Carrollton, OH 45449
TEL: (937) 847-6200
FAX: (937) 847-6277
24-Hour Service Hotline: (937) 847-3200
The information contained within this document is the proprietary property of Motoman, Inc., and may not be
copied, reproduced or transmitted to other parties without the expressed written authorization of Motoman,
Inc.
©2003 by MOTOMAN
All Rights Reserved
Because we are constantly improving our products, we reserve the right to change specifications without
notice. MOTOMAN is a registered trademark of YASKAWA Electric Manufacturing.
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The Motoman ES165N and NX100 controller represent state-of-the-art technology in robotics
today. The Motoman ES165N is a high speed spot welding robot with a 165 kg payload. It has
six individual axes: Sweep, Lower arm, Upper arm, Rotate, Bend, and Twist.
The NX100 controller coodinates the operation of the ES165N robot with external equipment
such as power supply and positioning tables. The NX100 processes input and output signals,
maintains variable data, and performs numeric processing to convert to and from different
coordinate systems. Furthermore, it provides main logic functions, servo control, program
and constant data memory, and power distribution. Please read this manual thoroughly to
familiarize yourself with the many aspects of the ES165N robot and NX100 controller.
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This manual provides system information for the ES165N robot and NX100 controller and
contains the following sections:
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Provides general information about the structure of this manual, a list of reference documents,
and customer service information.
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This section provides information regarding the safe use and operation of the ES165N robot.
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Provides detailed information about the ES165N, including installation, wiring, specifications,
and maintenance.
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For additional information refer to the following:
• NX100 Controller Manual (P/N 149201-1)
• Operator’s Manual for Spot Welding (Motor Gun) (P/N )
• Operator’s Manual for Spot Welding (Air Gun) (P/N )
• Concurrent I/O Manual (P/N )
• Vendor manuals for system components not manufactured by Motoman
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If you are in need of technical assistance, contact the Motoman service staff at (937) 847-3200.
Please have the following information ready before you call:
• Robot Type (ES165N)
• Application Type (spot welding)
• Robot Serial Number (located on back side of robot arm)
• Robot Sales Order Number (located on back of NX100 controller)
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We suggest that you obtain and review a copy of the ANSI/RIA National Safety Standard for
Industrial Robots and Robot Systems. This information can be obtained from the Robotic
Industries Association by requesting ANSI/RIA R15.06. The address is as follows:
Robotic Industries Association
900 Victors Way
P.O. Box 3724
Ann Arbor, Michigan 48106
TEL: (734) 994-6088
FAX: (734) 994-3338
Ultimately, the best safeguard is trained personnel. The user is responsible for providing
personnel who are adequately trained to operate, program, and maintain the robot cell. The
robot must not be operated by personnel who have not been trained!
We recommend that all personnel who intend to operate, program, repair, or use the robot
system be trained in an approved Motoman training course and become familiar with the
proper operation of the system.
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This safety section addresses the following:

• Standard Conventions (Section 2.2)
• General Safeguarding Tips (Section 2.3)
• Mechanical Safety Devices (Section 2.4)
• Installation Safety (Section 2.5)
• Programming Safety (Section 2.6)
• Operation Safety (Section 2.7)
• Maintenance Safety (Section 2.8)
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This manual includes information essential to the safety of personnel and equipment. As you
read through this manual, be alert to the four signal words:
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NOTE:
Pay particular attention to the information provided under these headings which are defined
below (in descending order of severity).
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Note: Information appearing in a Note caption provides additional information which is helpful in
understanding the item being explained.
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All operators, programmers, plant and tooling engineers, maintenance personnel,
supervisors, and anyone working near the robot must become familiar with the operation of
this equipment. All personnel involved with the operation of the equipment must
understand potential dangers of operation. General safeguarding tips are as follows:
• Improper operation can result in personal injury and/or damage to the equipment.
Only trained personnel familiar with the operation of this robot, the operator's
manuals, the system equipment, and options and accessories should be permitted to
operate this robot system.
• Do not enter the robot cell while it is in automatic operation. Programmers must
have the teach pendant when they enter the robot cell.
• Improper connections can damage the robot. All connections must be made within
the standard voltage and current ratings of the robot I/O (Inputs and Outputs).
• The robot must be placed in Emergency Stop (E-STOP) mode whenever it is not in
use.
• In accordance with ANSI/RIA R15.06, section 6.13.4 and 6.13.5, use lockout/tagout
procedures during equipment maintenance. Refer also to Section 1910.147 (29CFR,
Part 1910), Occupational Safety and Health Standards for General Industry (OSHA).
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The safe operation of the robot, positioner, auxiliary equipment, and system is ultimately the
user's responsibility. The conditions under which the equipment will be operated safely
should be reviewed by the user. The user must be aware of the various national codes,
ANSI/RIA R15.06 safety standards, and other local codes that may pertain to the installation
and use of industrial equipment. Additional safety measures for personnel and equipment
may be required depending on system installation, operation, and/or location. The following
safety measures are available:
• Safety fences and barriers
• Light curtains
• Door interlocks
• Safety mats
• Floor markings
• Warning lights
Check all safety equipment frequently for proper operation. Repair or replace any
non-functioning safety equipment immediately.
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Safe installation is essential for protection of people and equipment. The following
suggestions are intended to supplement, but not replace, existing federal, local, and state laws
and regulations. Additional safety measures for personnel and equipment may be required
depending on system installation, operation, and/or location. Installation tips are as follows:
• Be sure that only qualified personnel familiar with national codes, local codes, and
ANSI/RIA R15.06 safety standards are permitted to install the equipment.
• Identify the work envelope of each robot with floor markings, signs, and barriers.
• Position all controllers outside the robot work envelope.
• Whenever possible, install safety fences to protect against unauthorized entry into
the work envelope.
• Eliminate areas where personnel might get trapped between a moving robot and
other equipment (pinch points).
• Provide sufficient room inside the workcell to permit safe teaching and maintenance
procedures.
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understand potential dangers of operation. Programming tips are as follows:
Any modifications to PART 1 of the NX100 controller PLC can cause severe personal injury or
death, as well as damage to the robot! Do not make any modifications to PART 1. Making any
changes without the written permission of Motoman will VOID YOUR WARRANTY!
Some operations require standard passwords and some require special passwords. Special
passwords are for Motoman use only. YOUR WARRANTY WILL BE VOID if you use these
special passwords.
Back up all programs and jobs onto a floppy disk whenever program changes are made. To
avoid loss of information, programs, or jobs, a backup must always be made before any
service procedures are done and before any changes are made to options, accessories, or
equipment.
The concurrent I/O (Input and Output) function allows the customer to modify the internal
ladder inputs and outputs for maximum robot performance. Great care must be taken when
making these modifications. Double-check all modifications under every mode of robot
operation to ensure that you have not created hazards or dangerous situations that may
damage the robot or other parts of the system.
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Only trained personnel familiar with the operation, manuals, electrical design, and
equipment interconnections of this robot should be permitted to operate the system.
• Inspect the robot and work envelope to be sure no potentially hazardous conditions
exist. Be sure the area is clean and free of water, oil, debris, etc.
• Be sure that all safeguards are in place.
• Check the E-STOP button on the teach pendant for proper operation before
programming.
• Carry the teach pendant with you when you enter the workcell.
• Be sure that only the person holding the teach pendant enters the workcell.
• Test any new or modified program at low speed for at least one full cycle.
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understand potential dangers of operation. Operation tips are as follows:
• Be sure that only trained personnel familiar with the operation of this robot, the
operator's manuals, the system equipment, and options and accessories are
permitted to operate this robot system.
• Check all safety equipment for proper operation. Repair or replace any
• Inspect the robot and work envelope to ensure no potentially hazardous conditions
exist. Be sure the area is clean and free of water, oil, debris, etc.
• Ensure that all safeguards are in place.
have the teach pendant when they enter the cell.
use.
• This equipment has multiple sources of electrical supply. Electrical interconnections
are made between the controller, external servo box, and other equipment.
Disconnect and lockout/tagout all electrical circuits before making any modifications
or connections.
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• All modifications made to the controller will change the way the robot operates and
can cause severe personal injury or death, as well as damage the robot. This includes
controller parameters, ladder parts 1 and 2, and I/O (Input and Output)
modifications. Check and test all changes at slow speed.
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understand potential dangers of operation. Maintenance tips are as follows:
• Do not perform any maintenance procedures before reading and understanding the
proper procedures in the appropriate manual.
• Check all safety equipment for proper operation. Repair or replace any
• Back up all your programs and jobs onto a floppy disk whenever program changes
are made. A backup must always be made before any servicing or changes are made
to options, accessories, or equipment to avoid loss of information, programs, or jobs.
have the teach pendant when they enter the cell.
use.
• Be sure all safeguards are in place.
• Use proper replacement parts.
• This equipment has multiple sources of electrical supply. Electrical interconnections
are made between the controller, external servo box, and other equipment.
Disconnect and lockout/tagout all electrical circuits before making any modifications
or connections.
• All modifications made to the controller will change the way the robot operates and
can cause severe personal injury or death, as well as damage the robot. This includes
controller parameters, ladder parts 1 and 2, and I/O (Input and Output)
modifications. Check and test all changes at slow speed.
• Improper connections can damage the robot. All connections must be made within
the standard voltage and current ratings of the robot I/O (Inputs and Outputs).
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YASKAWA
MOTOMAN-ES165N
INSTRUCTIONS
YR-ES165N-A00 (STANDARD SPECIFICATION)
YR-ES165N-A01 (SLU-AXES WITH L.S. SPECIFICATION)
Upon receipt of the product and prior to initial operation, read these instructions thoroughly, and retain
for future reference.
MOTOMAN INSTRUCTIONS
MOTOMAN-ES165N INSTRUCTIONS
NX100 INSTRUCTIONS
NX100 OPERATOR’S MANUAL
NX100 MAINTENACE MANUAL
The NX100 operator’s manuals above correspond to specific usage.
Be sure to use the appropriate manual.
YASKAWA MANUAL NO. RE-MTO-A240 1

MANDATORY
• This instruction manual explains operating instructions and mainte-
nance procedures primarily for the MOTOMAN-ES165N.
• General items related to safety are listed in Section 1: Safety of the

NX100 Instructions. To ensure correct and safe operation, carefully
read the NX100 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 rep-

resentative to order a new copy. The representatives are listed on the
back cover. Be sure to tell the representative the manual number listed
on the front cover.
• YASKAWA is not responsible for incidents arising from unauthorized

modification of its products. Unauthorized modification voids your prod-
uct’s warranty.
ii
Notes for Safe Operation
Read this manual carefully before installation, operation, maintenance, or inspection of the
NX100.
In this manual, the Notes for Safe Operation are classified as “WARNING”, “CAUTION”,
“MANDATORY”, or “PROHIBITED”.
Indicates a potentially hazardous situation which, if not avoided,

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

could result in minor or moderate injury to personnel and dam-
CAUTION age to equipment. It may also be used to alert against unsafe
practices.
Always be sure to follow explicitly the items listed under this

MANDATORY heading.
PROHIBITED 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.
NOTE To ensure safe and efficient operation at all times, be sure to follow all instructions, even if
not designated as “CAUTION” and “WARNING”.
iii
WARNING
• Before operating the manipulator, check that servo power is turned off
when the emergency stop buttons on the front door of the NX100 and
programming pendant are pressed.
When the servo power is turned off, the SERVO ON LED on the program-
ming pendant is turned off.
Injury or damage to machinery may result if the emergency stop circuit cannot stop the
manipulator during an emergency. The manipulator should not be used if the emergency
stop buttons do not function.
Emergency Stop Button
• Once the emergency stop button is released, clear the cell of all items
which could interfere with the operation of the manipulator. Then turn
the servo power ON.
Injury may result from unintentional or unexpected manipulator motion.
TURN
Release of Emergency Stop
• Observe the following precautions when performing teaching operations

within the working envelope of the manipulator:
- View the manipulator from the front whenever possible.
- Always follow the predetermined operating procedure.
- Ensure that you have a safe place to retreat in case of emergency.
Improper or unintended manipulator operation may result in injury.
• Confirm that no persons are present in the manipulator’s work envelope

and that you are in a safe location before:
- Turning on the NX100 power
- Moving the manipulator with the programming pendant
- Running check operations
- Performing automatic operations
Injury may result if anyone enters the working envelope of the manipulator during opera-
tion. Always press an emergency stop button immediately if there are problems. The
emergency stop button is located on the right of the front door of the NX100 and the pro-
gramming pendant.
iv
CAUTION
• Perform the following inspection procedures prior to conducting manip-
ulator teaching. If problems are found, repair them immediately, and be
sure that all other necessary processing has been performed.
-Check for problems in manipulator movement.
-Check for damage to insulation and sheathing of external wires.
• Always return the programming pendant to the hook on the NX100 cabi-
net 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 the Warning Labels in the

NX100 instructions before operating the manipulator.
Definition of Terms Used Often in This Manual

The MOTOMAN manipulator is the YASKAWA industrial robot product.
The manipulator usually consists of the controller, the programming pendant, and manipulator
cables.
In this manual, the equipment is designated as follows:
Equipment Manual Designation
NX100 Controller NX100
NX100 Programming Pendant Programming Pendant
Cable between the manipulator and the controller Manipulator Cable
v
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 manipula-
tor. Prior to operating the manipulator, confirm the contents.
MOTOMAN WARNING WARNING

TYPE
PAYLOAD MASS
kg kg
ORDER NO. DATE
SERIAL NO.
YASKAWA ELECTRIC CORPORATION JAPAN
Moving parts may Do not enter

cause injury robot work area
vi
1 Product Confirmation
1.1 Contents Confirmation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.2 Order Number Confirmation . . . . . . . . . . . . . . . . . . . . . . . 1-2
2 Transporting
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 Installation of the Safeguarding . . . . . . . . . . . . . . . . . . . . 3-2
3.2 Mounting Procedures for Manipulator Base . . . . . . . . 3-2
3.2.1 Mounting Example. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3
3.3 Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
4 Wiring
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 NX100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3
5 Basic Specifications
5.1 Basic Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.2 Part Names and Working Axes . . . . . . . . . . . . . . . . . . . . 5-2
5.3 Manipulator Base Dimensions . . . . . . . . . . . . . . . . . . . . . 5-2
5.5 Alterable Operating Range . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5.5.1 Components for Altering Operating Range . . . . . . . . . . . . . . . .5-5
5.5.2 Notes on the Mechanical Stopper Installation . . . . . . . . . . . . . .5-6
5.5.3 Adjustment to the Pulse Limitation of S-Axis. . . . . . . . . . . . . . .5-7
Mounting the S-Axis Stopper by Settable Angles . . . . . . . . .5-9
vii
6 Allowable Load for Wrist Axis and Wrist Flange
6.1 Allowable Wrist Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.2 Wrist Flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
7 System Application
7.1 Peripheral Equipment Mounts . . . . . . . . . . . . . . . . . . . . . . 7-1
7.2 Internal User I/O Wiring Harness and Air Line . . . . . . 7-2
8 Motoman Construction
8.1 Position of S-Axis Limit Switch . . . . . . . . . . . . . . . . . . . . . 8-1
8.2 Internal Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
9 Maintenance and Inspection

9.1 Inspection Schedule
(Manipulator in the Home Position: Refer to “Fig.21.”) . . . . . . . . . . 9-1
9.2 Notes on Maintenance Procedures . . . . . . . . . . . . . . . . . 9-6
9.2.1 Battery Pack Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6
9.2.2 Grease Replenishment/Exchange for S-Axis Speed Reducer . 9-8
Grease Replenishment (Refer to " Fig. 24 S-Axis Speed
Reducer and Gear Diagram ".) . . . . . . . . . . . . . . . . . . . . . . . 9-8
Grease Exchange (Refer to " Fig. 24 S-Axis Speed
Reducer and Gear Diagram ".) . . . . . . . . . . . . . . . . . . . . . . . 9-9
9.2.3 Grease Replenishment/Exchange for L-Axis Speed Reducer 9-10
Grease Replenishment (Refer to " Fig. 25 L-Axis Speed
Reducer Diagram ".) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10
Grease Exchange (Refer to " Fig. 25 L-Axis Speed Reducer
Diagram ".) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-11
9.2.4 Grease Replenishment/Exchange for U-Axis Speed
Reducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-11
Grease Replenishment (Refer to " Fig. 26 U-Axis Speed
Reducer Diagram ".) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12
Grease Exchange (Refer to " Fig. 26 U-Axis Speed Reducer
Diagram ".) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-13
9.2.5 Grease Replenishment/Exchange for U-Arm . . . . . . . . . . . . . 9-14
Grease Replenishment for R-, B-, T-Axis Gears in the
Casing (Refer to " Fig. 27 U-Arm Diagram ".). . . . . . . . . . . 9-15
Grease Replenishment for R-Axis Speed Reducer
(Refer to " Fig. 27 U-Arm Diagram ".) . . . . . . . . . . . . . . . . . 9-15
Grease Replenishment for B-Axis Speed Reducer
(Refer to " Fig. 27 U-Arm Diagram ".) . . . . . . . . . . . . . . . . . 9-16
viii
Grease Replenishment for T-Axis Speed Reducer
(Refer to " Fig. 27 U-Arm Diagram ".) . . . . . . . . . . . . . . . . .9-16
Grease Exchange for R-, B-, T-Axis Gears in the Casing
Grease Exchange for R-Axis Speed Reducer
Grease Exchange for B-Axis Speed Reducer
Grease Exchange for T-Axis Speed Reducer
9.2.6 Grease Replenishment for Balancer Connection Part. . . . . . .9-20
9.2.7 Notes for Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-21
Battery Pack Connection . . . . . . . . . . . . . . . . . . . . . . . . . . .9-21
10 Recommended Spare Parts
11 Parts List
11.1 Balancer Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1
11.2 S-Axis Driving Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-3
11.3 L-Axis Driving Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-5
11.4 U.R.B.T-Axis Driving Unit . . . . . . . . . . . . . . . . . . . . . . . 11-7
11.5 U-Arm Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-9
11.6 Wrist Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-11
ix
1.1 Contents Confirmation
1 Product Confirmation
CAUTION
• Confirm that the manipulator and the NX100 have the same order num-
ber. Special care must be taken when more than one manipulator is to
be installed.
If the numbers do not match, manipulators may not perform as expected and cause injury
or damage.
1.1 Contents Confirmation
Confirm the contents of the delivery when the product arrives.

Standard delivery includes the following four items (Information for the content of optional
goods is given separately):
• Manipulator
• NX100
• Programming Pendant
• Manipulator Cables (Three cables, between manipulator and NX100)
1-1
1.2 Order Number Confirmation
1.2 Order Number Confirmation
Check that the order number of the manipulator corresponds to the NX100. The order number
is located on a label as shown below.
Label (Enlarged view)
THE MANIPULATOR AND THE CONTROLLER

SHOULD HAVE SAME ORDER NUMBER. Check that the manipulator
and the NX100 have the
ORDER. No. same order number.
NX100
TYPE ERCR-
******
POWER SUPPLY
200V 50Hz
220V 50/60Hz 3PHASE kVA GE N
ER
EM
SERIAL No.
Y
DATE
MADE IN JAPAN NJ2484-1
THE MANIPULATOR AND THE CONTROLLER S

SHOULD HAVE SAME ORDER NUMBER. T O P
ORDER NO.
NJ1529
WARNING
Do not open the door
REMOTE TEACH
PLAY
ON
ED
IPP
TR
OFF
ET
RES
MULTI
COORD. SERVO
DISPLAY
SWITCH POWER
SELECT
MAIN SHORTCUT ASSIST
MENU MENU
X- X+ x x
S- S+ R- R+
Y- Y+ y y
L- L+ B- B+
- + z z
R- R+ T- T+
SHIFT INTER
LOCK
7 WEAVING
8WELD
9 TEST RUN SHIFT
START START FEED
ROBOT 4 5 6
RETRUCT BACK NEXT
AUXILIARY WEAVING WELD
SWITCH COMPLETE COMPLETE
EX-AXIS 1 2 3CURRENT DELETE INSERT

SWITCH AUXILIARY TIMER VOLTAGE
CABCEK 0 . -CURRENT ENTER

INTER. REF.
POINT VOLTAGE MODIFY
(a) NX100 (Front View) (b) Manipulator (Side View)
Fig. 1 Location of Order Number Labels
1-2
2.1 Transporting Method
2 Transporting
CAUTION
• Sling applications and crane or forklift operations must be performed by
authorized personnel only.
Failure to observe this caution may result in injury or damage.
• Avoid excessive vibration or shock during transporting.
Failure to observe this caution may adversely affect the performance as the system con-
sists of precision components.
• The weight of the manipulator is approximately 1150kg including the shipping bolts and
NOTE brackets. Use a wire rope strong enough to withstand the weight.
• Shipping bolts and brackets 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 exerting force on the arm or motor unit when transporting, and use caution when
using transporting equipment other than a crane or forklift, as injury may occur.
2.1.1 Using a Crane

As a rule, when removing the manipulator from the package and moving it, a crane should be
used. The manipulator should be lifted using wire rope threaded through shipping bolts and
brackets. Be sure the manipulator is fixed with the shipping bolts and brackets before trans-
porting, and lift it in the posture as shown in " Fig. 2 Transporting Position ".
2-1
Details of shipping bolt

Rubber plate
Electrical tape
painted in yellow
B Shipping bolt
(1 piece)
Shipping bracket
A (4 pieces)
Hook
Fig. 2 Transporting Position
2-2
2.2 Shipping Bolts and Brackets
2.2 Shipping Bolts and Brackets
The manipulator is provided with shipping bolts and brackets at position A and with the hexa-
gon socket head cap screws at point B. (" Fig. 2 Transporting Position ").
A Shipping bracket B Shipping bolt

Hook
Rubber plate
Electrical tape painted

in yellow
Fig. 3 Shipping Bolts and Brackets
• The A-shipping brackets are painted in yellow

• The B-shipping bolt: hexagon socket head cap screw is taped in yellow .
Position Bolt Type Pcs
A Hexagon socket head cap screw M20 X 70 mm 12
B Hexagon socket head cap screw M16 X 20 mm 1
Before turning ON the power, check to be sure that the shipping bolts and brackets have
NOTE been removed. The shipping bolts and brackets then must be stored for future use, in the
event that the robot must be moved again.
2-3
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 NX100 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 the manipulator which 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 explained in “Fig. 3 Shipping Bolts and Brackets” are
removed.
Failure to observe this caution may result in damage to the driving parts.
3-1
3.1 Installation of the Safeguarding
3.1 Installation of the Safeguarding
To insure safety, be sure to install the safeguarding. They prevent unforeseen accidents with
personnel and damage to equipment. The following is quoted for your information and guid-
ance.
Responsibility for Safeguarding (ISO 10218)

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 safe-
guarding, 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 sup-
port 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.1 Maximum Repulsion Forces of the Manipulator
at Emergency Stop” and “Table.2 Endurance Torque in Operation”.
During installation, if the flatness is not right, the manipulator shape may change and its func-
tional ability may be compromised. Baseplate flatness must be kept at 0.5mm or less. Mount
the manipulator base as in the following way: “3.2.1 Mounting Example”.
Table. 1 Maximum Repulsion Forces of the Manipulator at Emergency Stop
Horizontal rotating maximum torque 32000N • m

(S-axis moving direction) (3265kgf • m)
Vertical rotating maximum torque 78500N • m

(L-, U-axes moving direction) (8000kgf • m)
Table. 2 Endurance Torque in Operation
Horizontal acceleration and decel- 9400N • m

eration maximum torque (960kgf • m)
Vertical acceleration and decelera- 23900N • m

tion maximum torque (2434kgf • m)
3-2
3.3 Location
3.2.1 Mounting Example

Fix the baseplate onto the floor. The baseplate should be rugged and durable to prevent shift-
ing of the manipulator or the fixture. The thickness of the baseplate is 50mm or more, and an
M20 size or larger anchor bolt is recommended.
Fix the manipulator base onto the baseplate with the hexagon socket head cap screw M20.
The plate is tapped for M20 (length: 80mm) screws. Tighten the screws and anchor bolts
securely so that they will not work loose during operation. See " Fig. 4 Mounting the Manipula-
tor on Baseplate ".
Hexagon socket head cap screw

M20 (8 screws)
Spring washer
Flat washer
Manipulator base
40
Baseplate
Flatness: 0.5mm
or less
Units: mm
Fig. 4 Mounting the Manipulator on Baseplate
3.3 Location
When the manipulator is installed, it is necessary to satisfy the undermentioned environmental

conditions:
• Ambient temperature: 0° to 45°C

• Humidity: 20 to 80%RH at constant temperature
• Free from exposure to water, oil, or dust
• Free from corrosive gas or liquid, or explosive gas
• Free from excessive shock or vibration (less than 4.9m/s2 [0.5G])
• Free from large electrical noise (plasma)
• Flatness for installation is 0.5mm or less
3-3
4 Wiring
WARNING
• Ground resistance must be 100 Ω or less.
Failure to observe this warning may result in fire or electric shock.
• Before wiring, make sure to turn the primary power supply off, and put
up a warning sign. (ex. DO NOT TURN THE POWER ON.)
Failure to observe this warning may result in fire or electric shock.
CAUTION
• Wiring must be performed by authorized or certified personnel.
Failure to observe this caution may result in fire or electric shock.
• Do not cover the cable or allow it to tangle. Keep the cable as straight
as possible.
Failure to observe this caution may result in preventing heat of the cable from being dis-
charged.
4-1
4.1 Grounding
4.1 Grounding
Follow local regulations for grounding line size. A line of 5.5mm2 or more is recommended.
• Do not use this line in common with other ground lines or grounding electrodes for other
NOTE electric power, motor power, welding devices, etc.
• Where metal ducts, metallic conduits, or distributing racks are used for cable laying,
ground in accordance with Electric Equipment Technical Standards.
A Bolt M8 (for grounding)

Delivered with manipulator
View A
5.5mm2 or more
Fig. 5 Grounding Method
4.2 Manipulator Cable Connection
Three manipulator cables are provided; an encoder cable for detection (1BC) and two power
cables (2BC and 3BC). (Refer to " Fig. 6 Manipulator Cable Connections ".) Connect these
cables to the manipulator base connectors and the NX100. (Refer to “ Fig. 7 (a) Details of the
Manipulator Cable Connectors (Manipulator Side) ” and " Fig. 7 (b) Manipulator Cable Con-
nections to the NX100 ".
4.2.1 Connection to the Manipulator

Before connecting the manipulator cables to the manipulator, confirm the numbers: 1BC, 2BC,
and 3BC on both the cables and the manipulator base connectors. When connecting, insert
cables adjusting the cable connector positions to the main key positions of the manipulator,
and then set the lever until it clicks.
4-2
4.2.2 Connection to the NX100

First connect the 2BC cable then 3BC and 1BC cables respectively after verifying the num-
bers. The numbers are on both the manipulator cables and the NX100 board connectors.
When connecting, insert cables adjusting the cable connector positions to the main key posi-
tions of the NX100, and then set the lever until it clicks.
NX100 side Manipulator side

X11
1BC
X11
1BC
1BC
Encoder cable
X21 2BC
2BC
2BC
X21
Power cable
X22 3BC
3BC
3BC
X22
Power cable
Fig. 6 Manipulator Cable Connections
4-3
1BC
AIR S1
2BC
molex
molex
3BC
1BC 2BC 3BC
Key positions
Connector details
(Manipulator side) A
Fig. 7 (a) Details of the Manipulator Cable Connectors (Manipulator Side)
X11
X21
X22
Fig. 7 (b) Manipulator Cable Connections to the NX100
4-4
5.1 Basic Specifications
5 Basic Specifications
5.1 Basic Specifications

Table.3 Basic Specifications*1
MOTOMAN-ES165N
Item Model MOTOMAN-ES165N with external cabling for
SRBT-axes
Configuration Vertically Articulated

Degree of Freedom 6
Payload 165kg
Repeatability*2 ±0.2mm
S-Axis (turning) ±180°
L-Axis (lower arm) +76°, -60°
Range of U-Axis (upper arm) +230°, -142.5°
Motion
R-Axis (wrist roll) ±360° ±205°
B-Axis (wrist pitch/yaw) ±130° ±120°
T-Axis (wrist twist) ±360° ±200°
S-Axis 1.92 rad/s, 110°/s
L-Axis 1.92 rad/s, 110°/s
Maximum U-Axis 1.92 rad/s, 110°/s
Speed
R-Axis 3.05 rad/s, 175°/s
B-Axis 2.53 rad/s, 145°/s
T-Axis 4.19 rad/s, 240°/s
R-Axis 921N•m (94kgf•m)
Allowable
B-Axis 921N•m (94kgf•m)
Moment*3
T-Axis 490N•m (50kgf•m)
Allowable R-Axis 85kg•m2
Inertia B-Axis 85kg•m2
(GD2/4)
T-Axis 45kg•m2
Mass 1100kg
Temperature 0° to 45°C
Humidity 20 to 80% RH at constant temperature
Vibration acceleration Less than 4.9m/s2 (0.5G)
Ambient
• Free from corrosive gas or liquid, or explosive gas
Conditions
• Free from exposure to water, oil, or dust
Others • Free from excessive electrical noise (plasma)
Power Capacity 7.5kVA
*1 SI units are used in this table. However, gravitational unit is used in ( ).

*2 Conformed to ISO9283
*3 Refer to 6.1 "Allowable Wrist Load" for details on the permissible moment of inertia.
5-1
5.2 Part Names and Working Axes
5.2 Part Names and Working Axes

U+ R+ Wrist
Upper arm B+ T+
(U arm)
Wrist flange
U- R- B- T-
L- L+
Rotary head Lower arm

(S head) (L arm)
S+
S-
Base
Fig. 8 Part Names and Working Axes
5.3 Manipulator Base Dimensions

893
640
+0.021
Fitting surface 290 0.1 290 0.1 20 0 dia. (2 holes)
(Pin hole for manipulator
540 positioning)
350 0.1
290 0.1
735
640
540
40
Fitting surface
290 0.1
A 290 0.1 290 0.1 +0.018

16 0 dia. (2 holes)
353 0.1 (Pin hole for manipulator
Units: mm 22 dia. (8 holes) positioning)
(For fixing the manipulator)
View A
Fig. 9 Manipulator Base Dimensions
5-2
5.4 Dimensions and P-Point Maximum Envelope
5.4 Dimensions and P-Point Maximum Envelope
R7
29
73
R608
410
491
R26
51
4612
1961 2651
3050
P-point maximum
153 envelope
285 1225 225

250
P-point
42°
25° 18°
491 337
50°
1150
76
° °
60
2203
1024
.5°
142
687 650
495
348
650
126
0 0
16
Units: mm
945
729
524
727
701
582
322
1307
Fig. 10 Dimensions and P-Point Maximum Envelope
5-3
5.5 Alterable Operating Range
The operating range of the S-Axis can be altered according to the operating conditions as
shown in “Table. 4 S-Axis Operating Range”. If alteration is necessary, contact your Yaskawa
representative in advance.
Table. 4 S-Axis Operating Range
Item Specifications
±180° (standard)
±165°
±150°
±135°
±120°
S-Axis
±105°
Operating
±90°
Range
±70°
±60°
±45°
±30°
(±15°)
NOTE The interval between stopper and stopper can correspond only by 60° or more.
5-4
5.5.1 Components for Altering Operating Range

Arrange the components listed in " Fig. 11 The Components of the S-Axis Stopper ", when
modifying the angle of S-axis.
Pin (drawing No. HW0402104-1, 1 pin)

Stopper (drawing No. HW0302424-2, 1 stopper)
Hexagon socket head cap screw M20
(length: 45mm) (3 screws) (tightening torque: 402 N m)
Flat washer M20 (3 flat washers)
Hexagon socket head cap screws M20 (3 screws)

(length: 45) (tightening torque: 12.9)
Flat washer M20
Stopper
HW0302424-2
Section A-A
Pin
HW0402104-1
A A
Fig. 11 The Components of the S-Axis Stopper
5-5
5.5.2 Notes on the Mechanical Stopper Installation

• For S-Axis mechanical stopper, install the stopper (drawing No. HW0302424-2) with the
pin which is used bottom up (drawing No. HW0402104-1) as in " Fig. 11 The Components
of the S-Axis Stopper ".
• DO NOT forget applying the locktite 242 to screwed parts of the pin as inserting it into the
stopper.
• Install the stopper to the S head with the hexagon socket head cap screws M20 (length;
45mm, 3 screws) fastening by the tightening torque intensified 12.9 (tightening torque:
402 N m).
• To avoid the mechanical troubles, refer to "Table. 5 The Settable Angle for S-Axis Stop-
per" when mounting the S-Axis mechanical stopper. The stopper can be installed by
every 15 degrees.
• Confirm to stabilize both sides of the protrusion with the hexagon socket head cap screws
as in " Fig. 12 Properly-Mounted Image " on account of the limitation of strength to the
unit.
• Refer to the figures: “Fig.13” as adjusting the setting angle of the S-Axis mechanical stop-
per. When mounting the S-Axis mechanical stopper by inverse angle to the examples in
the figures: “Fig.13”, settle the machinery symmetrical to those models.
• As in the figures: “Fig.13”, the component is reversible that both sides of the machinery
can be attached to the stopper, except for the angles of ±30, ±60, ±120, ±150 degrees.
Flip side and retry installing the S-Axis mechanical stopper if finding any difficulty to set
the machinery to the stopper based on " Fig. 11 The Components of the S-Axis Stopper ".
.
Hexagon socket Hexagon socket

head cap scerws head cap scerws
Improperly-mounted Properly-mounted
Fig. 12 Properly-Mounted Image
1. Apply the specified components when mounting the S-Axis mechanical stopper.
NOTE 2.TURN OFF the electric power supply before mounting.
5-6
5.5.3 Adjustment to the Pulse Limitation of S-Axis

Apply the Instruction for NX100 Concurrent I/O Parameter (Manual No.:RE-CKI-A442) as
part of reference materials for adjusting the programming pendant when modifying the range
of motion of S-Axis.
The limitation to the pulse (Pulse Soft Limit + 1st Axis ) : SICxG200
The limitation to the pulse (Pulse Soft Limit - 1st Axis ) : SICxG208
Degree ±0° ±15° ±30° ±45° ±60° ±75° ±90°
Number
±0 ±35109 ±70217 ±105326 ±140434 ±175543 ±210651
of Pulse
Degree ±105° ±120° ±135° ±150° ±165° ±180° (Standard)
Number
±245760 ±280869 ±315977 ±351086 ±386194 ±421303
of Pulse
NOTE Adjust both of the pulse limitation and the angle of S-Axis mechanical stopper as
modifying the range of motion for machinery.
5-7
Table 5. The settable angle for S-Axis Stopper
The Angle of S-Axis Stopper for + Direction

180 165 150 135 120 105 90 75 60 45 30 15 0 -15 -30 -45 -60 -75 -90 -105 -120 -135 -150 -165 -180
-180
-165
-150
-135
-120
-105
-90
-75
-60
-45
-30
-15
0
5-8
15
30
45
60
75
90
105
The Angle of S-Axis Stopper for - Direction

120
135
150
165
180
…Settable angle "Table. 5 The Settable Angle for S-Axis Stopper" indicates the angle range
…Non settable angle which allows S-axis to be set for + direction and - direction angles.
Mounting the S-Axis Stopper by Settable Angles

　
Hexagon socket
head cap screws
The stopper could be

utlized by either side.
The Settled Model of +180 Degree
Hexagon socket
head cap screws

Fig. 13 (a) The Properly-Mounted Models for S-Axis Stopper
5-9
The stopper only utlized by one side with this angle
Hexagon socket
head cap screws

Hexagon socket
head cap screws
Fig. 13 (b) The Properly-Mounted Models for S-Axis Stopper
5-10
The stopper is only utlized

by one side with this angle
Hexagon socket
head cap screws
Hexagon socket
The stopper could
head cap screws
be utlized by either side.
Fig. 13 (c) The Properly-Mounted Models for S-Axis Stopper
5-11
The stopper could be utlized by either side.

Hexagon socket
head cap screws
The Settled Model of + 90 Degree

Hexagon socket
head cap screws
Fig. 13 (d) The Properly-Mounted Models for S-Axis Stopper
5-12
Hexagon socket
head cap screws

utilized by either side.
Hexagon socket
head cap screws
Fig. 13 (e) The Properly-Mounted Models for S-Axis Stopper
5-13

Hexagon socket
head cap screws
Hexagon socket
head cap screws
Fig. 13 (f) The Properly-Mounted Models for S-Axis Stopper
5-14
Hexagon socket
head cap screws
The Settled Model of 0 Degree
Fig. 13 (g) The Properly-Mounted Models for S-Axis Stopper
5-15
6.1 Allowable Wrist Load
6 Allowable Load for Wrist Axis and Wrist Flange
6.1 Allowable Wrist Load

The allowable wrist load including the weight of the mount/gripper is:
• YR-ES165N-A00, -A01: 165kg maximum
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 Allowable Total Moment and Total Inertia ". Contact your
Yaskawa representative for further information or assistance.
Table. 6 Allowable Total Moment and Total Inertia
Moment N•m
Model Axis GD2/4 Inertia kg•m2
(kgf•m)*1
R-Axis 921 (94) 85
YR-ES165N-A00 B-Axis 921 (94) 85
T-Axis 490 (50) 45
*1 ( ): Gravitational unit
When the volume load is small, refer to the moment arm rating shown in " Fig. 14 Moment
Arm Rating ".
The allowable total inertia is calculated when the moment is at the maximum. Contact your
Yaskawa representative when only inertia, or load moment is small and inertia is large. Also,
when the load mass is combined with an outside force, contact your Yaskawa representative.
LT(mm)
1000 40kg
800 60kg
600 80kg
400
P-point
165kg T-, R-axis
200
130kg center of rotation
100kg
400 600 800 1000 1200 1400 LB(mm)
200
400
600
800
1000
LT(mm)
B-axis center of rotation
Fig. 14 Moment Arm Rating
6-1
6.2 Wrist Flange
6.2 Wrist Flange
The wrist flange dimensions are shown in " Fig. 15 Wrist Flange ". In order to see the align-
ment mark, it is recommended that the attachment be mounted inside the fitting. Fitting depth
of inside and outside must be 8mm or less.
8
P.
C. Tapped hole M10
D.
92 (6 holes) (depth: 12mm)
25
.D.1
P.C
Tapped hole M10

(6 holes) (depth: 12mm)
dia.
dia.
+0.015
+0.030
0
-0.025
0
9 0 dia.
Alignment (2 holes) (depth: 8mm)

63
160
mark +0.018
10 0 dia.
(2 holes) (depth: 8mm) Units: mm
Fig. 15 Wrist Flange
NOTE Wash off anti-corrosive paint (Yellow) on the wrist flange surface with thinner or light oil
before mounting the tools.
6-2
7.1 Peripheral Equipment Mounts
7 System Application
7.1 Peripheral Equipment Mounts
When peripheral equipment is attached to the manipulator, the following conditions should be
observed.
133
120
A1
Tapped hole M8
255 40
120
40 255
A2
133
Tapped hole M8
120
255 40
40 255
Tapped hole M12

B
120
75 137.5
153
117 73
5
50 30
85
B 75 137.5
117 73
Tapped hole M12

30
5

85
50
Fig. 16 Installing Peripheral Equipment
Table. 7 Constraint for Attaching
Application Note
A1, Cable Processing and 30 kg max.

A2 Valve Load 49N m (5kgf m) max. for moment
increase amount of upper arm
B Others 250 kg max.
7-1
7.2 Internal User I/O Wiring Harness and Air Line
3 cables for valves (0.75mm2), 18 internal user I/O wires (0.5mm2 x 6 wires, 0.75mm2 x 12
wires), the cables for the external axis (1.0mm2 x 4 cables, 0.5mm2 x 2 cables), and an air
line are used in the manipulator for the drives of the peripheral devices mounted on the upper
arm as shown in " Fig. 17 (a) Connectors for Internal User I/O Wiring Harness and Air Line ".
The connector pins, and the terminals are assigned as shown in " Fig. 17 (b) Connectors for
Internal User I/O Wiring Harness and Air Line (Pin Details) ". Wiring must be performed by
user.
• The allowable current for wires : 8.0A or less / wire. (1.25mm2)
: 7.0A or less / wire. (1.0mm2)
• The maximum pressure for the air line is 490kPa (5kgf/cm2) or less
(The air line inside diameter: 8mm dia.)
7-2
Connector for the external axis (Encoder cable):

JL05-2A20-29SC
Exhaust port (air flow)
(socket connector with cap).
Tapped holes PT3/8 Prepare pin connector: JL05-6A20-29P.
with pipe plug
Connector for internal user I/O wiring harness (Casing):
JL05-2A22-14SC
Connector for the external (socket connector with cap).
axis (Power cable): Prepare pin connector: JL05-6A22-14P.
JL05-2A18-1SC
(socket connector with cap).
Prepare pin connector:
JL05-6A18-1P.
Key position
Connector for internal user I/O wiring harness (Base):

JL05-2A28-21PC (pin connector with cap).
Prepare socket connector: JL05-6A28-21S.
1BC
AIR S1
3BC
Air inlet (air flow)

Tapped holes PT3/8 with pipe plug
2BC
View A
Fig. 17 (a) Connectors for Internal User I/O Wiring Harness and Air Line
7-3
P
1
2
3 2 P
1
P 0.5mm (6 pins) 2
4 3 2
P
5 P 4 0.5mm (6 pins)
6 5
7 P 6
8 7
9 8
10 9
11 Pins used 10
12 2 11
13 0.75mm (12 pins) 12 2
14 13 0.75mm (12 pins)
15 14
Pins used 16 15
17 16
17
18 18
19
20 2
0.75mm (3 pins)
21
1 2 3
4 5 6 7
1 2 3 4 8 9 10 11 12
13 14 15 16
5 6 7 8 9
17 18
10 11 12 13 14 15
16 17 18 19 20 21 22
Pin details for internal user I/O wiring harness
23 24 25 26 27 28 (Casing side)
29 30 31 32 33
34 35 36
Pin details for internal user I/O wiring harness 1

(Base side) 2 2
3 1.0mm (4 pins)
Pins used
4
5 2
0.5mm (2 pins)
6
P
1 1 2
2 2
0.2mm (4 pins) 3 4 5
Pins used P 9
10 6 7 8
15 Shielded wire 9
1
2 3 Pin details for external axis power cable
4 5 6
7 8
9 10
13 11 12 14
15 16
Pin details for external axis encoder cable

(~RH9550-4077)
Fig. 17 (b) Connectors for Internal User I/O Wiring Harness and Air Line (Pin Details)
7-4
P
1
2
3 2 P
1
P 0.5mm (6 pins) 2
4 3 2
P
5 P 4 0.5mm (6 pins)
6 5
7 P 6
8 7
9 8
10 9
11 Pins used 10
12 2 11
13 0.3mm (12 pins) 12 2
14 13 0.3mm (12 pins)
15 14
Pins used 16 15
17 16
17
18 18
19
20 2
0.75mm (6 pins)
21
22 1 2 3
23 4 5 6 7
24 8 9 10 11 12
13 14 15 16
17 18
1 2 3 4
5 6 7 8 9
Pin details for internal user I/O wiring harness
10 11 12 13 14 15 (Casing side)
16 17 18 19 20 21 22
23 24 25 26 27 28
29 30 31 32 33
34 35 36
1
2 2
3 1.25mm (4 pins)
Pin details for internal user I/O wiring harness Pins used
4
(Base side) 5 2
0.75mm (2 pins)
6
7 2
8 1.25mm (3 pins)
9
P
1
2 2
0.2mm (4 pins)
Pins used P 9 1 2
10
15 Shielded wire 3 4 5
6 7 8
9
2 1 3
4 5 6
7 8
9 10 Pin details for external axis power cable
13 11 12 14
15 16
Pin details for external axis encoder cable

(RH9550-4077~)
Fig. 17 (c) Connectors for Internal User I/O Wiring Harness and Air Line (Pin Details)
7-5
8.1 Position of S-Axis Limit Switch
8 Motoman Construction
8.1 Position of S-Axis Limit Switch
The limit switches are optional. For the S, L, and U-Axes with limit switches specifications,
L.S. are located on S-Axis, L-Axis, and U-Axis respectively. For the location, refer to " Fig. 18
Location of Limit Switches ". The inspection and adjustment of the limit switches should be
made after removing the cover.
LU-axes interference
limit switch
L-axis overrun limit switch
S-axis overrun limit switch
1BC
AIR S1
2BC
3BC
Fig. 18 Location of Limit Switches
8-1
8.2 Internal Connections
High reliability connectors which can be easily put on and removed are used with each con-
nector part. For the numbers, types, and locations of connectors, see " Fig. 19 Location of
Connectors " and “Table.8 List of Connector Types”.
Connector for external axis

(Power cable)
Connector for external axis

(Encoder cable)
Connector for internal user

I/O wiring harness (Casing)
1BC
AIR S1
2BC
molex
molex
3BC
Connector for
Internal user I/O
1BC wiring harness
(Base)
2BC 3BC
Fig. 19 Location of Connectors
Table. 8 List of Connector Types
Name Type of Connector
Connector Base Connector for internal user I/O JL05-2A28-21PC

wiring harness (JL05-6A28-21S: Optional)
U-arm Connector for internal user I/O JL05-2A22-14SC

wiring harness (JL05-6A22-14P: Optional)
Connector for external axis JL05-2A20-29SC

(Encoder cable) (JL05-6A20-29P: Optional)
Connector for external axis JL05-2A18-1SC

(Power cable) (JL05-6A18-1P: Optional)
8-2
0BT 1 0BAT11 17 0BAT1

K R P BAT 2 BAT11 18 BAT1
0BT 3 0BAT12 19 0BAT2
K R P BAT 4 BAT12 20
21
BAT2
0BAT3 Note)
22 BAT3
23
0BT 5 0BAT21
24
25 0BAT4
1. This diagram is for the MOTOMAN-ES165N.
K R P BAT
0BT
6
7
BAT21
0BAT22
26
27
BAT4
0BAT5 For the limit switch specification, the connection of the section A was changed.
K R P BAT 8 BAT22 28 BAT5
29 0BAT6
30 BAT6
1 31
2
3
32
1 PG0V1
2. For RH9550-4077 and over, the connections of the sections X , Y , Z were changed.
4 2 PG5V1
5 3 PG0V2
6 4 PG5V2
7 5 PG0V3
8 6 PG5V3
7 PG0V4
8 PG5V4
1BC(10Px4) 9 PG0V5
NX100 No.22CN X 10 PG5V5
CN1-5 +24V CN1-5 +24V -1 +24V 1 11 PG0V6
0V P CN1-4 0V -3 0V 3 12 PG5V6
CN1-4
13
CN1-10 +24V CN1-10 +24V -2 +24V 2 14
0V P CN1-9 0V -4 0V 4 15
CN1-9
16 No.1CN
CN1-1 SPG+1 CN1-1 SPG+1 1CN-1 DATA+1
SPG-1 P CN1-2 SPG-1 No.16CN S P -2 DATA-1
CN1-2
-1 BAT1 -6 BAT
-2
-3
0BAT1
PG5V1
P -5
-4
OBT
+5V
PG S-AXIS
-4 PG0V1 P -9 0V
CN1-3 FG1 CN1-3 FG1 -7 FG1
OBT
BAT
No.2CN
SPG-2 P CN1-7 SPG-2 No.17CN L P -2 DATA-2
CN1-7
-1 BAT2 -6 BAT
-2
-3
0BAT2
PG5V2
P -5
-4
OBT
+5V
PG L-AXIS
-4 PG0V2 P -9 0V
CN1-8 FG2 CN1-8 FG2 -7 FG2
OBT
BAT
No.3CN
SPG-3 P CN2-2 SPG-3 No.18CN U P -2 DATA-3
CN2-2
-1 BAT3 -6 BAT
-2
-3
0BAT3
PG5V3
P -5
-4
OBT
+5V
PG U-AXIS
-4 PG0V3 P -9 0V
CN2-3 FG3 CN2-3 FG3 -7 FG3
OBT
BAT
No.4CN
SPG-4 P CN2-7 SPG-4 No.19CN R P -2 DATA-4
CN2-7
-1 BAT4 -6 BAT
-2 0BAT4 P -5 OBT PG R-AXIS
-3 PG5V4 -4 +5V
-4 PG0V4 P -9 0V
CN2-8 FG4 CN2-8 FG4 -7 FG4
OBT
BAT
No.5CN
SPG-5 P CN3-2 SPG-5 No.20CN B P -2 DATA-5
CN3-2
-1 BAT5 -6 BAT
-2 0BAT5 P -5 OBT PG B-AXIS
-3 PG5V5 -4 +5V
-4 PG0V5 P -9 0V
CN3-3 FG5 CN3-3 FG5 -7 FG5
OBT
BAT
No.6CN
SPG-6 P CN3-7 SPG-6 No.21CN T P -2 DATA-6
CN3-7
-1 BAT6 -6 BAT
-2
-3
0BAT6
PG5V6
P -5
-4
OBT
+5V
PG T-AXIS
-4 PG0V6 P -9 0V
CN3-8 FG6 CN3-8 FG6 -7 FG6
SS1 OBT
BAT
CN4-1 +24V CN4-1 +24V LA1 LB1
CN4-6 LB1 P CN4-6 LB1
LA2
LB2
LA3
LA2
LB2
LA3
A
LB3 LB3
CN4-2 SS2 CN4-2 SS2 SS2

CN4-7 AL1 P CN4-7
BC1
CN4-3 BC2
AL2 P
CN4-3
CN4-8
BC2 BC2 FOR LAMP(OPTION)
CN4-8
No.7CN(20-29)
SPG+7 CN4-4 SPG+7 1
CN4-4 SPG-7 P CN4-5 SPG-7 P 2
SPG+7
CN4-5 FG7 CN4-9 FG7 10
SPG-7
CN4-9 0V P CN2-4 0V P 9
0V
CN2-4 5V CN2-5 5V 15
5V
CN2-5 0V P CN2-9 0V FG7
CN2-9 5V CN2-10 5V E
CN2-10 0V P CN3-4 0V
CN3-4 5V CN3-5 5V
CN3-5 0V P CN3-9 0V
CN3-9 5V CN3-10 5V
CN3-10
E
E E
Base MANIPULATOR Casing

S1(28-21)
E E E E E E
19 SP19
20 SP20
21 SP21
22 SP22
23 SP23 No.8CN(22-14)
24 SP24
E
RH9550-4077~ X
1 1 SP1
P 2 SP2
2 3
3 SP3
P 4
4 5 SP4
5 SP5
6
P 6
SP6 Y
7 SP7
7 P 8
8 9 SP8
9 P 10 SP9
10 11 SP10
11 P 12 SP11
12 13 SP12
13 P 14 SP13
14 15 SP14
15 P 16 SP15
16 17 SP16
17 P 18 SP17
18 SP18
RH9550-4077~ ~RH9550-4077
Y
Fig. 20 (a) Internal Connection Diagram
8-3
S-AXIS OVERRUN L.S.

LA1
2BC(8PX5+12PX1) LB1 L-AXIS OVERRUN L.S.(OPTION)
E E LA2
LB2
LA2 A
LB2
LA3 LA3
LB3 LB3
CN1-1 MU1 CN1-1 MU1
CN1-2 MU1 CN1-2 MU1
CN1-3 MU1 CN1-3 MU1
S-axis L.S.
CN1-5 MV1 CN1-5 MV1
CN1-6 MV1 CN1-6 MV1
CN1-7 MV1 CN1-7 MV1 No.9CN
9CN-A MU1
-B MV1 S-AXIS OVERRUN L.S.
CN2-1 MW1 CN2-1 MW1 LA1
CN2-2 MW1 CN2-2 MW1 -C MW1 SM S-AXIS LB1 L-AXIS OVERRUN L.S.(OPTION)
CN2-3 MW1 CN2-3 MW1 -D ME1
LA2 LA2
-E BA1 LB2 LB2 A
CN1-4 ME1 CN1-4 ME1 -F BB1 YB LB1 LA3 LA3
CN1-8 ME1 CN1-8 ME1 LB3 LB3
CN2-4 ME1 CN2-4 ME1
CN6-1 BA1 CN6-1 BA1
CN6-2 BB1 CN6-2 BB1 L-axis L.S.
S-AXIS OVERRUN L.S.

CN2-5 MU2 CN2-5 MU2 LA1
CN2-6 MU2 CN2-6 MU2 LB1 L-AXIS OVERRUN L.S.(OPTION)
CN2-7 MU2 CN2-7 MU2 LA2 LA2
LB2 LB2 A
CN3-1 MV2 CN3-1 MV2 LA3 LA3
CN3-2 MV2 CN3-2 MV2 LB3 LB3
10CN-A MU2 LB1 L AND U-AXIS INTERFERENCE L.S.
CN3-5 MW2 CN3-5 MW2 -B MV2
CN3-6 MW2 CN3-6 MW2 -C MW2 SM L-AXIS LU-axis L.S.
-E BA2
CN2-8 ME2 CN2-8 ME2 -F BB2 YB
CN3-4 ME2 CN3-4 ME2
CN3-8 ME2 CN3-8 ME2
CN6-3 BA2 CN6-3 BA2
CN6-4 BB2 CN6-4 BB2
CN4-1 MU3 CN4-1 MU3

CN4-2 MU3 CN4-2 MU3
CN4-3 MU3 CN4-3 MU3
CN4-5 MV3 CN4-5 MV3

CN4-6 MV3 CN4-6 MV3
11CN-A MU3
CN5-2 MW3 CN5-2 MW3 -C MW3 SM U-AXIS
-E BA3
CN4-4 ME3 CN4-4 ME3 -F BB3 YB
CN4-8 ME3 CN4-8 ME3
CN5-4 ME3 CN5-4 ME3
CN6-5 BA3 CN6-5 BA3
CN6-6 BB3 CN6-6 BB3
CN6-7 BA4 CN6-7 BA4
CN6-8 BB4 CN6-8 BB4
CN6-9 BA5 CN6-9 BA5
CN6-10 BB5 CN6-10 BB5
CN6-11 BA6 CN6-11 BA6

CN6-12 BB6 CN6-12 BB6
3BC(6PX6)
E E
CN1-1 MU4 CN1-1 MU4

CN1-2 MU4 CN1-2 MU4
CN1-5 MV4 CN1-5 MV4 12CN-A MU4
CN2-2 MW4 CN2-2 MW4 -C MW4 SM R-AXIS
CN1-3 ME4 CN1-3 ME4 -D ME4
CN1-6 ME4 CN1-6 ME4 -E BA4
-F BB4 YB
CN2-4 MU5 CN2-4 MU5

CN2-5 MU5 CN2-5 MU5
CN3-2 MW5 CN3-2 MW5 -C MW5 SM
CN3-3
CN3-6
ME5
ME5
CN3-3
CN3-6
ME5
ME5
-D
-E
ME5
BA5
B-AXIS
-F BB5 YB
CN3-4 MU6 CN3-4 MU6

CN3-5 MU6 CN3-5 MU6
CN4-3 MW6 CN4-3 MW6 -C MW6 SM
CN4-5
CN4-6
ME6
ME6
CN4-5
CN4-6
ME6
ME6
-D
-E
ME6
BA6
T-AXIS
-F BB6 YB
No.15CN No.15CN
E E
CN5-1 MU7 CN5-1 MU7 1
CN5-4 MU7 CN5-4 MU7 7
CN6-1 MV7 CN6-1 MV7 2
1
CN6-4 MV7 CN6-4 MV7 8 2
CN6-5 MW7 CN6-5 MW7 3 3
CN6-6 MW7 CN6-6 MW7 9 4
CN5-2 ME7 CN5-2 ME7 4
CN5-5 ME7 CN5-5 ME7
CN5-3 BA7 CN5-3 BA7 5 5

CN5-6 BB7 CN5-6 BB7 6 6
RH9550-4077~ ~RH9550-4077
PE Z Z
Fig. 20 (b) Internal Connection Diagram
8-4
9 Maintenance and Inspection
WARNING
• Before maintenance or inspection, be sure to turn the main power sup-
ply off, and put up a warning sign. (ex. DO NOT TURN THE POWER ON.)
Failure to observe this warning may result in electric shock or injury.
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 manipu-
lator’s arm.
• The battery unit must be connected before removing detection connec-

tor when maintenance and inspection.
Failure to observe this caution may result in the loss of home position data.
Proper inspections are essential not only to assure that the mechanism will be able to function
for a long period, but also to prevent malfunctions and assure safe operation. Inspection inter-
vals are displayed in six levels. Conduct periodical inspections according to the inspection
schedule in " Table. 9 Inspection Items ".
In " Table. 9 Inspection Items ", the inspection items are classified into three types of opera-
tion: operations which can be performed by personnel authorized by the user, operations
which can be performed by personnel being trained, and operations which can be performed
by service company personnel. Only specified personnel are to do inspection work.
9-1
• The inspection interval must be based on the servo power supply on time.
NOTE • For any different or special applications, the inspection process should be developed on
an case-by-case basis.
• For axes which are used very frequently (in handling applications, etc.), it is recom-
mended that inspections be conducted at shorter intervals. Contact your Yaskawa repre-
sentative.
Table. 9 Inspection Items
Schedule Inspection Charge
Items*4 1000 6000 12000 Method Operation

24000 36000 Specified Service
Daily H H H Person
Licensee
Company
H H
Cycle Cycle Cycle
Check alignment
Alignment mark accordance
Visual
mark and damage at the
home position.
Check for damage

External lead Visual and deterioration of
leads.
Clean the work area

Working area if dust or spatter is
and Visual present. Check for
manipulator damage and outside
cracks.
L-,U-axes Check for grease

Visual
motor leakage.*5
Baseplate Tighten loose bolts.

Spanner Replace if necessary.
mounting Wrench
bolts
Cover mount- Screw- Tighten loose bolts.

driver, Replace if necessary.
ing screws Wrench
S-,L-,U-axes Check for loose con-

motor Manual nectors and tighten if
necessary.
connector
Connector Check for loose con-

Manual nectors.
Base
Grease Supply grease.

Balancer Gun See Par. 9.2.6
Check for conduc-

tion between the
Wire harness main connector of
in manipulator base and intermedi-
ate connector with
(Lead wire for
Multimeter manually shaking the
SLU-axes) wire. Check for wear
(Lead wire for of protective spring*1
RBT-axes)
Replace*2
Replace the battery

pack when the bat-
Battery pack tery alarm occurs or
11 the manipulator
in manipulator
drove for 36000H.
See Par.9.2.1
9-2
Table. 9 Inspection Items
Schedule Inspection Charge
Items*4 1000 6000 12000 Method Operation

24000 36000 Specified Service
Daily H H H Person
Licensee
Company
H H
Cycle Cycle Cycle
Check for malfunc-

tion. (Replace if nec-
essary.)
S-axis speed Replenish grease*3
Grease
12 reducer, Gun
(6000H cycle).
S-axis gear See Par. 9.2.2
Exchange grease*3
(12000H cycle).
See Par. 9.2.2
Check for malfunc-

essary.)
L-axis speed Replenish grease*3

Grease
13 (6000H cycle).
reducer Gun
See Par. 9.2.3
Exchange grease*3
(12000H cycle). See
Par. 9.2.3
Check for malfunc-

essary.)
U-axis speed Replenish grease*3

14 Grease
(6000H cycle).
reducer Gun
See Par. 9.2.4
Exchange grease*3
(12000H cycle). See
Par. 9.2.4
Check for malfunc-

essary.)
R-axis speed Replenish grease*3

15 Grease
(6000H cycle).
reducer Gun
See Par. 9.2.5
Exchange grease*3
(12000H cycle). See
Par. 9.2.5
Check for malfunc-

essary.)
B-, T-axis Replenish grease*3
Grease
16 speed Gun
(6000H cycle).
reducer See Par. 9.2.5
Exchange grease*3
(12000H cycle). See
Par. 9.2.5
17 Overhaul
*1 When checking for conduction with multimeter, connect the battery to “BAT” and “OBT” of connectors on the
motor side for each axis, and then remove connectors on detector side for each axis from the motor. Other-
wise, the home position may be lost. (Refer to” 9.2.7 Notes for Maintenance ”)
*2 Wire harness in manipulator to be replaced at 24000H inspection.
*3 For the grease, refer to " Table. 10 Inspection Parts and Grease Used ".
*4 Inspection numbers correspond to the numbers in “ Fig. 21 Inspection Parts and Inspection Numbers ”.
*5 The occurrence of a grease leakage indicates the possibility that grease has seeped into the motor. This can
cause a motor breakdown. Contact your Yaskawa representative.
9-3
Table. 10 Inspection Parts and Grease Used
No. Grease Used Inspected Parts
Molywhite RE No.00 Speed Reducers for all Axes

12 13 14 R-, B-, and T-Axes gears
15 16
Alvania EP Grease 2 L-Axis Balancer

9
Inspection numbers correspond to the numbers in " Table. 9 Inspection Items ".
9-4
R-Axis B-Axis
5 T-Axis
1 1
S-Axis 1
1
Note: The manipulator is in the home position.
16
15
14
2
10 U-Axis
1
7
L-Axis
1 9 4
13
7
7
2
2
12
11
8
Fig. 21 Inspection Parts and Inspection Numbers (manipurator in Home Position)
9-5
9.2 Notes on Maintenance Procedures
9.2.1 Battery Pack Replacement

The battery packs are attached in the two positions indicated in " Fig. 22 (a) Battery Location
(Back View) " and “ Fig.22 (b) Battery Location (Top View) “.
If a battery alarm occurs in the NX100, replace the battery in accordance with the following
procedure:
Plate
Plate screw M4
1BC
AIR S1
Base 2BC
3BC
Connector base
Fig. 22 (a) Battery Location (Back View)
Battery pack
Board
Fig. 22 (b) Battery Location (Top View)
9-6
Battery pack before replacement

See procedure 5
Connector
Board
See procedure 4
New battery pack
Fig. 23 Battery Connection
1. Turn the NX100 main power supply off.

2. Uninstall the plate from the base connector and pull the battery pack out to replace with
a new battery pack.
3. Remove the battery pack from the battery holder.
4. Connect the new battery pack to the unoccupied connectors on the board.
5. Remove the old battery pack from the board.
NOTE Remove the old battery pack after connecting the new one so that the encoder absolute
data does not disappear.
6. Mount the new battery pack to the battery holder.

7. Reinstall the plate.
NOTE Do not pinch the cable when the plate is installed.
9-7
9.2.2 Grease Replenishment/Exchange for S-Axis Speed

Reducer
1BC
A
AIR S1
2BC
3BC
Grease inlet
Grease exhaust port S-axis speed
Hexagon socket head plug A-PT1/4
Hexagon socket head plug PT1/8 reducer
Fig. 24 S-Axis Speed Reducer and Gear Diagram
Grease Replenishment (Refer to " Fig. 24 S-Axis Speed Reducer

and Gear Diagram ".)
1. Remove the hexagon socket head plug PT1/8 from the grease exhaust port.
NOTE If grease is added with the plug on, the grease will go inside the motor and may damage it.
It is absolutely necessary to remove the plug.
2. Remove the hexagon socket head plug A-PT1/4 from the grease inlet and install the
grease zerk A-PT1/4. Inject the grease into the grease inlet using a grease gun. (The
grease zerk is delivered with the manipulator.)
Grease type: Molywhite RE No.00

Amount of grease: Approx. 1200 cc
(2400 cc for 1st apply)
3. Move the S-axis for a few minutes to discharge the excess grease.
4. Wipe the exhaust port with a cloth and reinstall the plug PT1/8. Tighten the plug with a
tightening torque of 5 N・m (0.51kgf・m). (Apply Three Bond 1206C to screwed parts
of the plug.)
5. Remove the grease zerk from the grease inlet and reinstall the plug A-PT1/4. Tighten
the plug with a tightening torque of 5 N・m (0.51kgf・m). (Apply Three Bond 1206C to
screwed parts of the plug.)
9-8
Grease Exchange (Refer to " Fig. 24 S-Axis Speed Reducer and

Gear Diagram ".)
1. Remove the hexagon socket head plug PT1/8 from the exhaust port.

3. The grease exchange is complete when new grease appears in the exhaust port. The
new grease can be distinguished from the old grease by color.
4. Move the S-axis for a few minutes to discharge the excess grease.
of the plug.
NOTE If the plug is installed when the grease is being exhausted, the grease will go inside the
motor and may damage it.
9-9
9.2.3 Grease Replenishment/Exchange for L-Axis Speed

Reducer
Grease exhaust port

Hexagon socket head plug PT1/8
Grease inlet
Fig. 25 L-Axis Speed Reducer Diagram
Grease Replenishment (Refer to " Fig. 25 L-Axis Speed Reducer

Diagram ".)
1. Tilt the L-arm vertical to ground.
3. Remove the hexagon socket head plug PT1/8 from the grease inlet and install the

4. Move the L-axis for a few minutes to discharge the excess grease.
of the plug.)
6. Remove the grease zerk from the grease inlet and reinstall the plug PT1/8. Tighten the
plug with a tightening torque of 5 N・m (0.51kgf・m). (Apply Three Bond 1206C to
9-10
Grease Exchange (Refer to " Fig. 25 L-Axis Speed Reducer Dia-

gram ".)
1. Tilt the L-arm vertical to ground.

5. Move the L-axis for a few minutes to discharge the excess grease.
of the plug.
9.2.4 Grease Replenishment/Exchange for U-Axis Speed

Reducer
Grease exhaust port

Grease inlet
Fig. 26 U-Axis Speed Reducer Diagram
9-11
Grease Replenishment (Refer to " Fig. 26 U-Axis Speed Reducer

Diagram ".)
1. Tilt the U-arm horizontal to ground.

4. Move the U-axis for a few minutes to discharge the excess grease.
of the plug.)
9-12
Grease Exchange (Refer to " Fig. 26 U-Axis Speed Reducer Dia-

gram ".)
1. Tilt the U-arm horizontal to ground.

5. Move the U-axis for a few minutes to discharge the excess grease.
of the plug.
NOTE If the plug is installed when the grease is being exhausted, the grease will go inside the
motor and may damage it.
9-13
9.2.5 Grease Replenishment/Exchange for U-Arm
Grease inlet (R-,B-, and T-gears in the casing)

T-axis speed reducer
Grease exhaust port

(T-axis speed reducer
Hexagon socket head
plug PT1/16
Grease Inlet B-, and T-axis speed reducer)

R-axis speed reducer
B-axis speed reducer
Grease exhaust port R-, and B-axis speed reducer)

Grease inlet (R-axis speed reducer

Grease exhaust port

(R-,B-,and T-gears in the casing)
View A
Fig. 27 U-Arm Diagram
9-14
Grease Replenishment for R-, B-, T-Axis Gears in the Casing (Refer
to " Fig. 27 U-Arm Diagram ".)

3. Move the R, B, and T-axes for a few minutes to discharge the excess grease.
of the plug.)
Grease Replenishment for R-Axis Speed Reducer (Refer to " Fig. 27

U-Arm Diagram ".)

3. Move the R-axis for a few minutes to discharge the excess grease.
of the plug.)
9-15
Grease Replenishment for B-Axis Speed Reducer (Refer to " Fig. 27

U-Arm Diagram ".)

3. Move the B-axis for a few minutes to discharge the excess grease.
of the plug.)
Grease Replenishment for T-Axis Speed Reducer (Refer to " Fig. 27

U-Arm Diagram ".)

3. Move the T-axis for a few minutes to discharge the excess grease.
of the plug.)
9-16
Grease Exchange for R-, B-, T-Axis Gears in the Casing (Refer to
" Fig. 27 U-Arm Diagram ".)

4. Move the R, B, and T-axes for a few minutes to discharge the excess grease.
of the plug.
Grease Exchange for R-Axis Speed Reducer (Refer to " Fig. 27 U-

Arm Diagram ".)

4. Move the R-axis for a few minutes to discharge the excess grease.
of the plug.
9-17
Grease Exchange for B-Axis Speed Reducer (Refer to " Fig. 27 U-

Arm Diagram ".)

4. Move the B-axis for a few minutes to discharge the excess grease.
of the plug.
9-18
Grease Exchange for T-Axis Speed Reducer (Refer to " Fig. 27 U-

Arm Diagram ".)

4. Move the T-axis for a few minutes to discharge the excess grease.
5. Wipe the exhaust port with a cloth and reinstall the plug PT1/16. Tighten the plug with
a tightening torque of 5 N・m (0.51kgf・m). (Apply Three Bond 1206C to screwed
parts of the plug.
9-19
9.2.6 Grease Replenishment for Balancer Connection Part
Connection 2 Grease inlet

Grease zerk A-PT1/8
Exhaust port 2
Exhaust port 1
Connection 2 Needle bearing
Connection 1 Tapered roller bearing

(2 bearings)
Connection 1 Grease inlet

Grease zerk A-PT1/8 (2 grease zerks)
Fig. 28 Balancer Connection Part
1. Remove the hexagon socket head plugs of connection and . (Refer to " Fig. 28
Balancer Connection Part ".)
2. Inject grease into grease inlets of connection and using a grease gun.
Grease type: Alvania EP grease 2

Amount of grease: 5 cc
(10 cc for 1st supply)
NOTE The exhaust port is used only for air flow.

Do not inject excessive grease into the gear grease inlet.
3. Reinstall the plugs PT1/8 of connection 1 and 2. Tighten the plug to 5 N・m
(0.51kgf・m). (Apply Three Bond 1206C to screwed parts of the plug.)
9-20
9.2.7 Notes for Maintenance

When performing maintenance such as replacement of a wire harness in the manipulator,
NOTE 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 disappear-
ance of the encoder absolute data.
For the battery pack connection, refer to " Fig. 29 Battery Pack Connection ".
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. Removed the cap attached to the battery backup connector of the motors.
2. Connect the battery packs (HW9470932-A) with the battery backup 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 bat-
tery packs. Install the caps attached to the battery backup connectors of the motors.
NOTE Do not remove the battery pack in the connector base.
Motor
Motor power connector

Connector for the encoder
0BT b a 0BT*
BAT a b BAT*
Battery Pack: HW9470932-A
Connector for the battery backup

a:Insertion-type pin terminal (Pin)
b:Insertion-type pin terminal (Socket)
Fig. 29 Battery Pack Connection
9-21
10 Recommended Spare Parts
It is recommended that the following parts and components be kept in stock as spare parts for
the MOTOMAN-ES165N. The spare parts list for the MOTOMAN-ES165N is shown below.
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. 11 Spare Parts for the Motoman-ES165N
Qty
Parts
Rank Name Type Manufacturer Qty per Remarks
No.
Unit
Yaskawa for all axes speed

A 1 Grease Molywhite RE No.00 Electric 16kg - reducers and
Corporation wrist units
Alvania EP Showa Oil for balancer joint

A 2 Grease 16kg -
Grease 2 Co.,Ltd. part
ThreeBond Co.,
A 3 Liquid Gasket Three Bond 1208D 1 1
Ltd.
Yaskawa
A 4 Battery Pack HW0470360-A Electric 1 1
Corporation
Yaskawa
A 5 Battery Pack HW9470932-A Electric - 1
Corporation
Yaskawa
S-Axis
B 6 HW0380936-A Electric 1 1
Speed Reducer
Corporation
Yaskawa
B 7 S-Axis Input Gear HW0301627-1 Electric 1 1
Corporation
Yaskawa
L-Axis
B 8 HW9381442-B Electric 1 1
Speed Reducer
Corporation
Yaskawa
B 9 L-Axis Input Gear HW0303271-1 Electric 1 1
Corporation
Yaskawa
U-Axis
B 10 HW9381465-C Electric 1 1
Speed Reducer
Corporation
10-1
Table. 11 Spare Parts for the Motoman-ES165N
Qty
Parts
Rank Name Type Manufacturer Qty per Remarks
No.
Unit
Yaskawa
B 11 U-Axis Input Gear HW0303272-1 Electric 1 1
Corporation
Yaskawa
R-Axis
B 12 HW0380500-B Electric 1 1
Speed Reducer
Corporation
Yaskawa
B-Axis
B 13 HW9380961-D Electric 1 1
Speed Reducer
Corporation
Yaskawa
T-Axis
B 14 HW9381400-D Electric 1 1
Speed Reducer
Corporation
Yaskawa
B 15 Wrist Unit HW0171254-A Electric 1 1
Corporation
Yaskawa
AC Servomotor for HW0382157-A
C 16 Electric 1 3
S-, L-, and U-Axes SGMRS-37A2A-YR1*
Corporation
Yaskawa
AC Servomotor for HW0382156-A
C 17 Electric 1 3
R-, B-, and T-Axes SGMRS-13A2A-YR1*
Corporation
Yaskawa
Wire Harness in
C 18 HW0171231-A Electric 1 1
Manipulator
Corporation
Yaskawa
Wire Harness in
C 19 HW0370954-A Electric 1 1
Manipulator
Corporation
10-2
11.1 Balancer Unit
11 Parts List
11.1 Balancer Unit
6011
6004
6007
6005
6001
6006
6016
6015 6002
6012
6003
6008
6003
6012
6013
6010 6014
6009
2006
2016
2014
2004
2013
2015
2008
2030
2029
11-1
11.1 Balancer Unit
No. DWG No. Name Pcs

6001 HW0481740-A Coil spring 1
6002 HW0481741-A Coil spring 1
6003 SOB607440 Oiless 2
6004 HW0100477-1 Case 1
6005 HW0303580-1 Flange 1
6006 HW0200420-1 Flange 1
6007 HW0401112-1 Flange 1
6008 HW0303581-1 Rod 1
6009 HW9405057-1 Clevis 1
6010 FD3187A0 Dust seal 1
6011 EZ2228B0 Cap 1
6012 IRTW-75 Stopper 2
6013 M6X8 Socket set 2
screws
6014 PT1/8 Plug 3
6015 M10X40 Socket screw 8
6016 2H-10 Spring washer 8
2006 HW0100472-1 L arm 1
2004 NA6912 Needle bearing 1
2008 HW9302054-1 Shaft 1
2013 AR-85 Clip 1
2014 WR60 Sir clip 1
2015 VB75X95X6 Oil seal 1
2016 VB60X78X9 Oil seal 1
2029 12X50 Socket screw 12
11-2
11.2 S-Axis Driving Unit
1029
1030
1002
1004
1003 1005
1025 1015 7021

(Zeroing Option) 1006
1026 7022
(Zeroing Option)
7023 1032
(Zeroing Option)
1001
1037 1031
1038 7034 (Zeroing Option)
1020
1021
1027
1028
1014 1033
1035
1009 1034
1012
1036
1023 1010
1024 1008
7024 (Zeroing Option)
1013
1011
1022
1007
1019
1018
11-3

1001 HW0380936-A Reduction gear 1
1002 SGMRS-37A2A-YR11 Motor 1
1003 TC12015014 Oil seal 1
1004 STW-50 Retaining rings 1
1005 6310 Bearing 1
1006 HW0301627-1 Gear 1
1007 HW0100193-2 Base 1
1008 HW0100471-1 S head 1
1009 HW0402102-1 Stopper 1
1010 HW0302424-2 Stopper 1
1011 HW0402104-1 Pin 1
1012 HW0301626-1 Pipe 1
1013 HW0403903-1 Plate 1
1014 HW9404486-1 Shaft 1
1015 MSTH12-30 Pin 1
1016 MSTH12-40 Pin 2
1017 MSTH6-20 Pin 2
1018 KQS10-01S Union 1
1019 NB-1075 Tube 1
1020 PT1/8 Plug 1
1021 G415 O ring 1
1022 G105 O ring 1
1027 M8X40 Socket Screw 1
1030 GT-SH-12 Spring washer 3
1035 M20X45(12.9) Bolt 3
1036 M20 Spring washer 3
7021 M6X12 (Zeroing Option) Socket screw 1
7022 M6 (Zeroing Option) Spring washer 1
7023 HW0403909-1 (Zeroing Shaft 1
Option)
7025 HW0404294-1 (Zeroing Cover 1
Option)
7035 M6 (Zeroing Option) Washer 1
11-4
11.3 L-Axis Driving Unit
2033
2034
2018
2019
2020-26
2012
2037 2010 2005
2019
2038 2017
2009
6004 2031
2032
2045 2019 2027

2028
2019 2002
2009
2017
2005 1008
2012 2032
2020-26
2031
2018
2003
2019
2007
2034 2036
2033 2035

2040
2006 2039 2011
2001
2042
2041
2046
2019
2044
2043
11-5

2001 H9381442-B Reduction gear 1
2003 Y507212.5 Oil seal 1
2005 HR32916J Bearing 2
2006 HW0100472-1 L arm 1
2007 HW0303271-1 Gear 1
2008 HW9302054-1 Shaft 1
2009 HW9405055-1 Shaft 2
2010 EZ0094-A0 Air breather 1
2011 G300 O ring 1
2012 S105 O ring 2
2017 KE901107 Oil seal 2
2018 HW9405699-1 B Cover 2
2019 PT1/8 Plug 5
2020 HW9405195-1 Shim 1
2021 HW9405195-2 Shim 2
2022 HW9405195-3 Shim 1
2023 HW9405195-4 Shim 1
2024 HW9405195-5 Shim 1
2025 HW9405195-6 Shim 1
2026 HW9405195-7 Shim 1
2040 SW-2H-12 Spring washer 24
2045 62PP050BG14 Plug 6
2046 CP-30-BC-12 Cap 6
1008 HW0100471-1 S head 1
6004 HW0100477-1 Case 1
7031 M5X8 (Zeroing Option) Screw 2
Option)
7033 HW0481889-A (Zeroing Packin 1
Option)
11-6
11.4 U.R.B.T-Axis Driving Unit
3003
3002
3042 3018
3041 3039
3007 3040
3005
3021 3029
3013 3030
3004
3014
3020
3042 3041 3022
3015
3003 3028 3010
3008 3027 3045
3005 3046 3038
3003
3042 3028
3041 3009 3037
3005 3027
3019 3024
3028 3006
3027
3026 3012
3025
3024
3024
3023
3011
3016

3036
3035
3017
4009
3044
3043
3034
3001
3033
3032
3031 2006
11-7

3001 HW9381465-C Reduction gear 1
3004 TAFI405520 Needle bearing 1
3005 Y507212.5 Oil seal 3
3006 Y507212.5 Oil seal 1
3007 HW0303963-1 Gear 1
3008 HW0303949-1 Gear 1
3009 HW0303947-1 Gear 1
3010 HW0303272-1 Gear 1
3011 HW0100196-3 Casing 1
3012 HW9405703-1 Flange 1
3013 HW0402391-1 Coller 1
3014 HW0402390-1 Coller 1
3015 HW0402406-1 Coller 1
3016 GS210 O ring 1
3017 G270 O ring 1
3018 HW0401506-1 Plate 3
3019 HW0401507-1 Plate 1
3020 ISTW-36 Stopper 1
3021 IRTW-55 Stopper 1
3022 HW0402885-1 Cover 1
3023 MSTM8-20 Pin 1
3024 PT1/8 Plug 5
3025 TSH6-01M Union 2
3026 UB-0640-0.1C Tube 2
3044 SW-2H-12 Spring washer 16
2006 HW0100472-1 L arm 1
4009 HW0100172-2 U arm 1
7027 M6 (Zeroing Option) Spring washer 1
Option)
Option)
11-8
11.5 U-Arm Unit
11.5 U-Arm Unit
3011
4024
4025
4017 4021
4018
4024
4025
4016 4006
4026 4013
4006
4027
4010
4014
4011
4001
4026
4027
4005
4015
4004
4012
4008
4028
4009
4003 4020
4019
4007
4002
4023
4022
11-9
11.5 U-Arm Unit

4001 NK25/20R Bearing 1
4002 HW0380500-B Reduction gear 1
4003 6810DDU Bearing 1
4004 HR32017XJ Bearing 1
4007 AC2847-F3-FKM Oil seal 1
4008 AC3842-F1-FKM Oil seal 1
4009 HW0100172-2 U arm 1
4010 HW0302260-A Shaft 1
4011 HW0302261-A Shaft 1
4012 HW0302262-B Shaft 1
4013 HW0303948-1 Gear 1
4014 HW0303950-1 Gear 1
4015 HW0303951-1 Gear 1
4016 HW0100173-1 Housing 1
4017 HW0401508-1 Plate 1
4018 HW0401505-1 B nut 1
4019 WR50 Sir clip 1
4020 MSTH6-15 Pin 1
4021 M4X6 H set screw 1
4028 PT1/8 Plug 1
3011 HW0100196-3 Casing 1
11-10
11.6 Wrist Unit
11.6 Wrist Unit
4010
5090
5022 5045
5004 5089 5090
5023
5014 5003
5078
5035 5041 5024-28 5079
5011 5012
7020 5048
5074 5040
7019 7018 5017
(Zeroing Option) (Zeroing Option) 5088
7017
7016 5047
5015 7013 5058-61
5046 7015 (Zeroing Option) 5067
5006 5068
7012 7014 5007
5063-66 (Zeroing Option) (Zeroing Option) 5040 5047
5039
5062 5018
5042
5093 5008 5007
5085
5084 5043 5016 5088
5083 5038
5092 5082 5072 5071 5054-57
5007
7011 (Zeroing Option) 5019
5010 7003 7005
5081 7004
5044 7006
5045 5020 7009 (Zeroing Option)
5070 5029-31 5050-53 7007
(Zeroing Option) (Zeroing Option)
5069
5033 7008
(Zeroing Option)
5009
5001 5049
5034 5002
5048 5087 5075
5013 5086
5077
5032
5076 7002
(Zeroing Option)
7001
(Zeroing Option)
11-11
11.6 Wrist Unit
No. DWG No. Name Pcs No. DWG No. Name Pcs
5001 HW9380961-D Reduction gear 1 5063 SP-009010 Shim 1

5002 HW9381400-D Reduction gear 1 5064 SP-009020 Shim 1
5003 6908DB Bearing 1 5065 SP-009050 Shim 1
5004 6909 Bearing 1 5066 SP-009100 Shim 1
5005 6009 Bearing 1 5067 M12X35 Socket screw 8
5006 6907 Bearing 1 5068 2H-12 Spring washer 8
5007 HR32004XJ Bearing 4 5069 M8X85 Socket screw 6
5008 6911 Bearing 1 5070 2H-8 Spring washer 6
5009 MSTH6-20 Pin 1 5071 M8X40 Socket screw 14
5010 HW0100475-1 Wrist 1 5072 2H-8 Spring washer 14
5011 HW0100476-1 Wrist base 1 5073 M8X20 Socket screw 19
5012 HW0200180-1 Cover 1 5074 2H-8 Spring washer 19
5013 HW0300889-1 Cover 1 5075 M8X15 Socket screw 14
5014 HW0301230-1 Gear 1 5076 M6X25 Socket screw 4
5015 HW0301222-1 Gear 1 5077 2H-6 Spring washer 4
5022 HW0401509-1 Housing 1 5084 M4X12 Socket screw 8
5023 HW0401510-1 B nut 1 5085 2H-4 Spring washer 8
5024 HW0401516-1 Shim 1 5086 M14X40 Socket screw 4
5025 HW0401516-2 Shim 1 5087 GT-SH-M14 Spring washer 4
5027 HW0401516-4 Shim 1 5089 M4X8 H set screw 1
5030 HW0401517-2 Shim 1 5093 2H-8 Spring washer 1
5031 HW0401517-3 Shim 1 4010 HW0302260-A Shaft 1
5032 HW0303590-1 Flange 1 7001 M6X12 (Zeroing Option) Socket screw 1
5033 HW9482951-A Packing 1 7002 M6 (Zeroing Option) Sping washer 1
5034 ARP568-263 O ring 1 7003 M8X115 (Zeroing Option) Socket screw 2
5035 G110 O ring 1 7004 2H-8 (Zeroing Option) Spring washer 2
5036 S60 O ring 1 7005 M4X8 (Zeroing Option) Socket screw 2
5037 HW9403618-1 Housing 1 7006 HW0404424-1 (Zeroing Cover 1
Option)
5038 HW9403617-1 Housing 1
5039 AE3290E3 Oil seal 1
Option)
5040 HW0401514-1 B nut 2 7008 HW0403900-1 (Zeroing Block 1
5041 HW0401511-1 B cover 1 Option)
5042 HW0401512-1 Shaft 1 7009 MSTH6-20 (Zeroing Pin 2
5043 HW0401513-1 Cover 1 Option)
5044 HW0401515-1 Plate 1 7010 M6X10 (Zeroing Option) Socket screw 1
5045 STW-45 C stopper 2 7011 M6 (Zeroing Option) Spring washer 1
5046 ISTW-35 Stopper 1 7012 M4X8 (Zeroing Option) Socket screw 2
5047 M5X7 Socket set 2 7013 HW0403901-1 (Zeroing Cover 1
screw Option)
5048 PT1/8 Plug 2 7014 HW0403902-1 (Zeroing Packin 1
Option)
5049 PT1/16 Plug 1
5050 HW9403620-1 Shim 1
7016 2H-4 (Zeroing Option) Spring washer 2
5051 HW9403620-2 Shim 1
7017 HW0403913-1 (Zeroing Block 1
5052 HW9403620-6 Shim 1 Option)
5053 HW9403620-7 Shim 1 7018 MSTH6-10 (Zeroing Pin 2
5054 HW9403621-1 Shim 1 Option)
5055 HW9403621-2 Shim 1 7019 M6X10 (Zeroing Option) Socket screw 1
5056 HW9403621-5 Shim 1 7020 M6 (Zeroing Option) Spring washer 1
5057 HW9403621-6 Shim 1
5058 HW9403622-1 Shim 1
5059 HW9403622-2 Shim 1
5060 HW9403622-4 Shim 1
5061 HW9403622-6 Shim 1
5062 HW0404270-1 Shim 1
11-12
MOTOMAN-ES165N
INSTRUCTIONS
HEAD OFFICE
2-1 Kurosaki-Shiroishi, Yahatanishi-ku, Kitakyusyu-shi, 806-0004, Japan
Phone 81-93-645-7745 Fax 81-93-645-7746
MOTOMAN INC. HEADQUARTERS
805 Liberty Lane West Carrollton, OH 45449, U.S.A.
Phone 1-937-847-6200 Fax 1-937-847-6277
YASKAWA MOTOMAN CANADA LTD.
3530 Laird Road, Unit 3, Mississauga, Ontario, L5L 5Z7, Canada
Phone 1-905-569-6686 Fax 1-905-813-5911
MOTOMAN ROBOTICS EUROPE AB
Franska Vagen 1039854, Kalmar, Sweden
Phone 46-480-417800 Fax 46-480-417999
MOTOMAN ROBOTEC GmbH
Kammerfeld strasse 1, DE-85391 Allershausen, Germany
Phone 49-8166-90100 Fax 49-8166-90103
YASKAWA ELECTRIC KOREA CORPORATION
1F Samyang Bldg. 89-1, Shinchun-dong, Donk-Ku, Daegu, Korea
Phone 82-53-745-7844 Fax 82-2-784-8495
YASKAWA ELECTRIC (SINGAPORE) PTE. LTD.
151 Lorong Chuan, #04-01, New Tech Park, Singapore 556741, Singapore
Phone 65-6282-3003 Fax 65-6289-3003
YASKAWA ELECTRIC (MALAYSIA) SDN. BHD.
No.71, Jalan Bandar Rawang 2, 48000 Rawang, Selangor D.E., Malaysia
Phone 60-3-6092-1377 Fax 60-3-6092-6377
YASKAWA ELECTRIC TAIWAN CORPORATION
9F, 16 Nanking E. Rd., Sec. 3, Taipei, Taiwan
Phone 886-2-2502-5003 Fax 886-2-2505-1280
SHOUGANG MOTOMAN ROBOT CO., LTD.
7,Yongchang-North Road, Beijing Economic & Technological Development Area, Beijing 100076, China
Phone 86-10-6788-0541 Fax 86-10-6788-2878
YASKAWA ELECTRIC CORPORATION
YASKAWA
Specifications are subject to change without notice MANUAL NO. RE-MTO-A240 1

for ongoing product modifications and improvements. C Printed in Japan September 2005 05-03

149200-1 Manipulador Manual

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Part Number: 149200-1

This safety section addresses the following:

YASKAWA MANUAL NO. RE-MTO-A240 1

• General items related to safety are listed in Section 1: Safety of the

• The drawings and photos in this manual are representative examples

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

• YASKAWA is not responsible for incidents arising from unauthorized

Indicates a potentially hazardous situation which, if not avoided,

Indicates a potentially hazardous situation which, if not avoided,

Always be sure to follow explicitly the items listed under this

PROHIBITED Must never be performed.

Emergency Stop Button

Injury may result from unintentional or unexpected manipulator motion.

Release of Emergency Stop

• Observe the following precautions when performing teaching operations

Improper or unintended manipulator operation may result in injury.

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

• Read and understand the Explanation of the Warning Labels in the

Definition of Terms Used Often in This Manual

Equipment Manual Designation

NX100 Controller NX100

NX100 Programming Pendant Programming Pendant

Cable between the manipulator and the controller Manipulator Cable

MOTOMAN WARNING WARNING

YASKAWA ELECTRIC CORPORATION JAPAN

Moving parts may Do not enter

9 Maintenance and Inspection

10 Recommended Spare Parts

1.1 Contents Confirmation

Confirm the contents of the delivery when the product arrives.

1.2 Order Number Confirmation

Label (Enlarged view)

THE MANIPULATOR AND THE CONTROLLER

MADE IN JAPAN NJ2484-1

THE MANIPULATOR AND THE CONTROLLER S

EX-AXIS 1 2 3CURRENT DELETE INSERT

CABCEK 0 . -CURRENT ENTER

(a) NX100 (Front View) (b) Manipulator (Side View)

Fig. 1 Location of Order Number Labels

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

• Avoid excessive vibration or shock during transporting.

2.1 Transporting Method

2.1.1 Using a Crane

Details of shipping bolt

Fig. 2 Transporting Position

2.2 Shipping Bolts and Brackets

A Shipping bracket B Shipping bolt

Electrical tape painted

Fig. 3 Shipping Bolts and Brackets

• The A-shipping brackets are painted in yellow

Position Bolt Type Pcs

A Hexagon socket head cap screw M20 X 70 mm 12

B Hexagon socket head cap screw M16 X 20 mm 1

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

• Install the manipulator in a location where the manipulator’s tool or the

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

The manipulator may overturn and cause injury or damage.

Failure to observe this caution may cause injury or damage.

3.1 Installation of the Safeguarding

Responsibility for Safeguarding (ISO 10218)

3.2 Mounting Procedures for Manipulator Base

Table. 1 Maximum Repulsion Forces of the Manipulator at Emergency Stop

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