Motoman Es165d

MOTOMAN-ES165D
INSTRUCTIONS
TYPE:
YR-ES0165D-A00 (STANDARD SPECIFICATION)
YR-ES0165D-A01 (SLU-AXES WITH LIMIT SWITCHES)
Upon receipt of the product and prior to initial operation, read these instructions thoroughly, and retain
for future reference.
MOTOMAN INSTRUCTIONS
MOTOVAN-ES165D INSTRUCTIONS
DX100 INSTRUCTIONS
DX100 OPERATOR’S MANUAL
DX100 MAINTENANCE MANUAL
The DX100 operator’s manual above corresponds to specific usage.

Be sure to use the appropriate manual.
Part Number: 155976-1CD

Revision: 6
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MANUAL NO.
HW0485249 9
155976-1CD
ES165D
Copyright © 2017, 2013 Yaskawa America, Inc.
Terms of Use and Copyright Notice

All rights reserved. This manual is freely available as a service to Yaskawa
customers to assist in the operation of Motoman robots, related equipment
and software This manual is copyrighted property of Yaskawa and may
not be sold or redistributed in any way. You are welcome to copy this
document to your computer or mobile device for easy access but you may
not copy the PDF files to another website, blog, cloud storage site or any
other means of storing or distributing online content.
Printed in the United States of America
First Printing, 2016
Yaskawa America, Inc.

Motoman Robotics Division
100 Automation Way
Miamisburg, OH 45342
Phone: 937-847-6200
www.motoman.com
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ES165D
MANDATORY
• This instruction manual is intended to explain mainly on the
mechanical part of the MOTOMAN-ES165D 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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ES165D
We suggest that you obtain and review a copy of the ANSI/RIA National
Safety Standard for Industrial Robots and Robot Systems (ANSI/RIA
R15.06-2012). You can obtain this document from the Robotic Industries
Association (RIA) at the following address:
Robotic Industries Association
900 Victors Way
P.O. Box 3724
Ann Arbor, Michigan 48106
TEL: (734) 994-6088
FAX: (734) 994-3338
www.roboticsonline.com
Ultimately, well-trained personnel are the best safeguard against
accidents and damage that can result from improper operation of the
equipment. The customer is responsible for providing adequately trained
personnel to operate, program, and maintain the equipment. NEVER
ALLOW UNTRAINED PERSONNEL TO OPERATE, PROGRAM, OR
REPAIR THE EQUIPMENT!
We recommend approved Yaskawa training courses for all personnel
involved with the operation, programming, or repair of the equipment.
This equipment has been tested and found to comply with the limits for a
Class A digital device, pursuant to part 15 of the FCC rules. These limits
are designed to provide reasonable protection against harmful
interference when the equipment is operated in a commercial
environment. This equipment generates, uses, and can radiate radio
frequency energy and, if not installed and used in accordance with the
instruction manual, may cause harmful interference to radio
communications.
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ES165D Notes for Safe Operation
Notes for Safe Operation

Read this manual carefully before installation, operation, maintenance, or
inspection of the MOTOMAN-ES165D.
In this manual, the Notes for Safe Operation are classified as “DANGER”,
“WARNING”, “CAUTION”, “MANDATORY”, or “PROHIBITED”.
Indicates an imminent hazardous

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

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

CAUTION situation which, if not avoided, could
result in minor or moderate injury to
personnel and damage to equipment.
It may also be used to alert against
unsafe practices.
Always be sure to follow explicitly the

MANDATORY items listed under this 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.
To ensure safe and efficient operation at all times, be sure to

NOTE follow all instructions, even if not designated as “DANGER”,
“WARNING” and “CAUTION”.
DANGER
• Maintenance and inspection must be performed by specified
personnel.
Failure to observe this caution may result in electric shock or injury.
• For disassembly or repair, contact your YASKAWA representative.
• Do not remove the motor, and do not release the brake.
Failure to observe these safety precautions may result in death or
serious injury from unexpected turning of the manipulator's arm.
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ES165D Notes for Safe Operation
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:
– Be sure to use a lockout device to the safeguarding when going
inside. Also, display the sign that the operation is being
performed inside the safeguarding and make sure no one closes
the safeguarding.
– View the manipulator from the front whenever possible.
– Always follow the predetermined operating procedure.
– Keep in mind the emergency response measures against the
manipulator’s unexpected motion toward you.
– Ensure that you have a safe place to retreat in case of
emergency.
Improper or unintended manipulator operation may result in injury.
• Confirm that no person is present in the P-point maximum envelope
of the manipulator and that you are in a safe location before:
– Turning ON the power for the DX100.
– Moving the manipulator with the programming pendant.
– Running the system in the check mode.
– Performing automatic operations.
Injury may result if anyone enters the P-point maximum envelope of the
manipulator during operation. Always press an emergency stop button
immediately if there is a problem.
The emergency stop buttons are located on the right of front door of the
DX100 and the programming pendant.
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ES165D Definition of Terms Used In this Manual
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:
Definition of Terms Used In this Manual

The 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:
Equipment Manual Designation
DX100 controller DX100
DX100 programming pendant Programming pendant
Cable between the manipulator and the Manipulator cable
controller
Description of the Operation Procedure

In the explanation of the operation procedure, the expression “Select • • •”
means that the cursor is moved to the object item and the SELECT key is
pressed, or that the item is directly selected by touching the screen.
Registered Trademark
In this manual, names of companies, corporations, or products are
trademarks, registered trademarks, or brand names for each company or
corporation. The indications of (R) and TM are omitted.
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ES165D Explanation of Warning Labels
Explanation of Warning Labels

The following warning labels are attached to the manipulator.
Always follow the warnings on the labels.
Also, an identification label with important information is placed on the
body of the manipulator. Prior to operating the manipulator, confirm the
contents.
Figure 3: Warning Label Locations
WARNING Label B
Nameplate WARNING Label A WARNING Label B
WARNING Label A
Nameplate: WARNING Label A:
MODEL
WARNING
MOTOMAN-
TYPE Moving parts
may cause
PAYLOAD MASS
kg kg injury
ORDER NO. DATE
SERIAL NO.
YASKAWA ELECTRIC CORPORATION WARNING Label B:

2-1 Kurosakishiroishi, Yahatanishi-ku,
Kitakyushu 806-0004 Japan
MADE IN JAPAN NJ3878
WARNING
Do not enter
robot
work area.
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ES165D Safeguarding Tips
Safeguarding Tips
All operators, programmers, maintenance personnel, supervisors, and
anyone working near the system 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 equipment, the operator's manuals, the system equipment, and
options and accessories should be permitted to operate this
equipment.
• Improper connections can damage the equipment. All connections
must be made within the standard voltage and current ratings of the
equipment.
• The system must be placed in Emergency Stop (E-Stop) mode
whenever it is not in use.
• In accordance with ANSI/RIA R15.06-2012, section 4.2.5, Sources of
Energy, use lockout/tagout procedures during equipment
maintenance. Refer also to Section 1910.147 (29CFR, Part 1910),
Occupational Safety and Health Standards for General Industry
(OSHA).
Mechanical Safety Devices

The safe operation of this equipment is ultimately the users 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 R15.06-2012 safety standards, and other local codes
that may pertain to the installation and use of this equipment.
Additional safety measures for personnel and equipment may be required
depending on system installation, operation, and/or location. The following
safety equipment is provided as standard:
• Safety barriers
• Door interlocks
• Emergency stop palm buttons located on operator station
Check all safety equipment frequently for proper operation. Repair or
replace any non-functioning safety equipment immediately.
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ES165D Programming, Operation, and Maintenance Safety
Programming, Operation, and Maintenance Safety

All operators, programmers, maintenance personnel, supervisors, and
anyone working near the system must become familiar with the operation
of this equipment. Improper operation can result in personal injury and/or
damage to the equipment. Only trained personnel familiar with the
operation, manuals, electrical design, and equipment interconnections of
this equipment should be permitted to program, or maintain the system.
All personnel involved with the operation of the equipment must
understand potential dangers of operation.
• Inspect the equipment to be sure no potentially hazardous conditions
exist. Be sure the area is clean and free of water, oil, debris, etc.
• Be sure that all safeguards are in place. Check all safety equipment
for proper operation. Repair or replace any non-functioning safety
equipment immediately.
• Check the E-Stop button on the operator station for proper operation
before programming. The equipment must be placed in Emergency
Stop (E-Stop) mode whenever it is not in use.
• Back up all programs and jobs onto suitable media before program
changes are made. To avoid loss of information, programs, or jobs, a
backup must always be made before any service procedures are
done and before any changes are made to options, accessories, or
equipment.
• Any modifications to the controller unit can cause severe personal
injury or death, as well as damage to the robot! Do not make any
modifications to the controller unit. Making any changes without the
written permission from Yaskawa will void the warranty.
• Some operations require standard passwords and some require
special passwords.
• The equipment allows modifications of the software for maximum
performance. Care must be taken when making these modifications.
All modifications made to the software will change the way the
equipment operates and can cause severe personal injury or death,
as well as damage parts of the system. Double check all
modifications under every mode of operation to ensure that the
changes have not created hazards or dangerous situations.
• This equipment has multiple sources of electrical supply. Electrical
interconnections are made between the controller and other
equipment. Disconnect and lockout/tagout all electrical circuits
before making any modifications or connections.
• Do not perform any maintenance procedures before reading and
understanding the proper procedures in the appropriate manual.
• Use proper replacement parts.
• Improper connections can damage the equipment. All connections
must be made within the standard voltage and current ratings of the
equipment.
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ES165D Maintenance Safety
Maintenance Safety
Turn the power OFF and disconnect and lockout/tagout all electrical
circuits before making any modifications or connections.
Perform only the maintenance described in this manual. Maintenance
other than specified in this manual should be performed only by Yaskawa-
trained, qualified personnel.
Summary of Warning Information

This manual is provided to help users establish safe conditions for
operating the equipment. Specific considerations and precautions are also
described in the manual, but appear in the form of Dangers, Warnings,
Cautions, and Notes.
It is important that users operate the equipment in accordance with this
instruction manual and any additional information which may be provided
by Yaskawa. Address any questions regarding the safe and proper
operation of the equipment to Yaskawa Motoman Customer Support.
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ES165D Customer Support Information
Customer Support Information

If you need assistance with any aspect of your ES165D system, please
contact YASKAWA Customer Support at the following 24-hour telephone
number:
(937) 847-3200
For routine technical inquiries, you can also contact YASKAWA Customer
Support at the following e-mail address:
techsupport@motoman.com
When using e-mail to contact YASKAWA Customer Support, please

provide a detailed description of your issue, along with complete contact
information. Please allow approximately 24 to 36 hours for a response to
your inquiry.
Please use e-mail for routine inquiries only. If you have an

NOTE urgent or emergency need for service, replacement parts,
or information, you must contact YASKAWA Customer
Support at the telephone number shown above.
Please have the following information ready before you call Customer
Support:
• System ES165D
• Robots ___________________________
• Primary Application ___________________________
• Controller DX100
• Software Version Access this information on the

Programming Pendant’s LCD
display screen by selecting {MAIN
MENU} - {SYSTEM INFO} -
{VERSION}
• Robot Serial Number Located on the robot data plate
• Robot Sales Order Number Located on the DX100 controller

data plate
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ES165D Table of Contents
Table of Contents
1 Product Confirmation ...................................................................................................................... 1-1
1.1 Contents Confirmation ....................................................................................................... 1-1
1.2 Order Number Confirmation .............................................................................................. 1-2
2 Transport......................................................................................................................................... 2-1
2.1 Transport Method .............................................................................................................. 2-1
2.1.1 Using a Crane ...................................................................................................... 2-2
2.2 Shipping Bolts and Brackets.............................................................................................. 2-3
3 Installation....................................................................................................................................... 3-1
3.1 Safeguarding Installation ................................................................................................... 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
4.1 Grounding .......................................................................................................................... 4-1
4.2 Cable Connection .............................................................................................................. 4-2
4.2.1 Connection to the Manipulator.............................................................................. 4-2
4.2.2 Connection to the DX100 ..................................................................................... 4-2
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 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
6 Allowable Load for Wrist Axis and Wrist Flange ............................................................................. 6-1
6.1 Allowable Wrist Load ......................................................................................................... 6-1
6.2 Wrist Flange....................................................................................................................... 6-3
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7 System Application.......................................................................................................................... 7-1
7.1 Peripheral Equipment Mounts............................................................................................ 7-1
7.2 Internal User I/O Wiring Harness and Air Line................................................................... 7-2
8 Electrical Equipment Specification .................................................................................................. 8-1
8.1 Position of Limit Switch ...................................................................................................... 8-1
8.1.1 Specification of Limit Switch ................................................................................. 8-1
8.1.2 Location of Limit Switch ........................................................................................ 8-1
8.1.3 Setting of Operation Range .................................................................................. 8-2

8.1.3.1 S-Axis Operation Range.......................................................................... 8-2
8.1.3.2 L-Axis Operation Range .......................................................................... 8-2
8.1.3.3 Setting Range of LU-Axes Interference Angle......................................... 8-3
8.2 Internal Connections .......................................................................................................... 8-4
9 Maintenance and Inspection ........................................................................................................... 9-1
9.1 Inspection Schedule........................................................................................................... 9-1
9.2 Notes on Maintenance Procedures.................................................................................... 9-6
9.2.1 Battery Pack Replacement ................................................................................... 9-6
9.3 Notes on Grease Replenishment/Exchange Procedures .................................................. 9-8
9.3.1 Grease Replenishment/Exchange for S-Axis Speed Reducer ............................. 9-8

9.3.1.1 Grease Replenishment............................................................................ 9-9
9.3.1.2 Grease Exchange.................................................................................... 9-9
9.3.2 Grease Replenishment/Exchange for L-Axis Speed Reducer............................ 9-10

9.3.2.1 Grease Exchange.................................................................................. 9-10
9.3.2.2 Grease Exchange.................................................................................. 9-11
9.3.3 Grease Replenishment/Exchange for U-Axis Speed Reducer ........................... 9-12

9.3.3.1 Grease Replenishment.......................................................................... 9-12
9.3.3.2 Grease Exchange.................................................................................. 9-13
9.3.4 Grease Replenishment/Exchange for U-Arm ..................................................... 9-14

9.3.4.1 Grease Replenishment for R-, B-, T-Axes Gears in the Casing ............ 9-14
9.3.4.2 Grease Replenishment for R-Axis Speed Reducer ............................... 9-15
9.3.4.3 Grease Replenishment for B-Axis Speed Reducer ............................... 9-16
9.3.4.4 Grease Replenishment for T-Axis Speed Reducer ............................... 9-16
9.3.4.5 Grease Exchange for R-, B-, T-Axes Gears in the Casing .................... 9-17
9.3.4.6 Grease Exchange for R-Axis Speed Reducer ....................................... 9-17
9.3.4.7 Grease Exchange for B-Axis Speed Reducer ....................................... 9-18
9.3.4.8 Grease Exchange for T-Axis Speed Reducer ....................................... 9-19
9.3.5 Grease Replenishment for Balancer Connection Part........................................ 9-20
9.3.6 Notes for Maintenance........................................................................................ 9-21

9.3.6.1 Battery Pack Connection ....................................................................... 9-21
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10 Recommended Spare Parts........................................................................................................ 10-1
11 Parts List ..................................................................................................................................... 11-1
11.1 S-Axis Unit ..................................................................................................................... 11-1
11.2 L-Axis Unit ..................................................................................................................... 11-3
11.3 URBT-Axes Unit ............................................................................................................ 11-5
11.4 U-Arm Unit ..................................................................................................................... 11-8
11.5 Wrist Unit ..................................................................................................................... 11-10
11.6 Balancer Unit ............................................................................................................... 11-13
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ES165D 1 Product Confirmation
1.1 Contents Confirmation
1 Product Confirmation
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.
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 are given separately):
• Manipulator
• DX100
• Programming pendant
• Manipulator cables (3 cables between the DX100 and the
Manipulator)
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ES165D 1 Product Confirmation
1.2 Order Number Confirmation
1.2 Order Number Confirmation

Check that the order number of the manipulator corresponds to the
DX100. The order number is located on a label as shown below.
Fig. 1-1: Location of Order Number Labels
Label (Enlarged View)
THE MANIPULATOR AND THE CONTROLLER Check that the manipulator

SHOULD HAVE SAME ORDER NUMBER.
and the DX100 have the
same order number.
ORDER NO.
DX100
TYPE ERDR-
ER
GE N
EM
POWER SUPPLY
Y
3PHASE AC200V 50/60Hz PEAK kVA

AC220V 60Hz AVERAGE kVA
INTERRUPT CURRENT kA
SERIAL No.
DATE
S
MADE IN JAPAN NJ2960-1
T O P
ON
D
PE
IP
TR
OFF
T
SE
RE
WARNING
Do not open the door
THE MANIPULATOR AND THE CONTROLLER

SHOULD HAVE SAME ORDER NUMBER.
ORDER NO.
NJ1529
PROGRAMMING PENDANT
X81
(a) DX100 (Front View) (b) Manipulator (Side View)
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ES165D 2 Transport
2.1 Transport Method
2 Transport
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 transport.
The system consists of precision components. Failure to observe this
caution may adversely affect performance.
• The weight of the manipulator is approximately 1150 kg

including the shipping bolts and 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
NOTE than transporting the manipulator.
• Mount the shipping bolts and brackets for transporting the
manipulator.
• Avoid putting external force on the arm or motor unit when
transporting by a crane, forklift, or other equipment.
Failure to observe this instruction may result in injury.
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ES165D 2 Transport
2.1.1 Using a Crane

As a rule, the manipulator should be lifted by a crane with four wire ropes
when removing it from the package and moving it. Be sure that the
manipulator is fixed with the shipping bolts and brackets before transport,
and lift it in the posture as shown in Fig. 2-1 “Transporting Position”.
Fig. 2-1: Transporting Position
Details of B part
Rubber plate
Electrical tape
painted in yellow
B
Shipping bolt
(1 piece)
Details of A part
Hook
A
Shipping bracket
(4 pieces)
Factory setting for angle and pulse of each axis

Axis S L U R B T
Angle 0 -60 -63.9 0 -86.1 0
Pulse 0 -143518 -134502 0 -147520 0
When equipped with external cablings,

those settings are subject to change depending on the specifications.
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ES165D 2 Transport
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 hexagon socket head cap screws at point B. (Fig. 2-1
“Transporting Position”).
Fig. 2-2: Shipping Bolts and Brackets
A Shipping bracket B Shipping bolt

Hook
Rubber plate
Electrical tape painted

in yellow
• 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

NOTE shipping bolts and brackets are removed. The shipping
bolts and brackets then must be stored for future use, in the
event that the manipulator must be moved again.
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ES165D 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 tool or the workpiece
held by its fully extended arm will not reach the wall, safeguarding,
or controller.
Failure to observe this warning may result in injury or damage.
• Do not start the manipulator or even turn ON the power before it is
firmly anchored.
The manipulator may overturn and cause injury or damage.
CAUTION
• Do not install or operate the manipulator that is damaged or lacks
parts.
Failure to observe this caution may cause injury or damage.
• Before turning ON the power, check to be sure that the shipping
bolts and brackets explained in Fig. 2-2 “Shipping Bolts and
Brackets” are removed.
Failure to observe this caution may result in damage to the driving
parts.
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3.1 Safeguarding Installation
3.1 Safeguarding Installation

To insure safety, be sure to install safeguarding. It prevents unforeseen
accidents with personnel and damage to equipment. Refer to the quoted
clause for your information and guidance.
Responsibility for Safeguarding (ISO10218)

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

The manipulator should be firmly mounted on a baseplate or foundation
strong enough to support the manipulator and withstand reaction forces
during acceleration and deceleration.
Construct a solid foundation with the appropriate thickness to withstand
maximum reaction forces of the manipulator referring to Table 3-1
"Maximum Reaction Forces of the Manipulator at Emergency Stop" and
Table 3-2 "Endurance Torque in Operation".
A baseplate flatness must be kept at 0.5 mm or less: insufficient flatness
of installation surface may deform the manipulator shape and affect its
functional abilities. Mount the manipulator base as instructed in section
3.2.1 “Mounting Example”.
Table 3-1: Maximum Reaction Forces of the Manipulator at Emergency

Stop
Maximum torque in horizontal rotation 32000 N•m
(S-axis moving direction) (3265 kgf•m)
Maximum torque in vertical rotation 78500 N•m
(L-, U-axes moving direction) (8000 kgf•m)
Table 3-2: Endurance Torque in Operation

Endurance torque in horizontal operation 9400 N•m
(S-axis moving direction) (960 kgf•m)
Endurance torque in vertical operation 23900 N•m
(L-, U-axes moving direction) (2434 kgf•m)
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3.3 Location
3.2.1 Mounting Example

For the first process, anchor the baseplate firmly to the ground. The
baseplate should be rugged and durable to prevent shifting of the
manipulator or the mounting fixture. It is recommend to prepare a
baseplate of 50 mm or more thick, and anchor bolts of M20 or larger size.
The manipulator base is tapped for eight mounting holes; securely fix the
manipulator base to the baseplate with eight hexagon head bolts M20
(80 mm long is recommended).
Next, fix the manipulator base to the baseplate. Tighten the hexagon
head bolts and anchor bolts firmly so that they will not work loose during
the operation.
Refer to Fig. 3-1 “Mounting the Manipulator on Baseplate”.
Fig. 3-1: Mounting the Manipulator on Baseplate
Hexagon socket head cap screw

M20 (8 screws)
Spring washer
Washer
Manipulator base
40
Baseplate
Flatness: 0.5mm or less
Units: mm
3.3 Location
When the manipulator is installed, it is necessary to satisfy the following
environmental conditions:
• Ambient temperature: 0° to + 45°C
• Humidity: 20 to 80%RH (at constant temperature)
• Free from dust, soot, or water
• Free from corrosive gases or liquids, or explosive gases
• Free from excessive vibration
(Vibration acceleration: 4.9 m/s2 or less [0.5 G] or less)
• Free from large electrical noise (plasma)
• Flatness for installation: 0.5 mm or less
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ES165D 4 Wiring
4.1 Grounding
4 Wiring
WARNING
• Ground resistance must be 100 Ω or less.
Failure to observe this warning may result in fire or electric shock.
• Before wiring, make sure to turn the primary power supply off, and
put up a warning sign. (ex. DO NOT TURN THE POWER ON.)
Failure to observe this warning may result in fire or electric shock.
CAUTION
• Wiring must be performed by authorized or certified personnel.
Failure to observe this caution may result in fire or electric shock.
• Do not cover the cable or allow it to tangle. Keep the cable as
straight as possible.
Failure to observe this caution may result in preventing heat of the
cable from being discharged.
4.1 Grounding
Follow electrical installation standards and wiring regulations for
grounding. A ground wire of 5.5 mm2 or more is recommended.
Refer to Fig. 4-1 “Grounding Method” to connect the ground line directly to
the manipulator.
• Never use this wire sharing with other ground lines or

grounding electrodes for other electric power, motor
power, welding devices, etc.
NOTE
• Where metal ducts, metallic conduits, or distributing racks
are used for cable laying, ground in accordance with
electrical installation standards.
Fig. 4-1: Grounding Method

A Bolt M8 (for grounding)
Delivered with manipulator
5.5mm2 or more View A
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ES165D 4 Wiring
4.2 Cable Connection

Three manipulator cables are delivered with the manipulator; an encoder
cable for detection (1BC) and two power cables (2BC and 3BC). (Refer to
Fig. 4-2 “Manipulator Cables”.)
Connect these cables to the manipulator base connectors and to the
DX100. Refer to Fig. 4-3(a) “Manipulator Cable Connectors (Manipulator
Side)” and Fig. 4-3(b) “Manipulator Cable Connection (DX100 Side)” .
4.2.1 Connection to the Manipulator

Before connecting three cables to the manipulator, verify the numbers on
both manipulator cables and the connectors on the connector base of the
manipulator. When connecting, adjust the cable connector positions to
the main key positions of the manipulator, and insert cables in the order of
2BC, 1 BC, then 3BC. After inserting the cables, depress the lever until it
clicks.
4.2.2 Connection to the DX100

Before connecting cables to the DX100, verify the numbers on both
manipulator cables and the connectors on the DX100. When connecting,
insert the cables in the order of X21, X22, then X11, and depress each
lever low until it clicks.
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ES165D 4 Wiring
Fig. 4-2: Manipulator Cables
The DX100 Side The Manipulator Side
1BC
X11
X11 1BC
1BC
Encoder Cable
X21 2BC
2BC
2BC
X21
Power Cable
X22 3BC
3BC
3BC
X22
Power Cable
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ES165D 4 Wiring
Fig. 4-3(a): Manipulator Cable Connectors (Manipulator Side)
1BC
AIR S1
2BC
molex
molex
3BC
1BC 2BC 3BC
Key positions
Connector Details
(Manipulator Side)
Fig. 4-3(b): Manipulator Cable Connection (DX100 Side)
X11
X21
X22
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ES165D 5 Basic Specifications
5.1 Basic Specifications
5 Basic Specifications
5.1 Basic Specifications

Table 5-1: Basic Specifications1)
Item Model MOTOMAN-ES165D MOTOMAN-ES165D
with external cabling for
SRBT-axes
Structure Vertically Articulated
Degree of Freedom 6
Payload 165 kg
Repeatability2) ±0.2 mm
Range of Motion S-Axis (turning) -180° - +180°
L-Axis (lower arm) -60° - +76°
U-Axis (upper arm) -142.5° - +230°
R-Axis (wrist roll) -360° - +360° -205° - +205°
B-Axis (wrist pitch/yaw) -130° - +130° -120° - +120°
T-Axis (wrist twist) -360° - +360° -200° - +200°
Maximum Speed S-Axis 1.92 rad/s, 110°/s
L-Axis 1.92 rad/s, 110°/s
U-Axis 1.92 rad/s, 110°/s
R-Axis 3.05 rad/s, 175°/s
B-Axis 2.62 rad/s, 150°/s
T-Axis 4.19 rad/s, 240°/s
3)
Allowable Moment R-Axis 921 N•m (94 kgf•m)
B-Axis 921 N•m (94 kgf•m)
T-Axis 490 N•m (50 kgf•m)
2/4)
Allowable Inertia (GD R-Axis 85 kg•m2
B-Axis 85 kg•m2
T-Axis 45 kg•m2
Approx. Mass 1100 kg
Ambient Conditions Temperature 0° C to 45° C
Humidity 20 to 80% RH (non-condensing)
Vibration Acceleration 4.9 m/s2 or less (0.5 G)
Others Free from corrosive gasses or liquids, or explosive
gasses
Free from exposure to water, oil, or dust
Free from excessive electrical noise (plasma)
Power Requirements 5.0 kVA
1 SI units are used in this table. However, gravitational unit is used in ( ).
2 Conformed to ISO9283
3 Refer to chapter 6.1 “Allowable Wrist Load” for details on the permissible moment of inertia.
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5.2 Part Names and Working Axes
5.2 Part Names and Working Axes

Fig. 5-1: Part Names and Working Axes
U+
R+ B+
T+
R- B- T-
U-
L- L+
S+
S-
5.3 Manipulator Base Dimensions

Fig. 5-2: 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
Fitting surface
40
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)
(For fixing the manipulator) positioning)
View A
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5.4 Dimensions and P-Point Maximum Envelope
5.4 Dimensions and P-Point Maximum Envelope

Fig. 5-3: Dimensions and P-Point Maximum Envelope
R7
29
180
R608
180
491
R26
51
View A
4612
1961 2651
3050
P-point maximum
envelope
491 294
285 1225 225
153
250
P-point
25 18
42
50
1150
76
2203
60
1024
5 .
687
142
650
495
650
348
40
126
0 0
16
1307
945
524
701
727
582
729
322
0
Note:
This figure shows the standard specification manipulator in the home position.
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5.5 Alterable Operating Range

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

Item Specifications
S-Axis Operating -180° - +180° (standard)
Range *(-165° - +165°)
-150° - +150°
-135° - +135°
-120° - +120°
-105° - +105°
-90° - +90°
-75° - +75°
-60° - +60°
-45° - +45°
-30° - +30°
*(-15° - +15°)
* The interval between stoppers must be 60° or more.
NOTE When altering the operating range to ±15° or ±165°, please

contact your YASKAWA representative.
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5.5.1 Components for Altering Operating Range

Arrange the components listed in Fig. 5-4 “The Components of the S-Axis
Stopper”, when modifying the angle of S-axis.
(1) Pin (drawing No. HW0402104-1, 1 pin)
(2) Stopper (drawing No. HW0302424-2, 1 stopper)
(3) Hexagon socket head cap screw M20
(length: 45 mm) (3 screws) (tightening torque: 402 N•m)
(4) Flat washer M20 (3 flat washers)
Fig. 5-4: The Components of the S-Axis Stopper
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
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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. 5-4 “The Components of the S-Axis
Stopper”.
• DO NOT forget to apply the locktite 242 to the thread part of pin before
inserting it into the stopper.
• Mount the stopper to the S-head with three hexagon head screws M20
(length: 45 mm) and tighten the screws to the tightening torque of 402
N•m (tensile strength: 1200 N/mm2 or more). The stopper is to be
installed as shown in the Fig. 5-4 “The Components of the S-Axis
Stopper” when the operating range is ±180°.
• The stopper can be installed by every 15 degree pitch, however, to
avoid the mechanical troubles caused by interference between
stoppers (e.g. ±15°, ±165°), install the S-axis mechanical stopper
referring to Table 5-3 "The settable angle for S-Axis Stopper".
• Confirm to stabilize both sides of the protrusion with the hexagon
socket head cap screws as in Fig. 5-5 “Properly-Mounted Image” on
account of the limitation of strength to the unit.
• Refer to the figures: Fig. 5-6(a) to Fig. 5-6(g) as adjusting the setting
angle of the S-Axis mechanical stopper. When mounting the S-Axis
mechanical stopper by inverse angle to the examples in the figures:
Fig. 5-6(a) to Fig. 5-6(g) , settle the machinery symmetrical to those
models.
• As in the figures: Fig. 5-6(a) to Fig. 5-6(g) , 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. 5-4 “The Components
of the S-Axis Stopper”.
Fig. 5-5: Properly-Mounted Image
Hexagon socket Hexagon socket

head cap scerws head cap scerws
Improperly-mounted Properly-mounted
1. Apply the specified components when mounting the

NOTE S-Axis mechanical stopper.
2. TURN OFF the electric power supply before mounting.
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5.5.3 Adjustment to the Pulse Limitation of S-Axis

To limit the operating range of the S-axis, refer to DX100 Instructions
section 8.17 “Changing the Parameter Setting (162536-1CD)” and
change the following parameters with the programming pendant.
The limitation to the pulse (Pulse Soft Limit + 1st Axis ) : SICxG400
The limitation to the pulse (Pulse Soft Limit - 1st Axis ) : SICxG408
Degree ±0° ∗(±15°) ±30° ±45° ±60° ±75° ±90°
Number
±0 ±35840 ±71680 ±107520 ±143360 ±179200 ±215040
of Pulse
Degree ±105° ±120° ±135° ±150° ∗(±165°) ±180° (Standard)
Number
±250880 ±286720 ±322560 ±358400 ±394240 ±430080
of Pulse
* Refer to section 5.5 “Alterable Operating Range”.
Adjust both of the pulse limitation and the angle of S-Axis

NOTE mechanical stopper as modifying the range of motion for
machinery.
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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
5-8
5 Basic Specifications
-90
-75
-60
-45
-30
-15
0
15
30
45
60
Table 5-3: The settable angle for S-Axis Stopper
75
90
105
The Angle of S-Axis Stopper for - Direction

120
135
150
165
180
Settable angle "Table 5-3 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.
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Fig. 5-6(a): The Properly-Mounted Models for S-Axis Stopper
Hexagon head screws
The stopper is reversible.

Either side of the stopper can be used.
Installation at + 180°
Hexagon head screws

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Fig. 5-6(b): The Properly-Mounted Models for S-Axis Stopper
The stopper is irreversible.

Only this side of the stopper can be used at this angle.
Hexagon head screws

Hexagon head screws
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Fig. 5-6(c): The Properly-Mounted Models for S-Axis Stopper

Hexagon head screws
Hexagon head screws The stopper is reversible.

Installation at + 105
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Fig. 5-6(d): The Properly-Mounted Models for S-Axis Stopper

Hexagon head screws

Hexagon head screws
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Fig. 5-6(e): The Properly-Mounted Models for S-Axis Stopper

Hexagon head screws

Hexagon head screws
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Fig. 5-6(f): The Properly-Mounted Models for S-Axis Stopper

Hexagon head screws

Hexagon head screws
Fig. 5-6(g): The Properly-Mounted Models for S-Axis Stopper

Hexagon head screws
Installation at 0°
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ES165D 6 Allowable Load for Wrist Axis and Wrist Flange
6.1 Allowable Wrist Load
6 Allowable Load for Wrist Axis and Wrist Flange

The allowable wrist load including the weight of the mount/gripper
is:
• YR-ES0165D-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 6-1 "Allowable Wrist
Load". Contact your YASKAWA representative for further information or
assistance.
Table 6-1: Allowable Wrist Load

Axis Moment N•m (kgf•m)1) GD2/4 Total Moment of Inertia kg•m2
R-Axis 921 (94) 85
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. 6-1 “Moment Arm Rating”.
The allowable total moment of inertia is calculated when the moment is at
the maximum. Contact your YASKAWA representative beforehand when
only moment of inertia, or load moment is small and moment of inertia is
large. Also, when the load mass is combined with an outside force,
contact your YASKAWA representative beforehand.
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Fig. 6-1: Moment Arm Rating

LT(mm)
1000 40kg
800 60kg
600 80kg
400
P-point
165kg
200 T-, R-axis
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
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6.2 Wrist Flange
6.2 Wrist Flange

The wrist flange dimensions are shown in Fig. 6-2 “Wrist Flange”. It is
recommended that the attachment be mounted inside the fitting in order to
identify the alignment marks. Fitting depth of inside and outside must be
8 mm or less.
Fig. 6-2: Wrist Flange
8
Tapped hole M10
P.
C (6 holes) (depth: 12 mm)
.D
.9
2
5
.D.12
dia. P.C
dia.
8
-0.025
0
+0.030
0
160
63
Tapped hole M10

(6 holes) (depth: 12 mm)
+0.015
9 0 dia.
+0.018 (2 holes) (depth: 8 mm)
Alignment 10 dia.
0
mark (2 holes) (depth: 8 mm)

Units: mm
NOTE Wash off anti-corrosive paint (yellow) on the wrist flange

surface with thinner or light oil before mounting the tools.
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ES165D 7 System Application
7.1 Peripheral Equipment Mounts
7 System Application
7.1 Peripheral Equipment Mounts

The peripheral equipment mounts are provided on the U-axis (upper arm)
and S-axis (rotary head) as shown in Fig. 7-1 “Installing Peripheral
Equipment” for easier installation of the user's system applications.
The following conditions shall be observed to attach or install peripheral
equipment. (Refer to Table 7-1 "Conditions for Installation".)
Fig. 7-1: Installing Peripheral Equipment
120
133
255 40 A1
Tapped hole M8
120
(4 holes) (depth: 15mm)

133
40 255
120
A2
Tapped hole M8
255 40
40 255
120
153 153
75 137.5
5
B Tapped hole M12

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

50
Table 7-1: Conditions for Installation

Application Note
A1, A2 Cable Processing 30 kg max.
and Valve Load 49 N•m (5 kgf•m) max. for moment increase
amount of upper arm
B Others 250 kg max.
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7.2 Internal User I/O Wiring Harness and Air Line

6 cables for valves (0.75 mm2), 18 internal user I/O wires (0.5 mm2 x
6 wires, 0.75 mm2 x 12 wires), the cables for the external axis (1.25 mm2
x 7 cables, 0.75 mm2 x 2 cables, 0.2 mm2 x 4 cables), and an air line are
used in the manipulator for the drives of peripheral devices mounted on
the upper arm as shown in Fig. 7-2 “Connectors for Internal User I/O
Wiring Harness and Air Line”.
The connector pins, and the terminals are assigned as shown in Fig. 7-2
“Connectors for Internal User I/O Wiring Harness and Air Line” and
Fig. 7-3 “Details of the Connector Pin Numbers”. Wiring must be
performed by users.
The allowable current for internal user 8.0A or less / wire. (1.25 mm2)
I/O wiring harness 5.0A or less / wire. (0.75 mm2)
3.5A or less / wire. (0.5 mm2)
The maximum pressure for the air line 490 kPa (5 kgf/cm2) or less
(The air line inside diameter: 8.0 mm )
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Fig. 7-2: Connectors for Internal User I/O Wiring Harness and Air Line
Exhaust port (air flow)

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

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

Tapped holes PT3/8 with pipe plug
2BC
View A
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Fig. 7-3: Details of the Connector Pin Numbers
1
P
2
3 0.5mm2
P
4
5 (6 pins)
P
6
1
7 P 2
8 3
9 P 0.5mm2
4 (6 pins)
10 5
11 P 6
12 7
0.3mm2
13 8
(12 pins)
14 9
Pins used 15 Pins used 10
16 11
17 12 0.3mm2
18 13 (12 pins)
14
19 15
20 16
21 0.75mm2
(6 pins) 17
22 18
23
24
1 2 3
4 5 6 7
1 2 3 4 8 9 10 11 12
5 6 7 8 9 13 14 15 16
10 11 12 13 14 15 17 18
16 17 18 19 20 21 22
23 24 25 26 27 28 Pin details for internal user I/O wiring harness
(Casing side)
29 30 31 32 33
34 35 36
1
2 1.25mm2
3 (4 pins)
Pin details for internal user I/O wiring harness Pins used 4
(Base side) 5 0.75mm2
6 (2 pins)
7
1.25mm2
8
(3 pins)
9
1
P
2 0.2mm2
Pins used P
9 (4 pins)
1 2
10
15 Shielded wire 3 4 5
6 7 8
9
2 1 3
4 5 6
9
7 8
10 Pin details for external axis power cable
13 11 12 14
15 16
Pin details for external axis encoder cable
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ES165D 8 Electrical Equipment Specification
8.1 Position of Limit Switch
8 Electrical Equipment Specification
8.1.1 Specification of Limit Switch

1. The interference limit switch at S-, L- and U-axes electrically limit the
operating range of respective axes by adjusting the position of the dog
using the limit switch.
The positions of the mechanical limits (mechanical stoppers) at S-, L-
and U-axes are changeable.
When the limit switch is activated, the power supply to the manipulator
is interrupted, then the manipulator makes an emergency stop as a
result. Refer to section 8.9 “Overrun/Tool Shock Sensor Releasing” in
“DX100 INSTRUCTIONS” for releasing the status of this overrun.
2. The range of S-, L- and U-axes limit switches are set to the maximum
operating range before shipping.
In case of re-adjusting the operating range of each subject

NOTE axis, it is also required to change the dog location and limit
values in software. Contact your YASKAWA representative
if re-adjustment is required.
8.1.2 Location of Limit Switch

The limit switch is optional. For the S-, L-, and U-axes with limit switch
specifications, the limit switch is located on S-, L-, and U-axis respectively.
For their locations, refer to Fig. 8-1 “Location of Limit Switch”.
Fig. 8-1: Location of Limit Switch
L- and U-axes interference

limit switch
L-axis overrun
limit switch
S-axis overrun
limit switch
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8.1.3 Setting of Operation Range
8.1.3.1 S-Axis Operation Range

By the S-axis limit switch, S-axis operation range can be set to those
ranges mentioned in Table 5-2 "S-Axis Operating Range".
8.1.3.2 L-Axis Operation Range

By the L-axis limit switch, the L-axis operation range can be set to any
angles within -61° to +77° as mentioned in the figure below.
Fig. 8-2: L-Axis Overrun Limit Switch Setting Range
Negative side Positive side
61 77
L-axis center of rotation
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8.1.3.3 Setting Range of LU-Axes Interference Angle

L- and U-axes interference limit switches are designed to check the
interference angle of L- and U-axes.
As shown in Fig. 8-3 “LU-Axes Interference Angle”, the operation range of
U-axis can be set to any angles within -8° to +280° as the interference
angle with L-axis.
Fig. 8-3: LU-Axes Interference Angle
28
0
U-axis center of rotation
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8.2 Internal Connections

Highly reliable connectors are equipped on each connection part of the
manipulator to enable easy removal and installation for maintenance and
inspection. For the number and location of connectors, see Fig. 8-4
“Locations and Numbers of Connectors”.
Diagrams for Internal connections of the manipulator are shown in Fig.
8-5(a) “Internal Connection Diagram” and Fig. 8-5(b) “Internal Connection
Diagram”.
Fig. 8-4: Locations and Numbers of Connectors
Connector for external axis

(Encoder cable)
I/O wiring harness (Casing)
Connector for external axis

(Power cable)
Connector for
1BC
2BC 3BC Internal user I/O
wiring harness
(Base)
Table 8-1: List of Connector Types

Name Type of Connector
Connector Base Connector for internal JL05-2A28-21PC
user I/O wiring harness (JL05-6A28-21S: Optional)
U-arm Connector for internal JL05-2A22-14SC
user I/O 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)
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Fig. 8-5(a): Internal Connection Diagram
Notes
0BT 1 0BAT11 17 0BAT1 1. For the limit switch specification, the connection of the section
P BAT 2 BAT11 18 BAT1
0BT 3 0BAT12 19 0BAT2 A and B parts are changed as follows:
P BAT 4 BAT12 20 BAT2
21 0BAT3
22 BAT3 LA1 LA1
23
24 LB1 LB1 S-AXIS OVERRUN L.S. Connected to A1
0BT 5 0BAT21 25 0BAT4
P BAT 6 BAT21 26 BAT4 LB1 LA2
0BT
P BAT
7
8
0BAT22
BAT22
27
28
0BAT5
BAT5
LB2 LB2 L-AXIS OVERRUN L.S. Connected to A2
29 0BAT6 LA3
30 BAT6 LB2
1
2
31
32
LB1 LB3 L AND U-AXIS INTERFERENCE L.S. Connected to A3
3 1 PG0V1
4 2 PG5V1
5 3 PG0V2 LC1 LC1
6 4 PG5V2 LD1 LD1 S-AXIS OVERRUN L.S. Connected to B1
7 5 PG0V3
8 6 PG5V3 LC2
7 PG0V4
LD1
8 PG5V4 LD2 LD2 L-AXIS OVERRUN L.S. Connected to B2
9 PG0V5
DX100 1BC(10P 4)
No.22CN X 10 PG5V5 LD2 LC3
+24V CN1-5 +24V -1 +24V 1 11 PG0V6
CN1-5
0V CN1-4 0V -3 0V 3 12 PG5V6 LD1 LD3 L AND U-AXIS INTERFERENCE L.S. Connected to B3
CN1-4
13
CN1-10
CN1-9
+24V
0V
CN1-10
CN1-9
+24V
0V
-2
-4
+24V
0V
2
4
14
15 SLU-axes with Limit Switch Specification
16 No.1CN
CN1-1 SPG+1 CN1-1 SPG+1 1CN-1 DATA+1
SPG-1 CN1-2 SPG-1 No.16CN S P -2 DATA-1
CN1-2
-1 BAT1 -6 BAT
-2 0BAT1 P -5 OBT PG S-AXIS
-3 PG5V1 -4 +5V
-4 PG0V1 P -9 0V
CN1-3 FG1 CN1-3 FG1 -10 FG1
OBT
BAT
No.2CN
SPG-2 CN1-7 SPG-2 No.17CN L P -2 DATA-2
CN1-7
-1 BAT2 -6 BAT
-2 0BAT2 P -5 OBT PG L-AXIS
-3 PG5V2 -4 +5V
-4 PG0V2 P -9 0V
CN1-8 FG2 CN1-8 FG2 -10 FG2
OBT
BAT
No.3CN
SPG-3 CN2-2 SPG-3 No.18CN U P -2 DATA-3
CN2-2
-1 BAT3 -6 BAT
-2 0BAT3 P -5 OBT PG U-AXIS
-3 PG5V3 -4 +5V
-4 PG0V3 P -9 0V
CN2-3 FG3 CN2-3 FG3 -10 FG3
OBT
BAT
No.4CN
SPG-4 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 -10 FG4
OBT
BAT
No.5CN
SPG-5 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 -10 FG5
OBT
BAT
No.6CN
SPG-6 CN3-7 SPG-6 No.21CN T P -2 DATA-6
CN3-7
-1 BAT6 -6 BAT
-2 0BAT6 P -5 OBT PG T-AXIS
B1 -3 PG5V6 -4 +5V
-4 PG0V6 P -9 0V
CN3-8 FG6 CN3-8 FG6 -10 FG6
SS1 LC1 LD1 OBT
BAT
CN4-1 +24V
LB1
CN4-1
CN4-6
+24V
LB1
LA1 LB1 A1
CN4-6
LB1
LB2
LA2
LB2 A2
LD1
CN4-2
LD2
LC2
LD2 B2
CN4-2 SS2 SS2 SS2
LB2
CN4-7 AL1 CN4-7
LB1
LA3
LB3 A3
LD2
LD1
LC3
LD3 B3
BC1
CN4-3 BC2 CN4-3 BC2 BC2 FOR LAMP (OPTION)
CN4-8 AL2 CN4-8
CN4-10 0V CN4-10 0V No.7CN(20-29)

SPG+7 CN4-4 SPG+7 1
CN4-4 SPG-7 CN4-5 SPG-7 P 2
SPG+7
CN4-5 FG7 CN4-9 FG7 10
SPG-7
CN4-9 0V
CN2-4
+24 CN2-4 +24 P 9 5V
LD1 CN2-5 LD1 15
CN2-5 FG7
CN2-9 CN2-9
CN2-10 CN2-10
CN3-4
0V CN3-4 0V
5V CN3-5 5V
CN3-5 0V CN3-9 0V
CN3-9 5V CN3-10 5V
CN3-10
E
EE E E EEEE
Base MANIPULATOR Casing

S1(28-21)
E E E E E E E
19 SP19
20 SP20
21 SP21
No.8CN(22-14)
22 SP22
23 SP23
24 SP24
1 1 SP1
2
P 2 SP2
3 SP3
3 P 4
4 5 SP4
5 P 6 SP5
6 SP6
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
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Fig. 8-5(b): Internal Connection Diagram
2BC(8PX5+12PX1)
E E
LA1 LA1
LB1 LB1 S-AXIS OVERRUN L.S. Connected to A1
CN1-1 MU1 CN1-1 MU1
CN1-2 MU1 CN1-2 MU1 LA2
CN1-3 MU1 CN1-3 MU1
LB1
LB2 LB2 L-AXIS OVERRUN L.S. Connected to A2
CN1-5 MV1 CN1-5 MV1
CN1-6 MV1 CN1-6 MV1 LC1 LC1
CN1-7 MV1 CN1-7 MV1 No.9CN
9CN-A MU1 LD1 LD1 S-AXIS OVERRUN L.S. Connected to B1
CN2-1 MW1 CN2-1 MW1 -B MV1
CN2-2 MW1 CN2-2 MW1 -C MW1 SM S-AXIS LD1 LC2
CN2-3 MW1 CN2-3 MW1 -D ME1
LD2 LD2 L-AXIS OVERRUN L.S. Connected to B2
CN1-4 ME1 CN1-4 ME1
CN1-8
CN2-4
ME1
ME1
CN1-8
CN2-4
ME1
ME1 SL-axes with Limit Switch Specification
CN6-1 BA1 CN6-1 BA1 -1 BA1
CN6-2 BB1 CN6-2 BB1 -2 BB1 YB
LC1 LC1
LD1 LD1 S-AXIS OVERRUN L.S. Connected to B1
CN2-5 MU2 CN2-5 MU2
CN2-6 MU2 CN2-6 MU2 LA1 LA1
CN2-7 MU2 CN2-7 MU2
LB1 LB1 S-AXIS OVERRUN L.S. Connected to A1
CN3-1 MV2 CN3-1 MV2
CN3-2
CN3-3
MV2
MV2
CN3-2
CN3-3
MV2
MV2 No.10CN S-axis with Limit Switch Specification
10CN-A MU2
CN3-6 MW2 CN3-6 MW2 -C
-D
MW2
ME2
SM L-AXIS
CN3-7 MW2 CN3-7 MW2
CN2-8 ME2 CN2-8 ME2

CN3-4 ME2 CN3-4 ME2
CN3-8 ME2 CN3-8 ME2
CN6-3 BA2 CN6-3 BA2 -1 BA2

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
CN5-3 MW3 CN5-3 MW3 -D ME3
CN4-4 ME3 CN4-4 ME3

CN4-8 ME3 CN4-8 ME3
CN5-4 ME3 CN5-4 ME3
CN6-5 BA3 CN6-5 BA3 -1 BA3

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
-1 BA4
-2 BB4 YB
CN2-4 MU5 CN2-4 MU5

CN2-5 MU5 CN2-5 MU5
CN3-2
CN3-3
MW5
ME5
CN3-2
CN3-3
MW5
ME5
-C
-D
MW5
ME5
SM B-AXIS
CN3-6 ME5 CN3-6 ME5
-1 BA5
-2 BB5 YB
CN3-4 MU6 CN3-4 MU6

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

CN5-6 BB7 CN5-6 BB7 6
PE
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ES165D 9 Maintenance and Inspection
9.1 Inspection Schedule
9 Maintenance and Inspection
DANGER
• Maintenance and inspection must be performed by specified
personnel.
Failure to observe this caution may result in electric shock or injury.
• For disassembly or repair, contact your YASKAWA representative.
• Do not remove the motor, and do not release the brake.
Failure to observe these safety precautions may result in death or
serious injury from unexpected turning of the manipulator's arm.
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
• 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.

Proper inspections are essential not only to assure that the mechanism
will be able to function for a long period, but also to prevent malfunctions
and assure safe operation. Inspection intervals are classified into six
levels as shown in Table 9-1 "Inspection Items".
In Table 9-1 "Inspection Items", the inspection items are categorized by
three types of operations: operations which can be performed by
personnel authorized by the user, operations to be performed by trained
personnel, and operations to be performed by service company
personnel. Only specified personnel shall perform the inspection work.
• The inspection interval depends on the total servo

operation time.
• For any different or special applications, the inspection
NOTE process should be developed on an case-by-case basis.
• 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.
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Table 9-1: Inspection Items (Sheet 1 of 2)
ES165D
Items1) Schedule Method Operation Inspection
Charge
12000HCycle
1000HCycle
6000HCycle
Personnel
Company
Specified
Licensee
Service
24000H
36000H
Daily
1 Alignment mark
• Visual Check alignment mark accordance at the home position.
Check for damage.
• • •
2 External lead
• Visual Check for damage and deterioration of leads.
• • •

3 Working area and
manipulator
• Visual Clean the work area if dust or spatter is present. Check for damage and
outside cracks.
• • •
4 Motors for L- and U-axes
• Visual Check for grease leakage.2)
• • •
5 Baseplate mounting bolts
• Spanner
Wrench
Tighten loose bolts. Replace if necessary.
• • •
6 Cover mounting screws
• Screwdriver,
Wrench
Tighten loose bolts. Replace if necessary.
• • •
9-2
7 S-,L-,U-axes motor connector

• Manual Check for loose connectors and tighten if necessary.
• • •
8 Connector base
• Manual Check for loose connectors.
• • •
9 Balancer
• Grease Gun Supply grease. See Chap. section 9.3.5.
• •
10 Wire harness in manipulator
(SLU-axis wires)
• Visual,
Multimeter
Check for conduction between the main connector of base and intermediate
connector with manually shaking the wires. Check for wear of protective
• •
(RBT-axis wires) spring.3)
• Replace4)
•
11 Battery pack in manipulator
• Replace the battery pack when the battery alarm occurs or the manipulator
drove for 36000H.
• •
12 S-axis speed reducer,
• • Grease Gun Check for malfunction. (Replace if necessary.)
• •
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S-axis gear Supply grease5). (6000H cycle) See section 9.3.1.

Replace grease5). (12000H cycle) See section 9.3.1.
13 L-axis speed reducer,
Supply grease5). (6000H cycle) See section 9.3.2.
• •
14 U-axis speed reducer,
Supply grease5) (6000H cycle). See section 9.3.3.
• •
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Replace grease5) (12000H cycle). See section 9.3.3.
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Table 9-1: Inspection Items (Sheet 2 of 2)
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ES165D
Items1) Schedule Method Operation Inspection
Charge
12000HCycle
1000HCycle
6000HCycle
Personnel
Company
Specified
Licensee
Service
24000H
36000H
Daily
15 R-axis speed reducer
• •

16 B- and T-axes speed reducer,
B- and T-axes gear
• •
17 Overhaul
• •
1 Inspection No. correspond to the numbers in Fig. 9-1 “Inspection Items”.
2 The occurrence of a grease leakage indicates the possibility that grease has seeped into the motor. This can cause a motor breakdown. Contact your YASKAWA
representative.
3 When checking for conduction with multimeter, connect the battery to “BAT” and “OBT” of connectors on the motor side for each axis, and then remove connectors on
9-3
detector side for each axis from the motor. Otherwise, the home position may be lost. (Refer to section 9.3.6 “Notes for Maintenance”)
4 Wire harness in manipulator to be replaced at 24000H inspection.
5 For the grease, refer to Table 9-2 "Inspection Parts and Grease Used".
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Fig. 9-1: Inspection Items
ES165D
5
R-AXIS B-AXIS T-AXIS

S-AXIS 1 1 1 1
16
15

14
2
10
9-4
7 U-AXIS
4 1
Check that no grease
is leaked into the tube
(2 tubes).
L-AXIS
13
1
4
9
7 7
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2
12
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11
8
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Table 9-2: Inspection Parts and Grease Used

No. Grease Used Inspected Parts
12, 13, Molywhite RE No. 00 Speed Reducers for all Axes
14, 15, 16 R-, B-, and T-Axes gears
9 Alvania EP Grease 2 L-Axis Balancer
The numbers in the above table correspond to the numbers in Table 9-1
"Inspection Items"
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9.2 Notes on Maintenance Procedures
9.2.1 Battery Pack Replacement

The battery packs are installed in the position shown in Fig. 9-2(a) “Battery
Location (Back View)” and Fig. 9-2(b) “Battery Location (Top View)”.
If a battery alarm occurs in the DX100, replace the battery in accordance
with the following procedure:
Fig. 9-2(a): Battery Location (Back View)
Plate
Plate fixing screw M4
1BC
AIR S1
2BC
3BC
Base
Connector base
Fig. 9-2(b): Battery Location (Top View)
Battery pack
Board
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Fig. 9-3: Battery Connection
Battery pack
See replacing step 5. before replacement
Connector
Board
See replacing step 4.
（Type：SGDR-EFBA02A）
New battery pack
1. Turn OFF the DX100 main power supply.

2. Remove the plate fixing screws and the plate on the connector base,
then pull the battery pack out to replace it with the new one.
3. Remove the battery pack from the battery holder.
4. Connect the new battery pack to the unoccupied connector 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 holder.

7. Reinstall the plate.
NOTE Do not allow plate to pinch the cables when reinstalling the
plate.
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9.3 Notes on Grease Replenishment/Exchange Procedures

Make sure to follow the instructions listed below at grease replenishment/
exchange. Failure to observe the following notes may result in damage to
motor and speed reducer.
• If grease is added without removing the plug/screw from

the grease exhaust port, the 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
NOTE 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.
9.3.1 Grease Replenishment/Exchange for S-Axis Speed Reducer

Fig. 9-4: S-Axis Speed Reducer Diagram
1BC
A
AIR S1
2BC
3BC
Grease inlet S-axis speed reducer

Hexagon socket head plug A-PT1/4
Grease exhaust port
Hexagon socket head plug PT3/8
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9.3.1.1 Grease Replenishment

(Refer to Fig. 9-4 “S-Axis Speed Reducer Diagram”.)
Replenish the grease according to the following procedure:
1. Remove the hexagon socket head plugs PT3/8 from the grease
exhaust port.
If grease is injected with the plug on, the grease will leak
NOTE inside the motor and may cause a damage. Make sure to
remove the plug before the grease injection.
2. Install a grease zerk A-PT1/4 to the grease inlet. (The grease zerk is
delivered with the manipulator.)
3. Inject the grease through the grease inlet using a grease gun
– Grease type: Molywhite RE No. 00
– Amount of grease: 1200 cc
(2400 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 plug. Before
installing the plug, apply Three Bond 1206C on the thread part of the
plug, then tighten the plug with a tightening torque of 5 N•m
(0.51 kgf•m).
9.3.1.2 Grease Exchange

(Refer to Fig. 9-4 “S-Axis Speed Reducer Diagram”.)
1. Remove the hexagon socket head plugs PT3/8 from the exhaust port.
3. Inject the grease through the grease inlet using a grease gun.
– Amount of grease: approx. 7000 cc
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.
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(0.51 kgf•m).
NOTE If the plug is installed when the grease is being exhausted,

the grease will go inside the motor and may damage it.
9.3.2 Grease Replenishment/Exchange for L-Axis Speed Reducer

Fig. 9-5: L-Axis Speed Reducer Diagram
Grease Inlet
Grease exhaust port

(Refer to Fig. 9-5 “L-Axis Speed Reducer Diagram”.)
1. Make the L-arm vertical to the ground.
2. Remove the hexagon socket head plug PT3/8 from the grease
exhaust port.
4. Inject grease through the grease inlet using a grease gun.
5. Move the L-axis for a few minutes to discharge excess grease.
(0.51 kgf•m).
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(Refer to Table 9-5 "L-Axis Speed Reducer Diagram".)
1. Make the L-arm vertical to the ground.
exhaust port.
6. Move the L-axis for a few minutes to discharge excess grease.
(0.51 kgf•m).
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9.3.3 Grease Replenishment/Exchange for U-Axis Speed Reducer

Fig. 9-6: U-Axis Speed Reducer Diagram
Grease exhaust port

Grease inlet
9.3.3.1 Grease Replenishment

(Refer to Fig. 9-6 “U-Axis Speed Reducer Diagram”.)
1. Make the U-arm horizontal to the ground.
2. Remove the hexagon socket head plug PT1/8 from grease exhaust
port.
5. Move the U-axis for a few minutes to discharge excess grease.
(0.51 kgf•m).
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(Refer to Fig. 9-6 “U-Axis Speed Reducer Diagram”.)
1. Make the U-arm horizontal to the ground.
exhaust port.
5. The grease exchange is complete when new grease appears in the
6. Move the U-axis for a few minutes to discharge excess grease.
(0.51 kgf•m).
NOTE If the plug is installed when the grease is being exhausted,

the grease will go inside the motor and may damage it.
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9.3.4 Grease Replenishment/Exchange for U-Arm

Fig. 9-7: U-Arm Diagram
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
R-axis speed reducer
Grease Inlet
(B-, and T-axes speed reducer)
A
B-axis speed reducer
Grease exhaust port
(R-, and B-axes speed reducer)
Grease inlet (R-axis speed reducer)

View A
Grease exhaust port
(R-,B-,and T-gears in the casing)
9.3.4.1 Grease Replenishment for R-, B-, T-Axes Gears in the Casing
(Refer to Fig. 9-7 “U-Arm Diagram”.)
exhaust port.
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4. Move the R-, B-, T-Axes for a few minutes to discharge excess grease.
(0.51 kgf•m).
6. Remove the grease zerk from the grease inlet, and reinstall the plug.
Before installing the plug, apply Three Bond 1206C on the thread part
of the plug, then tighten the plug with a tightening torque of 5 N•m
(0.51 kgf•m).
9.3.4.2 Grease Replenishment for R-Axis Speed Reducer

exhaust port.
4. Move the R-Axis for a few minutes to discharge excess grease.
(0.51 kgf•m).
of the screw, then tighten the plug with a tightening torque of 5 N•m
(0.51 kgf•m).
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9.3.4.3 Grease Replenishment for B-Axis Speed Reducer

exhaust port.
4. Move the B-Axis for a few minutes to discharge excess grease.
(0.51 kgf•m).
(0.51 kgf•m).
9.3.4.4 Grease Replenishment for T-Axis Speed Reducer

exhaust port.
4. Move the T-Axis for a few minutes to discharge excess grease.
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(0.51 kgf•m).
6. Remove the grease zerk from the grease inlet, and reinstall the plug
(0.51 kgf•m).
9.3.4.5 Grease Exchange for R-, B-, T-Axes Gears in the Casing
exhaust port.
5. Move the R-, B-, T-Axes for a few minutes to discharge excess grease.
(0.51 kgf•m).
(0.51 kgf•m).
9.3.4.6 Grease Exchange for R-Axis Speed Reducer

exhaust port.
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5. Move the R-Axis for a few minutes to discharge excess grease.
(0.51 kgf•m).
(0.51 kgf•m).
9.3.4.7 Grease Exchange for B-Axis Speed Reducer

exhaust port.
5. Move the B-Axis for a few minutes to discharge excess grease.
(0.51 kgf•m).
(0.51 kgf•m).
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9.3.4.8 Grease Exchange for T-Axis Speed Reducer

exhaust port.
5. Move the T-Axis for a few minutes to discharge excess grease.
(0.51 kgf•m).
(0.51 kgf•m).
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9.3.5 Grease Replenishment for Balancer Connection Part

Fig. 9-8: 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)
1. Remove the hexagon socket head plugs of connection and .

(Refer to Fig. 9-8 “Balancer Connection Part”.)
– Grease type: Alvania EP grease 2
2. Inject grease through grease inlets of connection and using a
grease gun.
The exhaust port is used only for air flow.

NOTE Do not inject excessive grease through the gear grease
inlet.
3. Reinstall the plugs PT1/8 of connection and . Before installing

the plug, apply Three Bond 1206C on the thread part of the plug, then
tighten the plug with a tightening torque of 5 N•m (0.51 kgf•m).
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9.3.6 Notes for Maintenance
When performing maintenance such as replacement of a

wire harness in the manipulator, the encoder connector may
be necessary to be removed. In this case, be sure to
connect the battery pack to the battery backup connector
before removing the encoder connector.
NOTE
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. 9-9 “Battery
Pack Connection”.
9.3.6.1 Battery Pack Connection

The connectors (crimped contact-pin) for the battery backup are installed
at the end point of the motors (BAT and OBT are marked). Connect the
battery packs according to the following procedure.
1. 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 battery packs. Install the caps attached to the battery
backup connectors of the motors.
NOTE Do not remove the battery pack in the connector base.
Fig. 9-9: Battery Pack Connection

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)
9-21 75 of 92
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ES165D 10 Recommended Spare Parts
10 Recommended Spare Parts

It is recommended to keep the parts and components in the following table
in stock as spare parts for the MOTOMAN-ES165D. Product performance
cannot be guaranteed when using spare parts from any company other
than YASKAWA. The spare parts are ranked as follows:
• Rank A: Expendable and frequently replaced parts.
• Rank B: Parts for which replacement may be necessary as a result of
frequent operation.
• Rank C: Drive unit.
NOTE For replacing parts in Rank B or Rank C, contact your

YASKAWA representative.
Table 10-1: Spare Parts for the YR-ES0165D-A00, -A01 (Sheet 1 of 2)

Rank Parts Name Type Manufacturer Qty Qty Remarks
No. per
Unit
A 1 Grease Molywhite RE No. 00 YASKAWA 16 kg - for all axes
speed reducers
and wrist units
A 2 Grease Alvania EP Grease 2 Showa Oil Co.,Ltd. 16 kg - for balancer
joint part
A 3 Liquid Seal Three Bond 1206C Three Bond Co., Ltd. 1 1
A 4 Battery Pack HW0470360-A YASKAWA 1 1
A 5 Battery Pack HW9470932-A YASKAWA 1 - for wire harness
in manipulator
replacing
B 6 S-Axis Speed HW0388208-A YASKAWA 1 1
Reducer
B 7 S-Axis Input Gear HW0314016-1 YASKAWA 1 1
B 8 L-Axis Speed HW0390225-A YASKAWA 1 1
Reducer
B 9 L-Axis Input Gear HW0303271-1 YASKAWA 1 1
B 10 U-Axis Speed HW0388209-A YASKAWA 1 1
Reducer
B 11 U-Axis Input Gear HW9482451-A YASKAWA 1 1
B 12 R-Axis Speed HW1382917-A YASKAWA 1 1
Reducer
B 13 B-Axis Speed HW9380961-D YASKAWA 1 1
Reducer
B 14 T-Axis Speed HW0389174-A YASKAWA 1 1
Reducer
B 15 Wrist Unit HW0174234-A YASKAWA 1 1
C 16 AC Servo Motor SGMRV-37ANA- YASKAWA 1 3
for S-, L-, and U- YR1*
Axes HW0388670-A
for R-Axis YR1*
HW0388666-A
10-1 76 of 92
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ES165D 10 Recommended Spare Parts
Table 10-1: Spare Parts for the YR-ES0165D-A00, -A01 (Sheet 2 of 2)

Rank Parts Name Type Manufacturer Qty Qty Remarks
No. per
Unit
for B-and T-Axes YR2*
HW0388667-A
C 19 Internal Wire HW0174287-A YASKAWA 1 1
Harness
C 20 Connector Base HW0374283-A YASKAWA 1 1
Set
C 21 Board SGDR-EFBA02A YASKAWA 1 1
C 22 Limit switch set HW0371747-A YASKAWA 1 1 Treatment of
for S-axis -A01 lead
terminal is done
C 23 Limit switch set HW0374590-A YASKAWA 1 1 Treatment of
for L-axis -A01 lead
terminal is done
C 24 Limit switch set HW0374590-B YASKAWA 1 1 Treatment of　
for U-axis -A01 lead
terminal is done
10-2 77 of 92
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ES165D 11 Parts List
11.1 S-Axis Unit
11 Parts List
11.1 S-Axis Unit

Fig. 11-1: S-Axis Unit
1037
1038 1020 1029
1030
1002
1004
1005
1035
1036 1006
1010
1008 1032
1031
1003
1011
1015
1025
1026
1001
1027
1028 1016
1014 1021
1009
1023
1024
1017
1013 1012
1033
1034
1039
1022
1007
1019
1018
11-1 78 of 92
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11.1 S-Axis Unit
Table 11-1: S-Axis Unit

No. DWG No. Name Pcs
1001 HW0388208-A Speed reducer 1
1002 SGMRV-37ANA-YR1* Motor 1
1003 TC12015014 Oil seal 1
1004 STW-50 Retaining rings 1
1005 6310 Bearing 1
1006 HW0314016-1 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 HW0306181-1 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 KQ2L10-01S Union 1
1019 NB-1075 Tube 1
1020 PT3/8 Plug 1
1021 G415 O ring 1
1022 G105 O ring 1
1023 M6X16 Socket screw 1
1024 2L-6 Spring washer 1
1026 SW2H-12 Spring washer 16
1027 M8X40 Socket Screw 1
1030 2H-12 Spring washer 3
1035 M20X45(12.9) Bolt 3
1036 M20 Spring washer 3
1038 GT-SH-16 Spring washer 12
1039 EZ5002A0 Cap 1
11-2 79 of 92
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11.2 L-Axis Unit
11.2 L-Axis Unit

Fig. 11-2: L-Axis Unit
2011
2040 2001
2006 2039
2042
2041
2046 2033
2037 2034
2038 2019
6004
2031 2020-26
2044 2032
2043 2012 2019
2005
2017 2002
2018
2019
2009 2010
2047
2019
2005 2027
2012
2018 2009 1008
2017
2045
2032
2020-26 2031
2019
2003
2034 2007
2033 2036
2035
11-3 80 of 92
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11.2 L-Axis Unit
Table 11-2: L-Axis Unit

2001 HW9381442-B Speed reducer 1
2003 Y507212.5 Oil seal 1
2005 HR32916J Bearing 2
2006 HW0100472-1 L arm 1
2007 HW0303271-1 Gear 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 (Stainless) 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
2027 GT-SA-M12X35 Socket screw 4
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
11-4 81 of 92
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11.3 URBT-Axes Unit
11.3 URBT-Axes Unit

Fig. 11-3: URBT-Axes Unit
3041
3042
3003 3039
R-axis 3040
3002
3007
3005
3041
3042 3013
3041 3018
3042 3014
B-axis 3050 3015
3050 3021 3027
3004 3037
3008 3045 3047
3020 3010
3005 3028 3046
T-axis 3009 3038
3005 3027
3028 3018 3024 3006
3027 3048
3018 3028 3049
3019 3026 3012
3025 3024
3024
3044
3043
3023 4009
2006 3016
3011
3034 3029 3036

3033 3030 3035
3017
3001 3022
3024
3032
3031
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11.3 URBT-Axes Unit
Table 11-3: URBT-Axes Unit (Sheet 1 of 2)

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 HW9482306-C Shaft 1
3011 HW0100196-3 Casing 1
3012 HW9405703-1 Flange 1
3013 HW0402391-1 Collar 1
3014 HW0402390-1 Collar 1
3015 HW0402406-1 Collar 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
3037 HW9482316-A Bolt 1
3038 HW0408806-1 Washer 1
3044 SW-2H-12 Spring washer 16
11-6 83 of 92
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11.3 URBT-Axes Unit
Table 11-3: URBT-Axes Unit (Sheet 2 of 2)

3047 HW9481343-A Shaft 1
3048 HW9482451-A Gear 1
2006 HW0100472-1 L arm 1
4009 HW0100172-2 U arm 1
11-7 84 of 92
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11.4 U-Arm Unit
11.4 U-Arm Unit

Fig. 11-4: U-Arm Unit
4004
4008
4009
4028
4019 4020
4011 4003
4007
4026
4002
4015 4023
4022
3011
4017 4021 4005

4018 4012
4024
4025 4013
4024
4025
4006
4016
4006 4010
4001
4030 4014
4029
4026
11-8 85 of 92
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11.4 U-Arm Unit
Table 11-4: U-Arm Unit

4001 NK25/20R Bearing 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 HW0312106-1 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
4029 WR20 Retaining rings 1
4030 LRT202526 Bearing 1
3011 HW0100196-3 Casing 1
11-9 86 of 92
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11.5 Wrist Unit
11.5 Wrist Unit
Fig. 11-5: Wrist Unit
4010
5089
5090
5023 5090
5041
5003
5024-28 5078
5022 5035
5011 5045
5073 5004 5091 5012 5048
5074
5014
5040
5088
5063-66
5046
5036 5047
5067 5098 5039
5068 5096 5007 5017 5040
5094 5008
5015 5100 5037 5007
5058-61 5038
5006 5016
5007 5047
5046
5097 5062 5018
5088
5054-57
5074 5007
5029-31 5020 5033 5019
5001 5099
5070 5045
5073 5002A 5002
5069 5010 5095
5021 5032 5049
5013 5050-53
5005 5071
5072
5075
5087
5034 5086
5048
5077
5076
11-10 87 of 92
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11.5 Wrist Unit
Table 11-5: Wrist Unit (Sheet 1 of 2)

5001 HW9380961-D Speed reducer 1
5002A FU00SC Fine U nut 1
5003 6908DB Bearing 1
5004 6909 Bearing 1
5005 6009 Bearing 1
5006 6907 Bearing 1
5008 6911 Bearing 1
5010 HW0100475-1 Wrist 1
5011 HW0100476-1 Wrist base 1
5012 HW0200615-1 Cover 1
5013 HW0300889-1 Cover 1
5014 HW0301230-1 Gear 1
5015 HW0309164-1 Gear 1
5016 HW0301223-1 Gear 1
5017 HW0301224-1 Gear 1
5018 HW0301225-1 Gear 1
5019 HW0301226-1 Gear 1
5020 HW0301227-1 Gear 1
5021 HW0301231-1 Gear 1
5022 HW0401509-1 Housing 1
5023 HW0401510-1 B nut 1
5024 HW0401516-1 Shim 1
5025 HW0401516-2 Shim 1
5026 HW0401516-3 Shim 1
5027 HW0401516-4 Shim 1
5028 HW0401516-5 Shim 1
5029 HW0401517-1 Shim 1
5030 HW0401517-2 Shim 1
5031 HW0401517-3 Shim 1
5032 HW0304688-1 Flange 1
5033 HW9482951-A Packing 1
5034 ARP568-263 O ring 1
5035 G110 O ring 1
5036 S60 O ring 1
5037 HW9403618-1 Housing 1
5038 HW9403617-1 Housing 1
5039 AE3290E3 Oil seal 1
5040 HW0401514-1 B nut 2
5041 HW0401511-1 B cover 1
5045 STW-45 C stopper 2
11-11 88 of 92
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11.5 Wrist Unit
Table 11-5: Wrist Unit (Sheet 2 of 2)

5048 PT1/8 Plug 2
5049 PT1/16 Plug 1
5050 HW0406766-1 Shim 1
5051 HW0406766-2 Shim 1
5052 HW0406766-6 Shim 1
5053 HW0406766-7 Shim 1
5054 HW9403621-1 Shim 1
5055 HW9403621-2 Shim 1
5056 HW9403621-5 Shim 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
5063 HW0410868-1 Shim 1
5064 HW0410868-2 Shim 1
5065 HW0410868-3 Shim 1
5066 HW0410868-4 Shim 1
5087 GT-SH-M14 Spring washer 4
5094 HW0411720-1 Cover 1
5095 HW0413886-3 Washer 1
5096 HW0411718-1 Collar 1
5097 HW0411721-1 B nut 1
5098 M5X7 Magic screw 2
5099 HW0406765-1 Collar 1
4010 HW0312106-1 Shaft 1
11-12 89 of 92
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11.6 Balancer Unit
11.6 Balancer Unit

Fig. 11-6: Balancer Unit
6011
6004
6017
6005
6001
6007
6002
6006
6016
6015
6012 6008
6003
6003
6012 6014
6010
6013
2006 6009
2004
2014
2015
2008 2016
2013
2030
2029
11-13 90 of 92
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11.6 Balancer Unit
Table 11-6: Balancer Unit

6001 HW0481740-A Coil spring 1
6002 HW0481741-A Coil spring 1
6003 SOB607440 Oiless 2
6004 HW0100477-1 Case 1
6005 HW0306033-1 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 Magic screw 2
2004 NA6912 Needle bearing 1
2006 HW0100472-1 L arm 1
2008 HW9302054-1 Shaft 1
2013 AR-85 Clip 1
2014 WR60 Sir clip 1
2015 VB75X95X6 Oil seal 1
2016 VB60X78X7 Oil seal 1
2029 12X50 Socket screw 12
11-14 91 of 92
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MOTOMAN-ES165D
INSTRUCTIONS
HEAD OFFICE
2-1 Kurosakishiroishi, Yahatanishi-ku, Kitakyushu 806-0004, Japan
Phone +81-93-645-7703 Fax +81-93-645-7802
YASKAWA America Inc. (Motoman Robotics Division)

100 Automation Way, Miamisburg, OH 45342, U.S.A.
Phone +1-937-847-6200 Fax +1-937-847-6277
YASKAWA Europe GmbHRobotics Divsion )

Yaskawastrasse 1, 85391 Allershausen, Germany
Phone +49-8166-90-100 Fax +49-8166-90-103
YASKAWA Nordic AB
Verkstadsgatan 2, Box 504 ,SE-385 25 Torsas, Sweden
Phone +46-480-417-800 Fax +46-486-414-10
YASKAWA Electric (China) Co., Ltd.

22F, One Corporate Avenue, No.222, Hubin Road, Huangpu District, Shanghai 200021, China
Phone +86-21-5385-2200 Fax 㸩86-21-5385-3299
YASKAWA SHOUGANG ROBOT Co. Ltd.
No7 Yongchang North Road, Beijing E&T Development AreaChina 100176
Phone +86-10-6788-2858 Fax +86-10-6788-2878
YASKAWA India Private Ltd. (Robotics Division)

#426, Udyog Vihar, Phase- IV,Gurgaon, Haryana, India
Phone +91-124-475-8500 Fax +91-124-475-8542
YASKAWA Electric Korea Corporation

35F, Three IFC, 10 Gukjegeumyung-ro, Yeongdeungpo-gu, Seoul, Korea 07326
Phone +82-2-784-7844 Fax +82-2-784-8495
YASKAWA Electric Taiwan Corporation

12F, No.207, Sec. 3, Beishin Rd., Shindian District, New Taipei City 23143, Taiwan
Phone +886-2-8913-1333 Fax +886-2-8913-1513
YASKAWA Electric (Singapore) PTE Ltd.

151 Lorong Chuan, #04-02A, New Tech Park, Singapore 556741
Phone +65-6282-3003 Fax +65-6289-3003
YASKAWA Electric (Thailand) Co., Ltd.

59,1st-5th Floor, Flourish Building, Soi Ratchadapisek 18,Ratchadapisek Road,
Huaykwang, Bangkok 10310, THAILAND
Phone +66-2-017-0099 Fax +66-2-017-0199
PT. YASKAWA Electric Indonesia

Secure Building-Gedung B Lantai Dasar & Lantai 1 JI. Raya Protokol Halim Perdanakusuma,
Jakarta 13610, Indonesia
Phone +62-21-2982-6470 Fax +62-21-2982-6741
Specifications are subject to change without notice

for ongoing product modifications and improvements.
92 of 92
MANUAL NO.
HW0485249 9

Motoman Es165d

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MOTOMAN-ES165D

The DX100 operator’s manual above corresponds to specific usage.

Part Number: 155976-1CD

Copyright © 2017, 2013 Yaskawa America, Inc.

Terms of Use and Copyright Notice

Printed in the United States of America

First Printing, 2016

Yaskawa America, Inc.

Notes for Safe Operation

Indicates an imminent hazardous

Indicates a potentially hazardous

Indicates a potentially hazardous

Always be sure to follow explicitly the

PROHIBITED Must never be performed.

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

To ensure safe and efficient operation at all times, be sure to

• Observe the following precautions when performing teaching

Definition of Terms Used In this Manual

Description of the Operation Procedure

Explanation of Warning Labels

Nameplate WARNING Label A WARNING Label B

Nameplate: WARNING Label A:

YASKAWA ELECTRIC CORPORATION WARNING Label B:

Mechanical Safety Devices

Programming, Operation, and Maintenance Safety

Summary of Warning Information

Customer Support Information

When using e-mail to contact YASKAWA Customer Support, please

Please use e-mail for routine inquiries only. If you have an

• Primary Application ___________________________

• Software Version Access this information on the

• Robot Serial Number Located on the robot data plate

• Robot Sales Order Number Located on the DX100 controller

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

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

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

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

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

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

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

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

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

3.3 Location ............................................................................................................................. 3-3

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

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

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

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

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 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

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

6.2 Wrist Flange....................................................................................................................... 6-3

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