HP 3 JC

Motoman NXC100 Controller
HP3JC
Manipulator Manual
Part Number: 151562-1CD

Revision: 0
Motoman, Incorporated
805 Liberty Lane
West Carrollton, OH 45449
TEL: (937) 847-6200
FAX: (937) 847-6277
24-Hour Service Hotline: (937) 847-3200
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The information contained within this document is the proprietary property of Motoman, Inc., and may not be
copied, reproduced or transmitted to other parties without the expressed written authorization of Motoman,
Inc.
©2007 by MOTOMAN
All Rights Reserved
Because we are constantly improving our products, we reserve the right to change specifications without
notice. MOTOMAN is a registered trademark of YASKAWA Electric Manufacturing.
HP3JC*
151562-1
Chapter 1
Introduction
1.1 About This Document

This manual provides information for the HP3JC manipulator and contains the following sections:
CHAPTER 1 - INTRODUCTION
Provides general information about the structure of this manual, a list of reference documents, and
customer service information.
CHAPTER 2 - SAFETY
This section provides information regarding the safe use and operation of Motoman products.
CHAPTER 3 - HP3JC* INSTRUCTIONS
Provides detailed information for the HP3JC manipulator.
1.2 Reference to Other Documentation

For additional information refer to the following:
• NXC100 Controller Manual (P/N 150975-1)
• Concurrent I/O Manual (P/N 149230-1)
• Operator’s Manual for your application
• Vendor manuals for system components not manufactured by Motoman
1.3 Customer Service Information

If you are in need of technical assistance, contact the Motoman service staff at (937) 847-3200. Please have
the following information ready before you call:
• Robot Type (HP3JC)
• Application Type (welding, handling, etc.)
• Robot Serial Number (located on back side of robot arm)
• Robot Sales Order Number (located on back of controller)
Final page 1
User’s Manual
Chapter 1 Introduction
Notes
page 2 Final
HP3JC*
151562-1
Chapter 2
Safety
2.1 Introduction
It is the purchaser’s responsibility to ensure that all local, county, state,

and national codes, regulations, rules, or laws relating to safety and safe
operating conditions for each installation are met and followed.
We suggest that you obtain and review a copy of the ANSI/RIA National Safety Standard for
Industrial Robots and Robot Systems. This information can be obtained from the Robotic Industries
Association by requesting ANSI/RIA R15.06-1999. The address is as follows:
Robotic Industries Association
900 Victors Way
P.O. Box 3724
Ann Arbor, Michigan 48106
TEL: (734) 994-6088
FAX: (734) 994-3338
INTERNET: www.roboticsonline.com
Ultimately, the best safeguard is trained personnel. The user is responsible for providing personnel
who are adequately trained to operate, program, and maintain the robot cell. The robot must not be
operated by personnel who have not been trained!
We recommend that all personnel who intend to operate, program, repair, or use the robot system be
trained in an approved Motoman training course and become familiar with the proper operation of the
system.
Final page 3
User’s Manual
Chapter 2 Safety
This safety section addresses the following:

• Standard Conventions (Section 2.2)
• General Safeguarding Tips (Section 2.3)
• Mechanical Safety Devices (Section 2.4)
• Installation Safety (Section 2.5)
• Programming, Operation, and Maintenance Safety (Section 2.6)
2.2 Standard Conventions
This manual includes the following alerts – in descending order of severity – that are essential to the
safety of personnel and equipment. As you read this manual, pay close attention to these alerts to
insure safety when installing, operating, programming, and maintaining this equipment.
DANGER!
Information appearing in a DANGER concerns the protection of personnel from the immediate
and imminent hazards that, if not avoided, will result in immediate, serious personal injury or
loss of life in addition to equipment damage.
WARNING!
Information appearing in a WARNING concerns the protection of personnel and equipment from
potential hazards that can result in personal injury or loss of life in addition to equipment
damage.
CAUTION!
Information appearing in a CAUTION concerns the protection of personnel and equipment,
software, and data from hazards that can result in minor personal injury or equipment damage.
Note: Information appearing in a Note provides additional information which is helpful in understanding the item being
explained.
page 4 Final
HP3JC*
151562-1
2.3 General Safeguarding Tips
All operators, programmers, plant and tooling engineers, maintenance personnel, supervisors, and
anyone working near the robot must become familiar with the operation of this equipment. All
personnel involved with the operation of the equipment must understand potential dangers of
operation. General safeguarding tips are as follows:
• Improper operation can result in personal injury and/or damage to the equipment. Only
trained personnel familiar with the operation of this robot, the operator's manuals, the system
equipment, and options and accessories should be permitted to operate this robot system.
• Do not enter the robot cell while it is in automatic operation. Programmers must have the
teach pendant when they enter the robot cell.
• Improper connections can damage the robot. All connections must be made within the
standard voltage and current ratings of the robot I/O (Inputs and Outputs).
• The robot must be placed in Emergency Stop (E-STOP) mode whenever it is not in use.
• In accordance with ANSI/RIA R15.06-1999, section 4.2.5, Sources of Energy, use
lockout/tagout procedures during equipment maintenance. Refer also to Section 1910.147
(29CFR, Part 1910), Occupational Safety and Health Standards for General Industry
(OSHA).
2.4 Mechanical Safety Devices
The safe operation of the robot, positioner, auxiliary equipment, and system is ultimately the user's
responsibility. The conditions under which the equipment will be operated safely should be reviewed
by the user. The user must be aware of the various national codes, ANSI/RIA R15.06-1999 safety
standards, and other local codes that may pertain to the installation and use of industrial equipment.
Additional safety measures for personnel and equipment may be required depending on system
installation, operation, and/or location. The following safety equipment is provided as standard:
• Safety fences and barriers
• Light curtains and/or safety mats
• Door interlocks
• Emergency stop palm buttons located on operator station, robot controller, and
programming pendant
Check all safety equipment frequently for proper operation. Repair or replace any non-functioning
safety equipment immediately.
Final page 5
User’s Manual
Chapter 2 Safety
2.5 Installation Safety
Safe installation is essential for protection of people and equipment. The following suggestions are
intended to supplement, but not replace, existing federal, local, and state laws and regulations.
Additional safety measures for personnel and equipment may be required depending on system
installation, operation, and/or location. Installation tips are as follows:
• Be sure that only qualified personnel familiar with national codes, local codes, and
ANSI/RIA R15.06-1999 safety standards are permitted to install the equipment.
• Identify the work envelope of each robot with floor markings, signs, and barriers.
• Position all controllers outside the robot work envelope.
• Whenever possible, install safety fences to protect against unauthorized entry into the work
envelope.
• Eliminate areas where personnel might get trapped between a moving robot and other
equipment (pinch points).
• Provide sufficient room inside the workcell to permit safe teaching and maintenance
procedures.
2.6 Programming, Operation, and Maintenance Safety
All operators, programmers, plant and tooling engineers, maintenance personnel, supervisors, and
anyone working near the robot must become familiar with the operation of this equipment. Improper
operation can result in personal injury and/or damage to the equipment. Only trained personnel
familiar with the operation, manuals, electrical design, and equipment interconnections of this robot
should be permitted to program, operate, and maintain the system. All personnel involved with the
operation of the equipment must understand potential dangers of operation.
• Inspect the robot and work envelope to be sure no potentially hazardous conditions exist. Be
sure the area is clean and free of water, oil, debris, etc.
• Be sure that all safeguards are in place. Check all safety equipment for proper operation.
Repair or replace any non-functioning safety equipment immediately.
• Do not enter the robot cell while it is in automatic operation. Be sure that only the person
holding the programming pendant enters the workcell.
• Check the E-STOP button on the programming pendant for proper operation before
programming. The robot must be placed in Emergency Stop (E-STOP) mode whenever it is
not in use.
• Back up all programs and jobs onto suitable media before program changes are made. To
avoid loss of information, programs, or jobs, a backup must always be made before any
service procedures are done and before any changes are made to options, accessories, or
equipment.
page 6 Final
HP3JC*
151562-1
• Any modifications to PART 1, System Section, of the robot controller concurrent I/O
program can cause severe personal injury or death, as well as damage to the robot! Do not
make any modifications to PART 1, System Section. Making any changes without the written
permission of Motoman will VOID YOUR WARRANTY!
• Some operations require standard passwords and some require special passwords. Special
passwords are for Motoman use only. YOUR WARRANTY WILL BE VOID if you use
these special passwords.
• The robot controller allows modifications of PART 2, User Section, of the concurrent I/O
program and modifications to controller parameters for maximum robot performance. Great
care must be taken when making these modifications. All modifications made to the
controller will change the way the robot operates and can cause severe personal injury or
death, as well as damage the robot and other parts of the system. Double-check all
modifications under every mode of robot operation to ensure that you have not created
hazards or dangerous situations.
• Check and test any new or modified program at low speed for at least one full cycle.
• This equipment has multiple sources of electrical supply. Electrical interconnections are
made between the controller and other equipment. Disconnect and lockout/tagout all
electrical circuits before making any modifications or connections.
• Do not perform any maintenance procedures before reading and understanding the proper
procedures in the appropriate manual.
• Use proper replacement parts.
• Improper connections can damage the robot. All connections must be made within the
standard voltage and current ratings of the robot I/O (Inputs and Outputs).
Final page 7
User’s Manual
Chapter 2 Safety
Notes
page 8 Final
YASKAWA
MOTOMAN-HP3J
INSTRUCTIONS
TYPE: YR-HP3J-J00
Upon receipt of the product and prior to initial operation, read these instructions thoroughly, and retain
for future reference.
MOTOMAN INSTRUCTIONS
MOTOMAN-HP3J INSTRUCTIONS
NXC100 INSTRUCTIONS
NX100 OPERATOR’S MANUAL
NXC100 MAINTENANCE MANUAL
The NX100 operator’s manual above corresponds to specific usage.
Be sure to use the appropriate manual.
YASKAWA MANUAL NO.
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MANDATORY
• This instruction manual is intended to explain operating instructions
and maintenance procedures primarily for the MOTOMAN-HP3J.
• General items related to safety are listed in the Section 1: Safety of the
NXC100 Instructions. To ensure correct and safe operation, carefully
read the NXC100 Instructions before reading this manual.
CAUTION
• Some drawings in this manual are shown with the protective covers or
shields removed for clarity. Be sure all covers and shields are replaced
before operating this product.
• The drawings and photos in this manual are representative examples

and differences may exist between them and the delivered product.
• YASKAWA may modify this model without notice when necessary due to
product improvements, modifications, or changes in specifications.
If such modification is made, the manual number will also be revised.
• If your copy of the manual is damaged or lost, contact a YASKAWA rep-

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

modification of its products. Unauthorized modification voids your prod-
uct’s warranty.
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Notes for Safe Operation

Read this manual carefully before installation, operation, maintenance, or inspection of the
NXC100.
In this manual, the Notes for Safe Operation are classified as “WARNING”, “CAUTION”,
“MANDATORY”, or “PROHIBITED”.
Indicates a potentially hazardous situation which, if not

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

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

MANDATORY heading.
PROHIBITED Must never be performed.
Even items described as “CAUTION” may result in a serious accident in some situations.
At any rate, be sure to follow these important items.
NOTE To ensure safe and efficient operation at all times, be sure to follow all instructions, even if
not designated as “CAUTION” and “WARNING”.
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WARNING
• Before operating the manipulator, check that servo power is turned OFF
when the emergency stop buttons on the front face of the NXC100 and
on the right side of the programming pendant are pressed.
When the servo power is turned OFF, the SERVO ON LED on the program-
ming pendant is turned OFF.
Injury or damage to machinery may result if the emergency stop circuit cannot stop the
manipulator during an emergency. The manipulator should not be used if the emergency
stop buttons do not function.
Emergency Stop Button
• Once the emergency stop button is released, clear the cell of all items
which could interfere with the operation of the manipulator.
Then turn the servo power ON.
Injury may result from unintentional or unexpected manipulator motion.
TURN
Release of Emergency Stop
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WARNING
• Observe the following precautions when performing teaching opera-
tions:
-Always follow the predetermined operating procedure.
-Ensure that you have a safe place to retreat in case of emergency.
Improper operation or unintended manipulator motion may result in injury.
• Confirm that no persons are present in the P-point maximum envelope of

the manipulator and that you are in a safe location before:
-Turing ON the robot system power.
-Moving the manipulator with the programming pendant.
-Running the system in the check mode.
-Performing automatic operations.
Injury may result if anyone enters the P-point maximum envelope of the manipulator dur-
ing operation. Always press an emergency stop button immediately if there is a problem.
The emergency stop button is located on the right side of the programming pendant and
on the front face of the NXC100.
Start button
Mode selector switch
Hold button
Emergency
stop button
REMOTE TEACH
PLAY START HOLD
Emergency stop button
SER NO. 44A220-011 DATE 3-2005

TYPE ERCR-NS00-A200
YASKAWA ELECTRIC CORPORATION
JAPAN NJ2518-2
POWER SUPPLY
AC200/220V 50/60Hz 1 1 KVA
NXC100
X31
NJ2519-2
Approx mass.
16 Kg NJ2520-2 X52
ON (I) F1
FU1
ON
SOURCE
BAT
SOURCE
FU2 BATTERY
FUSE
OFF
X51
OFF (O) F2
AC FUSE : F1,F2 I/O FUSE : F1,F2,F3,F4
X81 15A / 250V 3.15A / 250V
SLOW BLOW FAST BLOW
Programming pendant NXC100
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CAUTION
• Perform the following inspection procedures prior to conducting manip-
ulator teaching. If problems are found, repair them immediately,
and be sure that all other necessary processing has been performed.
-Check for problems in movement of the manipulator and servo track.
-Check for damage to insulation and sheathing of external wires.
• Read and understand the Explanation of Warning Labels before operat-

ing the robot system.
• For safety, operate under the proper lighting.
Definition of Terms Used Often in This Manual

The MOTOMAN manipulator is the YASKAWA industrial robot product.
The manipulator usually consists of the controller, the programming pendant, and supply
cables.
In this manual, the equipment is designated as follows:
Equipment Manual Designation
NXC100 Controller NXC100
NXC100 Programming Pendant Programming Pendant
Cable between the Manipulator and the Controller Manipulator Cable
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Explanation of Warning Labels

The following warning labels are attached to the manipulator.
Always follow the warnings on the labels.
Also, an identification label with important information is placed on the body of the manipula-
tor. Prior to operating the manipulator, confirm the contents.
Warning label B
Warning label B
Nameplate
Warning label A
Nameplate Warning Label A:
MOTOMAN WARNING
TYPE
Moving parts
PAYLOAD MASS
kg kg may cause
ORDER NO. DATE
injury
SERIAL NO.
YASKAWA ELECTRIC CORPORAION JAPAN
Warning Label B:
WARNING
Do not enter
robot
work area.
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1 Product Confirmation
1.1 Contents Confirmation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.2 Order Number Confirmation . . . . . . . . . . . . . . . . . . . . . . . . 1-2
2 Transporting
2.1 Transporting Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.1.1 Using a Crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.1.2 Using a Forklift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
3 Installation
3.1 Installation of Safeguarding . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3.2 Mounting Procedures for Manipulator Base . . . . . . . . . 3-2
3.2.1 When the Manipulator and Mounting Fixture are Installed on a
Baseplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3.2.2 When the Manipulator is Mounted Directly on the Floor
without the Mounting Fixture. . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3.3 Installation Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
3.4 Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
4 Wiring
4.1 Grounding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4.2 Manipulator Cable Connection . . . . . . . . . . . . . . . . . . . . . 4-3
4.2.1 Connection to the Manipulator . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.2.2 Connection to the NXC100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
5 Basic Specifications
5.1 Basic Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.2 Part Names and Working Axes . . . . . . . . . . . . . . . . . . . . . 5-2
5.3 Manipulator Base Dimensions . . . . . . . . . . . . . . . . . . . . . . 5-2
5.4 Dimensions and P-Point Maximum Envelope . . . . . . . 5-3
5.5 Special Interference Area . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5.6 B-Axis Operating Range. . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
5.7 Alterable Operating Range . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
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6 Allowable Load for Wrist Axis and Wrist Flange

6.1 Allowable Wrist Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.2 Wrist Flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
7 System Application
7.1 Peripheral Equipment Mount. . . . . . . . . . . . . . . . . . . . . . . 7-1
7.2 Internal User I/O Wiring Harness and Air Lines . . . . 7-2
8 Electrical Equipment Specification

8.1 Internal Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
9 Maintenance and Inspection

9.1 Inspection Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
9.2 Notes on Maintenance Procedures . . . . . . . . . . . . . . . . 9-5
9.2.1 Battery Pack Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-5
9.2.2 Grease Replenishment for S-axis Speed Reducer . . . . . . . . . .9-7
Grease Replenishment (Refer to " Fig. 22 S-axis
Speed Reducer Diagram ".) . . . . . . . . . . . . . . . . . . . . . . . . .9-7
9.2.3 Grease Replenishment for L-axis Speed Reducer . . . . . . . . . .9-8
Grease Replenishment (Refer to " Fig. 23 L-axis
Speed Reducer Diagram ".) . . . . . . . . . . . . . . . . . . . . . . . . .9-8
9.2.4 Grease Replenishment for Speed Reducers of U- and R-axes.9-9
Grease Replenishment (Refer to " Fig. 24 UR-Axis Speed
Reducer Diagram ".) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-9
9.2.5 Grease Replenishment for Speed Reducers of
B- and T-axes, and T-axis Gear . . . . . . . . . . . . . . . . . . . . . . .9-10
Grease Replenishment (Refer to " Fig. 25 BT-Axis
Speed Reducer and T-axis Gear Diagram ".) . . . . . . . . . . .9-10
9.2.6 Notes for Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-11
Battery Pack Connection . . . . . . . . . . . . . . . . . . . . . . . . . . .9-11
10 Recommended Spare Parts
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1.1 Contents Confirmation
1 Product Confirmation
CAUTION
• Confirm that the manipulator and the NXC100 have the same order num-
ber. Special care must be taken when more than one manipulator is to
be installed.
If the numbers do not match, manipulators may not perform as expected and cause injury
or damage.
1.1 Contents Confirmation
Confirm the contents of the delivery when the product arrives.

Standard delivery includes the following four items (information for the content of optional
goods is given separately):
• Manipulator
• NXC100
• Programming pendant
• Manipulator cable (2 cables, between the manipulator and NXC100)
1-1
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1.2 Order Number Confirmation
1.2 Order Number Confirmation
Check that the order number of the manipulator corresponds to the NXC100. The order
number is located on a label as shown below.
Label (Enlarged View)
THE MANIPULATOR AND THE CONTROLLER

SHOULD HAVE SAME ORDER NUMBER. Check that the manipulator
and the NXC100 have the
same order number.
ORDER NO.
WARNING WARNING
HEAVY OBJECT HAZAARDOUS VOLTAGE
Can cause muscle strain or 208/110 VAC PRESENT
back injury. Use lifting aids Contact may cause
proper lifting technjques electric shock or burn
when removing or replacing Turn off and lock out
system power before servicing
(a) NXC100 (Top View) (b) Manipulator (Top View)

Fig. 1 Location of Order Number Labels
1-2
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2 Transporting
CAUTION
• Sling and crane or forklift operations must be performed by authorized
personnel only.
Failure to observe this caution may result in injury or damage.
• Avoid excessive vibration or shock during transportation.
The system consists of precision components, so failure to observe this caution may
adversely affect performance.
• Be sure to mount two eyebolts and check that the eyebolts are securely fastened before
NOTE transporting the manipulator.
• The mass of the manipulator is approximately 27 kg. Use a wire rope strong enough to
withstand the mass.
• Attached eyebolts are designed to support the manipulator mass. Do not use them for
anything other than transporting the manipulator.
• Avoid exerting external force on the arm or motor unit when transporting the manipulator.
Use caution when using transporting equipment other than a crane or forklift to avoid
injury.
2-1
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2.1 Transporting Method
2.1.1 Using a Crane

As a rule, when removing the manipulator from the package and moving it, a crane should be
used. The manipulator should be lifted using wire rope threaded through attached eyebolts.
Be sure the manipulator is fixed with shipping bolts and brackets before transportation, and lift
it in the posture as shown in " Fig. 2 Transporting Position ".
Eyebolt M8 (2 eyebolts)
(Delivered with the manipulator)
Fig. 2 Transporting Position
Before turning ON the power, check to be sure that the eyebolts have been removed. The
NOTE eyebolts then must be stored for future use, in the event that the manipulator must be
moved by a crane again.
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2.1.2 Using a Forklift

When using a forklift, the manipulator should be fixed on a pallet as shown in " Fig. 3 Using a
Forklift ". Insert claws under the pallet and lift it. The pallet must be strong enough to support
the manipulator. Transportation of the manipulator must be performed slowly in order to avoid
overturning or slippage.
Bolts M8 (4 bolts)
Pallet
Forklift claw entry
Fig. 3 Using a Forklift
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3 Installation
WARNING
• Install the safeguarding.
Failure to observe this warning may result in injury or damage.
• Install the manipulator in a location where the manipulator’s tool or the

workpiece held by the manipulator will not reach the wall, safeguarding,
or NXC100 when the arm is fully extended.
Failure to observe this warning may result in injury or damage.
• Do not start the manipulator or even turn ON the power before it is

firmly anchored.
The manipulator may overturn and cause injury or damage.
• When mounting the manipulator on the ceiling or wall, the base section
must have sufficient strength and rigidity to support the mass of the
manipulator. Also, it is necessary to consider countermeasures to pre-
vent the manipulator from falling.
Failure to observe these warning may result in injury or damage.
CAUTION
• Do not install or operate the manipulator that is damaged or lacks parts.
Failure to observe this caution may cause injury or damage.
• Before turning ON the power, check to be sure that the eyebolts

explained in "2.1.1 Using a Crane" are removed.
Failure to observe this caution may result in damage to the driving parts.
3-1
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3.1 Installation of Safeguarding
3.1 Installation of Safeguarding
To insure safety, be sure to install the safeguarding. It prevents unforeseen accidents with
personnel and damage to equipment. The following is quoted for your information and
guidance.
Responsibility for Safeguarding (ISO10218)

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

support the manipulator and withstand repulsion forces during acceleration and deceleration.
Refer to "Table. 1 Maximum Repulsion Forces of the Manipulator" and " Table. 2 Endurance
Torque in Operation " to construct a solid foundation with the appropriate thickness to
withstand maximum repulsion forces of the manipulator.
A manipulator base flatness must be kept at 0.5 mm or less: insufficient flatness of installation
surface may deform the manipulator shape and affect its functional abilities. Mount the
manipulator base as described in "3.2.1 When the Manipulator and Mounting Fixture are
Installed on a Baseplate" or "3.2.2 When the Manipulator is Mounted Directly on the Floor
without the Mounting Fixture".
Table. 1 Maximum Repulsion Forces of the Manipulator
Horizontal rotating maximum torque 294 Nm

(S-axis moving direction) (30 kgfm)
Vertical rotating maximum torque 627 Nm

(LU-axes moving direction) (64 kgfm)
Table. 2 Endurance Torque in Operation
Endurance torque in horizontal operation 59 Nm

(S-axis moving direction) (6 kgfm)
Endurance torque in vertical operation 194 Nm

(LU-axes moving direction) (20 kgfm)
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3.2.1 When the Manipulator and Mounting Fixture are

Installed on a Baseplate
For the first process, anchor the baseplate firmly to the ground. The baseplate should be rug-
ged and durable to prevent shifting of the manipulator or the mounting fixture. It is recom-
mended to prepare a baseplate in 25 mm in thickness, and anchor bolts in M8 or larger size.
Next, fix the manipulator base to the baseplate. The manipulator base is tapped for four
mounting holes; securely fix the manipulator base to the baseplate with four hexagon socket
head screws M8 (35 mm long is recommended) and tighten the screw to a tightening torque of
24.5 Nxm (2.5 kgxm). Tighten the hexagon socket head cap screws and anchor bolts firmly so
that they will not work loose during the operation.
See "Fig. 4 Manipulator Installation Example" for the method.
Hexagon socket head cap screw M8

(4 screws),
Tightening torque: 24.5 Nxm (2.5 kgfxm)
Spring washer
Washer
12
Manipulator base
25 or
more
Manipulator base Baseplate
Anchor bolt (M8 or larger)

Baseplate
+0.012
6 dia. 0 (reference hole)
Baseplate
155 85
50±0.1
±0.1
50
50
78±0.1
170
150
88
145
150 9 dia. mounting hole (4 places)

170
88 ±0.1
Units: mm
Fig. 4 Manipulator Installation Example
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3.2.2 When the Manipulator is Mounted Directly on the

Floor without the Mounting Fixture
The floor should be strong enough to support the manipulator. Construct a solid foundation
with the appropriate thickness to withstand maximum repulsion forces of the manipulator as
shown in "Table. 1 Maximum Repulsion Forces of the Manipulator". When there is a concrete
thickness (floor) of 150 mm or more, the base of the manipulator can be fixed directly to the
floor with M8 anchor bolts. (The concrete breaking-stress should be 250 kg/cm2 or more.)
Before mounting the manipulator, check that the floor is level and that all cracks, etc. are
repaired. Any thickness less than 150 mm is insufficient for mounting, even if the floor is con-
crete.
Anchor bolts M8 (4 places)
45 or more
150 or more
Concrete floor
Units: mm
Fig. 5 Direct Mounting on the Floor
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3.3 Installation Method
3.3 Installation Method
The manipulator can be mounted in three different ways: floor-mounted (standard), wall-
mounted, and ceiling-mounted types are available. For wall- and ceiling-mounted types, the
three points listed below are different from the floor-mounted types.
1. For the wall-mounted type, the S-axis specification is different from the ceiling- and
floor-mounted types. (The specification is changed before shipment.)
• The S-axis operating range for the wall-mounted type must be ±25°.
2. For the ceiling- and wall-mounted types, four hexagon socket head cap screws M8
(tensile strength: 1200 N/mm2 or more) (35 mm long is recommended) should be used
to fix the manipulator base. Use a torque of 24.5 Nxm in tightening the screws.
3. For the ceiling- and wall-mounted types, take appropriate measures to avoid the falling
of manipulator in case of emergency. See "Fig. 6 Precaution to Prevent the Manipula-
tor from Falling" for details.
Support to prevent the manipulator from fall
Manipulator base Hexagon socket head cap screw M8 (4 places)

Tightening torque: 24.5 Nxm (2.5 kgfxm)
Spring washer
Washer
Fig. 6 Precaution to Prevent the Manipulator from Falling
If the manipulator is to be wall mounted or ceiling mounted, inform Yaskawa of the matter
NOTE when placing an order. And also, make sure to contact Yaskawa representative (listed on
the back cover of this instruction manual) for a wall/ceiling installation on side.
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3.4 Location
3.4 Location
When the manipulator is installed, it is necessary to satisfy the undermentioned environmental

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

• Humidity: 20 to 80%RH (no moisture, at constant temperature)
• Free from dust, soot, or water
• Free from corrosive gases or liquids, or explosive gases
• Free from excessive impact or vibration (vibration acceleration: 4.9 m/s2 [0.5 G] or less)
• Free from large electrical noise (plasma)
• The flatness for installation is 0.5 mm or less.
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4 Wiring
WARNING
• Ground resistance must be 100 Ω or less.
Failure to observe this warning may result in fire or electric shock.
• Before wiring, make sure to turn the primary power supply OFF, and put
up a warning sign. (ex. DO NOT TURN THE POWER ON.)
Failure to observe this warning may result in fire or electric shock.
CAUTION
• Wiring must be performed by authorized or certified personnel.
Failure to observe this caution may result in fire or electric shock.
• Do not cover the cable or allow it to tangle. Keep the cable as straight
as possible.
Failure to observe this caution may result in preventing heat of the cable from being dis-
charged.
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4.1 Grounding
4.1 Grounding
Follow the local regulations and electrical installation standards for grounding. The recom-
mended grounding wire size is 5.5 mm2 at minimum.
For grounding, connect the ground wire directly to the manipulator as shown in "Fig. 7
Grounding Method".
• Do not use this line in common with other ground lines or grounding electrodes for other
NOTE electric power, motor power, welding devices, etc.
• Where metal ducts, metallic conduits, or distributing racks are used for cable laying,
ground in accordance with Electric Equipment Technical Standards.
Section A-A’
Bolt M6 (for grounding)

Delivered with the manipulator
A A’
Fig. 7 Grounding Method
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4.2 Manipulator Cable Connection
There are two manipulator cables; an encoder cable for detection (1BC) and power cable
(2BC). (See "Fig. 8 Manipulator Cables (1BC and 2BC)".) Connect these cables respectively
to the connectors at the manipulator connector base and the NXC100. Refer to "Fig. 9 (a)
Manipulator Cable Connectors (Manipulator Side)" and "Fig. 9 (b) Manipulator Cable
Connectors (NXC100 Side)".
4.2.1 Connection to the Manipulator

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

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

1BC
1BC
Encoder Cable 1BC
The NXC100 Side The Manipulator Side

2BC
2BC
Power Cable 2BC

Fig. 8 Manipulator Cables (1BC and 2BC)
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2BC
1BC
3BC
Connector details
(Manipulator side)
Fig. 9 (a) Manipulator Cable Connectors (Manipulator Side)
X11
FAN3 FAN2
X72 X11
X54 X53
X21 X12
X55
X71
PPESP PPESP
X62
X64-X63
X21 Connector details

(NXC100 side)
Fig. 9 (b) Manipulator Cable Connectors (NXC100 Side)
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5.1 Basic Specifications
5 Basic Specifications
5.1 Basic Specifications

Table. 3 Basic Specifications*1
Item MOTOMAN-HP3J
Model YR-HP3J-J00
Configuration Vertically Articulated
Degree of Freedom 6
Payload 3 kg
Repeatability *2 ±0.03 mm
S-axis (turning) ±160°
L-axis (lower arm) +90°, -85°
Range of U-axis (upper arm) +260°, -105°
Motion R-axis (wrist roll) ±170°
B-axis (wrist pitch/yaw) ±120°
T-axis (wrist twist) ±360°
S-axis 3.49 rad/s, 200°/s
L-axis 2.62 rad/s, 150°/s
Maximum U-axis 3.32 rad/s, 190°/s
Speed R-axis 5.24 rad/s, 300°/s
B-axis 5.24 rad/s, 300°/s
T-axis 7.33 rad/s, 420°/s
R-axis 5.39 Nm (0.55 kgfm)
Allowable
B-axis 5.39 Nm (0.55 kgfm)
Moment*3
T-axis 2.94 Nm (0.3 kgfm)
Allowable
R-axis 0.1 kgm2
Inertia B-axis 0.1 kgm2
(GD2/4)*3
T-axis 0.03 kgm2
Approx. Mass 27 kg
Temperature 0 to 40°C
Humidity 20 to 80% RH (at constant temperature)
Vibration Acceleration Less than 4.9 m/s2 (0.5G)
Ambient
Conditions • Free from corrosive gas or liquid, or explosive
gas.
Others
• Free from water, oil, or dust.
• Free from excessive electrical noise (plasma).
Power Requirements 0.5 kVA
*1 SI units are used in this table. However, gravitational unit is used in ( ).

*2 Conformed to ISO9283
*3 Refer to " 6.1 Allowable Wrist Load " for details on the allowable moment of inertia.
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5.2 Part Names and Working Axes
5.2 Part Names and Working Axes
Upper arm Wrist

(U-arm) U R
B
T
Lower arm
(L-arm)
T
B
U R
L L
Rotary head
(S-head)
S
S
Base
Fig. 10 Part Names and Working Axes
5.3 Manipulator Base Dimensions

+0.012
6 dia. 0 hole (reference hole)
155 85
88±0.1
50±0.1
50
50
78±0.1
150
170
145
150 9 dia. mounting hole (4 places)
170
A
88±0.1
Units: mm
View A
Fig. 11 Manipulator Base Dimensions
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5.4 Dimensions and P-Point Maximum Envelope
5.4 Dimensions and P-Point Maximum Envelope
160
04
R5
R18
R1
32
8
160
372
532
229
188
531
40
270 90
99.5 99.5
822
68 68
79
57
583
95
30
474
260
55
P-point P-point maximum

85
0
envelope
90
659
26
189
10
193
133
290
47
74
42 21 18
0
0
(*2)
219
158
204
337
276
381
389
(*1)
(*1) Shows the LU-axes working envelope within the range of S-axis motion: -40 to 40 .
(*2) Shows the LU-axes working envelope within the range of S-axis motion: -160 to 125 or 125 to 160 .
Refer to " 5.5 Special Interference Area" for details.
Fig. 12 (a) Dimensions and P-Point Maximum Envelope
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5.5 Special Interference Area
5.5 Special Interference Area
Shows the LU-axes working envelope within the range of S-axis motion: -160 to 125 or 125 to 160 .
12
5
35 35
5
12
193 189
47
0
381
158
204
U-axis does not move the S-axis is in area

of the slash part in above figure.
Shows the LU-axes working envelope within the range of S-axis motion: -40 to 40 .
40
40
133
74
0
389
337
U-axis does not move the S-axis is in area

of the slash part in above figure.
Fig. 12 (b) Special Interference Area (LU interference)
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5.6 B-Axis Operating Range
5.6 B-Axis Operating Range
" Fig. 13 B-axis Operating Range " shows the operating range of the B-axis maintaining a
constant angle to the center of U-axis.
B-axis rotation center

U-axis rotation center
120
° Wrist
°
120
U-axis rotation center
S-axis rotation center
Fig. 13 B-axis Operating Range
5.7 Alterable Operating Range
The operating range of S-axis can be altered according to the operating conditions as shown
in "Table. 4 S-Axis Operating Range". If alteration is necessary, contact your Yaskawa
representative in advance.
Table. 4 S-Axis Operating Range
Item Specifications
±160° (standard)
S-Axis ±120°
Operating ±90°
Range ±60°
±25°
NOTE If readjustment (alteration of the S-axis operating range) is necessary, contact your
Yaskawa representative.
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6.1 Allowable Wrist Load
6 Allowable Load for Wrist Axis and Wrist

Flange
6.1 Allowable Wrist Load
The allowable wrist load is up to 3 kg. If force is applied to the wrist instead of the load, force
on R-, B-, and T-axes should be within the value shown in " Table. 5 Allowable Moment and
Inertia ". Contact your Yaskawa representative for further information or assistance.
Table. 5 Allowable Moment and Inertia
Axis Moment N•m (kgf•m)*1 Inertia kg•m2
R-axis 5.39 (0.55) 0.1

B-axis 5.39 (0.55) 0.1
T-axis 2.94 (0.3) 0.03
*1 ( ): Gravitational unit
When the volume load is small, refer to the moment arm rating shown in " Fig. 14 Moment
Arm Rating ".
The allowable inertia is calculated when the moment is at the maximum. Contact your
Yaskawa representative when only load inertia, or load moment is small and inertia is large.
Also, when the load is combined as a force but a mass, contact your Yaskawa representative.
LT (mm)
200
1.5kg
100
3kg RT-axis rotation center
LB (mm)
100 200 300
P-point 100
200
B-axis rotation center
LT (mm)
Fig. 14 Moment Arm Rating
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6.2 Wrist Flange
6.2 Wrist Flange
The wrist flange dimensions are shown in " Fig. 15 Wrist Flange ". In order to see the
alignment marks, it is recommended that the attachment be mounted inside the fitting. Fitting
depth of inside and outside fittings must be 5 mm or less.
Tapped hole M5 (4 places)

(Depth: 9) (Pitch: 0.8)
5 (fitting depth)
+0.013
40 dia. -0.016
45°
0
0
20 dia.
PC
D3
1.5
5 (fitting depth)
+0.012
5 dia. 0 hole Units: mm
(Depth: 7)
Fig. 15 Wrist Flange
NOTE • Wash off anti-corrosive paint (yellow color) on the wrist flange surface with thinner or light
oil before mounting the tools.
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7.1 Peripheral Equipment Mount
7 System Application
7.1 Peripheral Equipment Mount
The peripheral equipment mount is on the upper arm for easier installation of the user’s
system application as shown in " Fig. 16 Installing Peripheral Equipment Mounts ". When
peripheral equipment is attached to the U-axis, the following conditions should be observed.
18 37
Tapped hole M8 (3 places)

(Pitch: 1.25) (Depth: 16)
80
Units: mm
Fig. 16 Installing Peripheral Equipment Mounts
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7.2 Internal User I/O Wiring Harness and Air Lines
7.2 Internal User I/O Wiring Harness and Air Lines
Internal user I/O wiring harness (0.2 mm2 x 10 wires) and four air lines are used in the
manipulator for the drives of the peripheral devices mounted on the upper arm as shown in "
Fig. 17 Connectors for Internal User I/O Wiring Harness and Air Lines ".
The connector pins (1 to 10) are assigned as shown in " Fig. 17 Connectors for Internal User
I/O Wiring Harness and Air Lines ". Wiring must be performed by users, following the
conditions below:
• The allowable current for cables: 2.5 A or less for each cable
• The maximum pressure for the air line: 490 kPa (5 kgf/cm2) or less
(the inside diameter: 2.5 mm)
Connector for internal user I/O wiring harness:

4 Exhaust ports:
HR10A-10R-12S (socket connector).
Tapped hole M5 with pipe plug
Prepare pin connector: HR10A-10P-12P*HIROSE*.
View A
4 Air inlets:
B Tapped hole M5 with pipe plug
2BC
Details of the Connector Pin Numbers

1BC
Internal user I/O wiring harness: 0.2 mm2, 10 wires

1 9 1
2
3 10
4 8 2 3BC
5
Pins Used 6
7 7 12 11 3
8
9 Connector for internal user I/O wiring harness:
10 View B
6 4 HR10A-10R-12P (pin connector).
5 Prepare socket connector: HR10A-10P-12S*HIROSE*.
Fig. 17 Connectors for Internal User I/O Wiring Harness and Air Lines
The same pin number (1-10) of two connectors is connected by the lead wire of single
0.2 mm2.
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8.1 Internal Connections
8 Electrical Equipment Specification
High reliability connectors which can be easily put on and removed are used with each
connector part. For the numbers, types, and locations of connectors, see " Fig. 18 Location
Connectors " and " Table. 6 List of Connector Types ". Diagrams for internal connections
of the manipulator are shown in " Fig. 19 (a) Internal Connection Diagram " and " Fig. 19 (b)
Internal Connection Diagram ".
U-arm
Connector for internal user I/O wiring harness
Connector base
Connector for internal user I/O wiring harness
Fig. 18 Location Connectors
Table. 6 List of Connector Types
Name Type of Connector
Connector for internal user I/O HR10A-10R-12P

wiring harness on connector base (HR10A-10P-12S: Optional)
Connector for internal user I/O HR10A-10R-12S

wiring harness on U-arm (HR10A-10P-12P: Optional)
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0BT 1 0BAT11 17 0BAT1

BAT 2 BAT11 18 BAT1
0BT 3 0BAT12 19 0BAT2
BAT 4 BAT12 20 BAT2
21
22
23
0BT 5 0BAT21
24
25 0BAT4 Note:
BAT 6 BAT21 26 BAT4
0BT
BAT
7
8
0BAT22
BAT22
27
28
0BAT5
BAT5
The figure below shows the internal connection diagram for MOTOMAN-HP3J.
29
30
1 31
2 32
3 1 PG0V1
4 2 PG5V1
5 3 PG0V2
6 4 PG5V2
7 5 PG0V3
8 6 PG5V3
7 PG0V4
8 PG5V4
NXC100 1BC(10X4) 9
10
PG0V5
PG5V5
CN1-5 +24V 1 11 PG0V6
12 CN1-4 0V 3 12 PG5V6
52 13
CN1-10 +24V 2 14
13 CN1-9 0V 4 15
53 16 No.1CN
CN1-1 SPG+1 1CN-1 DATA+1
6 CN1-2 SPG-1 P -2 DATA-1
46 -3 BAT1
P -4 OBT1 PG S-axis
2CN-1 +5V1
P -2 0V1
CN1-3 FG1 -3 FG1
1
No.2CN OBT
BAT
No.3CN
47 -3 BAT2
P P -4 OBT2 PG L-axis
4CN-1 +5V2
P -2 0V2
CN1-8 FG2 -3 FG2
2
No.4CN OBT
P BAT
No.5CN
48 -3 BAT3
-4 OBT3 PG U-axis
6CN-1 +5V3
P -2 0V3
CN2-3 FG3 -3 FG3
3
No.6CN OBT
BAT
P For lamp (Option)
1BC(10X4) CN2-6 SPG+4

No.7CN
7CN-1 DATA+4
49 -3 BAT4
P -4 OBT4 PG R-axis
8CN-1 +5V4
P -2 0V4
CN2-8 FG4 -3 FG4
41
No.8CN OBT
BAT
No.9CN
10 CN3-2 SPG-5 P -2 DATA-5
50 -3 BAT5
P P -4 OBT5 PG B-axis
10CN-1 +5V5
P -2 0V5
CN3-3 FG5 -3 FG5
42
No.10CN OBT
BAT
No.11CN
11 CN3-7 SPG-6 P -2 DATA-6
51 -3 BAT6
P -4 OBT6 PG T-axis
12CN-1 +5V6
P -2 0V6
CN3-8 FG6 -3 FG6
43
No.12CN OBT
BAT
CN4-1 +24V
37
CN4-6 LB1
CN4-3 BC2
77
32
33
34
35
36
76
E E
Fig. 19 (a) Internal Connection Diagram
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E
Base
E
3BC 3BC
1 1
3BC-1 2 P 2 3BC-1
-2 -2
3 3
-3 -3
4 P 4
-4 -4
5 5
-5 -5 For spare (X)
6 P 6
-6 -6
7 7
-7 -7
8 P 8
-8 -8
9 9
-9 -9
10 P 10
-10 -10
2BC(6X6)
C5 E
No.13CN
D5 CN1-1 BA1 13CN-1 MU1
CN1-2 BA2 -2 MV1
E5 CN1-3 -3 MW1
SM S-axis
BB1
A4 CN1-4 ME1 -4 ME1
B4 CN1-5 ME2 14CN-1 BA1
-2 BB1 YB
No.14CN
No.15CN
A1 CN2-1 MU1 15CN-1 MU2
A2 CN2-2 MV1 -2 MV2
CN2-3 -3 MW2
SM L-axis
A3 MW1
B1 CN2-4 MU2 -4 ME2
B2 CN2-5 MV2 16CN-1 BA2
B3 CN2-6 MW2 -2 BB2 YB
No.16CN
No.17CN
17CN-1 MU3
-2 MV3
-3 MW3
SM U-axis
C1 CN3-4 MU3 -4 ME3
C2 CN3-5 MV3 18CN-1 BA3
C3 CN3-6 MW3 -2 BB3 YB
2BC(6X6) No.18CN
No.19CN
D1 CN4-1 MU4 19CN-1 MU4
D2 CN4-2 MV4 -2 MV4
D3 CN4-3 -3 MW4
SM R-axis
MW4
E1 CN4-4 MU5 -4 ME4
E2 CN4-5 MV5 20CN-1 BA4
E3 CN4-6 MW5 -2 BB4 YB
No.20CN
No.21CN
A5 CN5-1 MU6 21CN-1 MU5
A6 CN5-2 MV6 -2 MV5
B6 CN5-3 -3 MW5
SM B-axis
MW6
C4 CN5-4 ME3 -4 ME5
D4 CN5-5 ME4 22CN-1 BA5
E4 CN5-6 ME5 -2 BB5 YB
No.22CN
No.23CN
C6 CN6-1 ME6 23CN-1 MU6
CN6-2 BA3 -2 MV6
E6 CN6-3 -3 MW6
SM T-axis
BB4
D6 CN6-4 BA4 -4 ME6
CN6-5 BA5 24CN-1 BA6
CN6-6 BA6 -2 BB6 YB
No.24CN
PE
Fig. 19 (b) Internal Connection Diagram
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9.1 Inspection Schedule
9 Maintenance and Inspection
WARNING
• Before maintenance or inspection, be sure to turn the main power sup-
ply OFF, and put up a warning sign. (ex. DO NOT TURN THE POWER ON.)
Failure to observe this warning may result in electric shock or injury.
CAUTION
• Maintenance and inspection must be performed by specified personnel.
Failure to observe this caution may result in electric shock or injury.
• For disassembly or repair, contact your Yaskawa representative.
• Do not remove the motor or release the brake.
Failure to observe this caution may result in injury from unexpected turning of the manipu-
lator’s arm.
• The battery pack must be connected before removing detection connec-

tor when maintenance and inspection.
Failure to observe this caution may result in the loss of home position data.
Proper inspections are essential not only to assure that the mechanism will be able to function
for a long period, but also to prevent malfunctions and assure safe operation. Inspection
intervals are classified into six levels. Conduct periodical inspections according to the
inspection schedule in " Table. 7 Inspection Items ".
In " Table. 7 Inspection Items ", the inspection items are categorized by three types of
operations: operations which can be performed by personnel authorized of the user,
operations which can be performed by personnel being trained, and operations which can be
performed by service company personnel. Only specified personnel are to do the inspection
work.
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NOTE • The inspection interval must be based on the servo power supply ON time.
Table. 7 Inspection Items
Schedule Inspection Charge
Items*4 1000 6000 12000 Method Operation

24000 36000 Specified Service
Daily H H H Licensee
H H Person Company
Cycle Cycle Cycle
Working area Clean the working

and whole exte- area if dust or spatter
c rior of manipula-
{ Visual is present. { { {
Check for damage
tor and exterior cracks.
Check for grease

d LU-axis joint { Visual
leakage.*5
{ { {
Manipulator Tighten loose bolts.

e base { Wrench Replace if necessary. { { {
mounting bolts
Phillips Tighten loose bolts.

Cover mounting screw- Replace if necessary.
f screws
{ driver,
{ { {
wrench
Check for loose con-

g Connector base { Manual
nectors.
{ { {
LURBT-axis Check for belt

h timing belts
{ Manual tension and wear. { {
Check for conduc-

tion between the
main connector of
connector base and
Visual,
{ intermediate connec-
multimeter tor with manually
{ {
Wire harness in
i manipulator shaking the wire.
Check for wear of
protective spring.*1
{ Replace.*2 {
Replace the battery

Battery pack in pack when the bat-
j manipulator
{ Multimeter tery alarm occurs or { {
the manipulator
drove for 36000H.
Check for malfunc-

tion. (Replace if nec-
S-axis speed Grease
k reducer
{ gun
essary.) Supply { {
grease *3 (6000H
cycle). See Par.9.2.2.
Check for malfunc-

LU-axis speed Grease essary.) Supply
l reducer
{ gun grease *3 (6000H
{ {
cycle). See Par.9.2.3
and 9.2.4.
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Table. 7 Inspection Items
Schedule Inspection Charge
Items*4 1000 6000 12000 Method Operation

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

R-axis speed Grease
11
reducer
{ gun
essary.) Supply { {
grease *3 (6000H
Check for malfunc-

BT-axis speed tion. (Replace if nec-
Grease
12 reducer and T- { gun
essary.) Supply { {
axis gear grease *3 (6000H
13 Overhaul { {
*1 When checking for conduction with multimeter, connect the battery pack to “BAT” and “OBT” of connectors
on the motor side for each axis, and then remove connectors on detector side for each axis from the motor.
Otherwise, the home position may be lost. (Refer to " 9.2.6 Notes for Maintenance ".)
*2 Internal cables to be replaced at 24000H inspection.
*3 For the grease, refer to " Table. 8 Inspection Parts and Grease Used ".
*4 Inspection No. correspond to the numbers in " Fig. 20 Inspection Parts and Inspection Numbers ".
*5 The occurrence of a grease leakage indicates the possibility that grease has seeped into the motor. This can
cause a motor breakdown. Contact your Yaskawa representative.
Table. 8 Inspection Parts and Grease Used
No. Grease Used Inspected Parts
Harmonic Grease SK-1A S-, L-, U-, R-, B- and T-axis speed
9 , 10 , 11 , 12 reducers,
T-axis gear
The numbers in the above table correspond to the numbers in " Table. 7 Inspection Items ".
9-3
HW0483547 39/50
HW0483547
11 6
12
6 12
10
6
2
6
7 10
9
2
5
2BC
1BC
3
3BC
8
Fig. 20 Inspection Parts and Inspection Numbers
9-4
HW0483547 40/50
HW0483547
9.2 Notes on Maintenance Procedures
9.2.1 Battery Pack Replacement
The battery packs are installed in the two positions indicated in " Fig. 21 (a) Battery Pack
Location ".
• Battery Pack Type: HW0470360-B
If the battery alarm occurs in the NXC100, replace the battery pack in accordance with the
following procedure:
Connector base fixing screw
Connector base
2BC
1BC
3BC
Battery pack
tied with INSULOK-tie (T50R)
Fig. 21 (a) Battery Pack Location
See the step 5. Battery pack before replacement
Connector
Circuit board
See the step 4.
New battery pack
Fig. 21 (b) Battery Pack Connection
9-5
HW0483547 41/50
HW0483547
1. Turn the NXC100 main power supply OFF.

2. Remove the connector base fixing screws and pull out the connector base.
3. Remove the INSULOK-tie that ties the battery pack.
4. Connect the new battery pack to an unconnected connector.
5. Remove the old battery pack.
NOTE Connect the new battery pack before removing the old one so that the encoder absolute
data do not disappear.
6. Tie the new battery pack with INSULOK-tie, and reinstall the connector base.
NOTE Do not pinch the cable when the connector base is installed.
9-6
HW0483547 42/50
HW0483547
9.2.2 Grease Replenishment for S-axis Speed Reducer
Si: Grease inlet

Hexagon socket head plug PT1/8
S-axis speed reducer
2BC
1BC
3BC
So: Exhaust port

Hexagon socket head plug PT1/8
Fig. 22 S-axis Speed Reducer Diagram
Grease Replenishment (Refer to " Fig. 22 S-axis Speed Reducer Diagram ".)
1. Remove the hexagon socket head plug PT1/8 on the So exhaust port.
NOTE Injecting grease with the plug on increases inner pressure and may cause damage. Never
fail to remove the plug before the grease injection.
2. Remove the hexagon socket head plug PT1/8 on the Si grease inlet.
3. Install the grease zerk PT1/8 to the Si grease inlet. (The grease zerk PT1/8 is delivered
with the manipulator.)
4. Inject the grease into the Si grease inlet using a grease gun.
Grease type: Harmonic Grease SK-1A

Amount of grease: 10 cc
NOTE The So exhaust port is used for air flow. Do not inject excessive grease into the Si grease
inlet.
5. Remove the grease zerk on the Si grease inlet and reinstall the hexagon socket head
plug PT1/8. Tighten the plug to a tightening torque of 4.9 N·m (0.5 kgf·m). Apply Three
Bond 1206C on the thread part of the plug.
6. Reinstall the hexagon socket head plug PT1/8 on the So exhaust port. Apply Three
Bond 1206C on the thread part of the plug.
9-7
HW0483547 43/50
HW0483547
9.2.3 Grease Replenishment for L-axis Speed Reducer
Lo: Exhaust port

Plug
Cover
L-axis speed reducer
Li: Grease inlet

Hexagon socket head cap screw M6×6
Fig. 23 L-axis Speed Reducer Diagram
Grease Replenishment (Refer to " Fig. 23 L-axis Speed Reducer Diagram ".)
1. Remove the plug on the Lo exhaust port.
2. Remove the hexagon socket head cap screw M6×6 on the Li grease inlet.
3. Install the grease zerk A-MT6×1 to the Li grease inlet. (The grease zerk A-MT6×1 is
delivered with the manipulator.)
4. Inject the grease into the Li grease inlet using a grease gun.

Amount of grease: 15 cc
NOTE The Lo exhaust port is used for air flow. Do not inject excessive grease into the Li grease
inlet.
5. Remove the grease zerk on the Li grease inlet and reinstall the hexagon socket head
cap screw M6×6. Tighten the screw to a tightening torque of 6 N·m (0.6 kgf·m). Apply
Three Bond 1206C on the thread part of the screw.
6. Reinstall the plug on the Lo exhaust port. Apply Three Bond 1206C on the thread part
of the plug.
9-8
HW0483547 44/50
HW0483547
9.2.4 Grease Replenishment for Speed Reducers of U- and

R-axes
Ro: Exhaust port

R-axis speed reducer Plug
Li: Grease inlet Cover

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

Plug Hexagon socket head cap
screw M6×6
Cover
U-axis speed reducer
Fig. 24 UR-Axis Speed Reducer Diagram
Grease Replenishment (Refer to " Fig. 24 UR-Axis Speed Reducer

Diagram ".)
1. Uninstall the cover to remove the plug on the Uo/Ro exhaust port.
NOTE If grease is injected with the plug on, the grease will go inside the motor and may damage
it. Never fail to remove the plug before the grease injection.
2. Remove the hexagon socket head cap screw M6×6 on the Ui/Ri grease inlet.
3. Install the grease zerk A-MT6×1 to the Ui/Ri grease inlet. (The grease zerk A-MT6×1 is
4. Inject the grease into the Ui/Ri grease inlet using a grease gun.

Amount of grease: 10 cc (Ui)
10 cc (Ri)
NOTE The Uo/Ro exhaust port is used for air flow. Do not inject excessive grease into the Ui/Ri
grease inlet.
5. Remove the grease zerk on the Ui/Ri grease inlet and reinstall the hexagon socket
head cap screw M6×6. Tighten the screw to a tightening torque of 6 N·m (0.6 kgf·m).
Apply Three Bond 1206C on the thread part of the screw.
6. Reinstall the plug on the Uo/Ro exhaust port. Apply Three Bond 1206C on the thread
part of the plug.
9-9
HW0483547 45/50
HW0483547
9.2.5 Grease Replenishment for Speed Reducers of B- and

T-axes, and T-axis Gear
T-axis speed reducer

To: Exhaust port
Plug
Bo: Exhaust port Ti: Grease inlet

Plug Hexagon socket head
cap screw M6×6
B-axis speed reducer
Cover Bi: Grease inlet

Hexagon socket ehad cap screw M6×6
Fig. 25 BT-Axis Speed Reducer and T-axis Gear Diagram
Grease Replenishment (Refer to " Fig. 25 BT-Axis Speed Reducer

and T-axis Gear Diagram ".)
1. Uninstall the cover to remove the plug on the Bo/To exhaust port.
2. Remove the hexagon socket head cap screw M6×6 on the Bi/Ti grease inlet.
3. Install the grease zerk A-MT6×1 to the Bi/Ti grease inlet. (The grease zerk A-MT6×1 is
4. Inject the grease into the Bi/Ti grease inlet using a grease gun.

Amount of grease: 10 cc (Bi)
5 cc (Ti)
NOTE The Bo/To exhaust port is used for air flow. Do not inject excessive grease into the Bi/Ti
grease inlet.
5. Remove the grease zerk on the Bi/Ti grease inlet and reinstall the hexagon socket
head cap screw M6×6. Tighten the screw to a tightening torque of 6 N·m (0.6 kgf·m).
Apply Three Bond 1206C on the thread part of the screw.
6. Reinstall the plug on the Bo/To exhaust port. Apply Three Bond 1206C on the thread
part of the plug.
9-10
HW0483547 46/50
HW0483547
9.2.6 Notes for Maintenance

Battery Pack Connection
The connectors (crimped contact-pin) for the battery backup are installed at the end point of
the motors (marked as BAT and OBT). Connect the battery pack according to the following
procedure.
1. Connect the battery packs (HW9470932-A) with the battery backup connectors located
at the end point of the cables for the encoder. (Under this condition, remove the
encoder connector and carry out the maintenance checks).
2. After the maintenance check, verify that all the connectors are connected and remove
the battery pack.
NOTE Do not remove the battery pack in the connector base.
Encoder
Motor
Motor cable, etc.
Wire harness
in manipulator Power connector
Connection
b 0BT
0BT a a BAT
BAT b
removing conector.
to save the data before
Connect battery to encoder
CAUTION
Encoder connector Battery pack

(HW9470932-A)
CAUTION label
0BT a b 0BT
BAT b a BAT
CAUTION label (Enlarged view)
a: Crimped contact-pin (pin)

CAUTION b: Crimped contact-pin (socket)

to save the data before
removing conector.
Fig. 26 Encoder Connector
9-11
HW0483547 47/50
HW0483547
It is recommended that the following parts and components be kept in stock as spare parts for
the MOTOMAN-HP3J. The spare parts list for the MOTOMAN-HP3J is shown below.
Check the serial number and contact your Yaskawa representative for preparing lead wires for
internal wiring, etc.
Product performance can not be guaranteed when using spare parts from any company other
than Yaskawa. The spare parts are ranked as follows:
• Rank A: Expendable and frequently replaced parts

• Rank B: Parts for which replacement may be necessary as a result of frequent operation
• Rank C: Drive unit
NOTE To replace parts in Rank B or Rank C, be sure to contact your Yaskawa representative.
Table. 9 Spare Parts for the MOTOMAN-HP3J
Qty
Parts
Rank Name Type Manufacturer Qty per Remarks
No.
Unit
Harmonic Grease Harmonic Drive

A 1 Grease 2.5 kg -
SK-1A System Co., Ltd.
HW0470360-B Yaskawa Electric 1 1

A 2 Battery Pack Corporation
HW9470932-A 1 1
Three Bond
A 3 Liquid Gasket Three Bond 1206C - -
Co.,Ltd.
Mitsuboshi Belt-
B 4 L-axis Timing Belt 060S3M255 1 1
ing Limited
Mitsuboshi Belt-
B 5 U-axis Timing Belt 060S3M318 1 1
ing Limited
Mitsuboshi Belt-
B 6 R-axis Timing Belt 060S3M207 1 1
ing Limited
Mitsuboshi Belt-
B 7 B-axis Timing Belt 060S3M276 1 1
ing Limited
Mitsuboshi Belt-
B 8 T-axis Timing Belt 060S3M312 1 1
ing Limited
S-axis Yaskawa Electric

B 9 HW0385336-A 1 1
Speed Reducer Corporation
L-axis Yaskawa Electric

B 10 HW0385337-A 1 1
10-1
HW0483547 48/50
HW0483547
Table. 9 Spare Parts for the MOTOMAN-HP3J
Qty
Parts
No.
Unit
U-axis Yaskawa Electric

B 11 HW0385338-A 1 1
R-axis Yaskawa Electric

B 12 HW0385323-A 1 1
B-axis Yaskawa Electric

B 13 HW0385324-A 1 1
T-axis Yaskawa Electric

B 14 HW0385325-A 1 1
HW0384674-A With brake and

AC Servomotor for Yaskawa Electric
B 15 SGMAH-A8A2A- 1 3 lead terminal
SLU-axes Corporation
YR1* treatment
HW0384690-A With brake and

AC Servomotor for Yaskawa Electric
C 16 SGMAH-A3A2A- 1 3 lead terminal
RBT-axes Corporation
YR1* treatment
Wire Harness in Yaskawa Electric

C 17 HW0172731-A 1 1
Manipulator Corporation
10-2
HW0483547 49/50
MOTOMAN-HP3J
INSTRUCTIONS
HEAD OFFICE
2-1 Kurosaki-Shiroishi, Yahatanishi-ku, Kitakyusyu-shi, 806-0004, Japan
Phone 81-93-645-7745 Fax 81-93-645-7746
MOTOMAN INC. HEADQUARTERS
805 Liberty Lane West Carrollton, OH 45449, U.S.A.
Phone 1-937-847-6200 Fax 1-937-847-6277
YASKAWA MOTOMAN CANADA LTD.
3530 Laird Road, Unit 3, Mississauga, Ontario, L5L 5Z7, Canada
Phone 1-905-569-6686 Fax 1-905-813-5911
MOTOMAN ROBOTICS EUROPE AB
Franska Vagen 1039854, Kalmar, Sweden
Phone 46-480-417800 Fax 46-480-417999
MOTOMAN ROBOTEC GmbH
Kammerfeld strasse 1, DE-85391 Allershausen, Germany
Phone 49-8166-90100 Fax 49-8166-90103
YASKAWA ELECTRIC KOREA CORPORATION
1F Samyang Bldg. 89-1, Shinchun-dong, Donk-Ku, Daegu, Korea
Phone 82-53-745-7844 Fax 82-2-784-8495
YASKAWA ELECTRIC (SINGAPORE) PTE. LTD.
151 Lorong Chuan, #04-01, New Tech Park, Singapore 556741, Singapore
Phone 65-6282-3003 Fax 65-6289-3003
YASKAWA ELECTRIC (MALAYSIA) SDN. BHD.
No.71, Jalan Bandar Rawang 2, 48000 Rawang, Selangor D.E., Malaysia
Phone 60-3-6092-1377 Fax 60-3-6092-6377
YASKAWA ELECTRIC TAIWAN CORPORATION
9F, 16 Nanking E. Rd., Sec. 3, Taipei, Taiwan
Phone 886-2-2502-5003 Fax 886-2-2505-1280
SHOUGANG MOTOMAN ROBOT CO., LTD.
7,Yongchang-North Road, Beijing Economic & Technological Development Area, Beijing 100076, China
Phone 86-10-6788-0541 Fax 86-10-6788-2878
YASKAWA
Specifications are subject to change without notice

for ongoing product modifications and improvements. C Printed in Japan July 2006 06-07
MANUAL NO.
HW0483547 50/50
RE-MTO-A235
9.2.6 Notes for Maintenance

Connect the battery with reference to the following figure before removing the encoder con-
nector (with WARNING label).
Motor
Encoder
Motor cable, etc.

Power connector
Internal b 0BT
cable a BAT
0BT a
BAT b
removing connector.
to save the data bofore
Encoder connector Battery
WARNING label
a: Insertion-type pin terminal (female)

b: Insertion-type pin terminal (male)
0BT a b 0BT
BAT b a BAT
Connection Diagram
WARNING Label Enlarged View

to save the data bofore
removing connector.
Fig. 26 Encoder Connector Diagram
9-11
RE-MTO-A235
9-12
RE-MTO-A235
It is recommended that the following parts and components be kept in stock as spare parts for
the MOTOMAN-UPJ. The spare parts list for the MOTOMAN-UPJ is shown below. Product
performance cannot be guaranteed when using spare parts from any company other than
Yaskawa. The spare parts are ranked as follows:
• Rank A: Expendable and frequently replaced parts

• Rank B: Parts for which replacement may be necessary as a result of frequent operation
• Rank C: Drive unit
NOTE For replacing parts in Rank B or Rank C, contact your Yaskawa representative.
Table. 8 Spare Parts for the MOTOMAN-UPJ
Qty
Parts
No.
Unit
Grease Harmonic Grease Harmonic Drive

A 1 2.5kg -
SK-1A System Co, Ltd.
Battery HW9470917-B Yaskawa Electric For SLU-axes

A 2 Corporation 1 1
HW9470917-A For RBT-axes
L-axis Timing Belt 060S3M249 Mitsuboshi Belt-

B 3 1 1
ing Limited
U-axis Timing Belt 060S3M318 Mitsuboshi Belt-

B 4 1 1
ing Limited
R-axis Timing Belt 060S3M213 Mitsuboshi Belt- Only for YR-

B 5 1 1
ing Limited UPJ3-B00
B-axis Timing Belt 060S3M273 Mitsuboshi Belt-

B 6 1 1
ing Limited
T-axis Timing Belt 060S3M300 Mitsuboshi Belt-

B 7 1 1
ing Limited
Gear HW9381785-A Yaskawa Electric

B 8 Corporation 1 1
HW9381786-A
S-axis HW9381718-A Yaskawa Electric

B 9 1 1
L-axis HW9381719-A Yaskawa Electric

B 10 1 1
U-axis HW9381720-A Yaskawa Electric

B 11 1 1
10-1
RE-MTO-A235
Table. 8 Spare Parts for the MOTOMAN-UPJ
Qty
Parts
No.
Unit
R-axis HW9381721-A Yaskawa Electric Only for YR-

B 12 1 1
Speed Reducer Corporation UPJ3-B00
B-axis HW9381726-A Yaskawa Electric

B 13 1 1
T-axis HW9381727-A Yaskawa Electric

B 14 1 1
S-, L-, and U-axis HW9381714-A Yaskawa Electric With brake, lead
B 15 AC Servomotors Corporation 1 3 terminal treat-
ment completion
(R-,) B-, and T-axis HW9381716-A Yaskawa Electric With brake, lead
C 16 AC Servomotors Corporation 1 2 terminal treat-
ment completion
Internal Cable HW0170338-A Yaskawa Electric

C 17 1 1
Corporation
B- and T-axis HW0270114-A Yaskawa Electric Only for YR-

C 18 1 1
Internal Cable Corporation UPJ3-B00
10-2
RE-MTO-A235
11.1 S-axis Driving Unit
11 Parts List
2056
1027 1026
1004
1054 1055
1012
1049
1053
1043 1011
1044 1051
1052
1046 1042
1050 1048
1041
1047 1045
1001
1040
1032 1002
1029
1037
1038 1006
1005
1003
1033
1030
1031
1008
1009 1007
1033
1039
5007
1013
1014 1015
5010
5010 5011 5002
5011
5002
5009
1016 5001
5001
1017
11-1
RE-MTO-A235
No. DWG No. Name Pcs

1001 M3 × 20 Socket screw 1
1002 2H-3 Spring washer 1
1003 UE10257 Oil seal 1
1004 HW0100064-1 S head 1
1009 F6-M5MS Plug 1
1013 HW0100061-1 Base 1
1014 HW9381714-A Motor 1
1015 GT-SA M4 × 10 Socket screw 2
1016 HW0400655-1 Cover 1
1017 M 4×10 Cross recessed 4
head screw
1026 HW0400654-1 Cover 1
head screw
1029 HW9381718-A Reduction gear 1
1031 HW0400653-1 M base 1
1032 HW9406341-1 Support 1
1033 M4 × 8 APS bolt 4
1037 HW9406328-2 N base 1
1038 M4 × 8 APS bolt 4
head screw
1040 HW0400657-1 Support 1
1042 CD-12 Saddle 1
1043 M5 × 6 APS bolt 2
1044 M5 Washer Washer 2
1045 TA1-S8 Clamp
1046 M4 × 8 Round head 1
screw
1047 T50R Insulok’tie 1
1048 HW0400657-2 Support 1
1050 CD-12 Saddle 1
1051 M5 × 6 APS bolt 2
1052 M5 Washer Washer 2
1053 TA1-S8 Clamp 1
screw
2056 LP-M5 Plug 1
5001 CD-15 Saddle 2
screw
5007 HW9302878-1 Connector base 1
5009 TA1-S8 Clamp 2
screw
11-2
RE-MTO-A235
11.2 L-axis Driving Unit
2023
2015
2043 2038
2015 2044 2045
2001 2037
2042 2039
2036
2040 2035
2042
2034
2042 2032
2041 2033
2058
2023 2002
2029
2030
2057
2059
2028
2013 2016
2031
2014 2058
2017
2017
2016
2027
2020
2057 2025
2002
2024
2013
2014 2022
2019
2020
2009
2026
2010
2018
2008
2021
11-3
RE-MTO-A235

2002 HW9481967-A Sheet 1
2008 A-MT6 × 1 Grease nipple 1
2009 HW9482887-A Pulley 1
2013 HW9482888-A Pulley 2
2015 HW0200090-1 Cover 2
2016 HW9406271-1 M base 2
2018 06S3M249 Belt 1
2019 HW9406283-1 Housing 1
2020 6900ZZ Bearing 2
head screw
2025 6916DDU Bearing 1
2028 HW9406255-1 Housing 1
2029 HW010060-1 L arm 1
2033 HW0400658-1 Plate 1
2034 M5 Washer 2
2035 M5 × 6 APS bolt 2
2036 CD-22 Saddle 1
screw
2039 TA1-S8 Clamp 1
2041 HW0400659-1 Plate 1
2042 M6 × 6 Bolt 3
2043 M4 Washer 2
2044 CD-16 Sddle 1
2045 M4 × 8 APS bolt 2
2057 HW9381714-A Motor 2
2059 06S3M318 Belt 1
11-4
RE-MTO-A235
11.3 Wrist Unit
11.3 Wrist Unit
3062 3049
3063
3001 3061 3065
2055
3066 3007
3064
3003
3009 3005
2060 3067 3046

3068
3006
3053 3047
3052
3008
3048
3056 3057 3052

3053
3055 3031
3043 3032 3030

3058
3041
3060 3033 3050
3059
3037 3032
3040 3030
3068
3036
3039 3031
3038
3067 3051
3061
3034 3042
3064 3020 3013 3035
3021
3065 3069
3063
3062
3012 3028
3044 3011
3014
3045
3029 3018
3004 3019
3070 3027
3028
3025
3024
2049 3022
3026 3015
3017
3010
2048 3016
3054
3010
3054
11-5
RE-MTO-A235
11.3 Wrist Unit
No. DWG No. Name Pcs No. DWG No. Name Pcs
2048 HW9201033-1 Cover 1 3056 M4 × 8 Round head 1
2049 M 4×10 Cross recessed 4 screw
head screw 3057 T30R Insulok’tie 1
2055 HW9101029-1 U Arm 1 3058 HW9406288-1 Support 1
2060 LP-M5 Plug 1 3059 M3 × 8 Socket screw 2
3001 HW9406305-1 Connector base 1 3060 2H-4 Spring washer 1
3003 M 4×10 Cross recessed 3 3061 HW9406286-1 M base 2
head screw 3062 M4 × 12 Socket screw 4
3004 GT-SA M4 × 10 Socket screw 4 3063 GT-LH M4 Washer 4
3005 GT-SA M4 × 12 Socket screw 1 3064 HW9482888-A Pulley 2
3006 HW9406259-1 B cover 1 3065 GT-SA M3 × 12 Socket screw 2
3007 GT-SA M4 × 10 Socket screw 4 3066 HW9481967-A Seat 1
3008 HW9406256-1 Housing 1 3067 HW9381716-A Motor 2
3009 GT-SA M4 × 10 Socket screw 6 3068 GT-SA M4 × 10 Socket screw 4
3010 M 4×10 Cross recessed 10 3069 LP-M5 Plug 1
head screw
3058 HW9406288-1 Support 1
3011 S60 O ring 1
3012 HW9381786-A Gear 1
3070 M6×6 H set screw 1
3014 SP-0090 Sim 1
3015 HW9380739-A Bearing 1
3016 HW9406262-1 B nut 1
3017 AB2551E0 Oil seal 1
3022 HW9302842-1 Frange 1
3024 HW9406257-1 Housing 1
3025 HW9106260-1 Housing 1
3026 HW9406266-1 B nut 1
3029 HW9302841-1 Housing 1
3031 AD526808 Oil seal 2
3036 A-MT6 Grease nipple 1
3037 HW9483147-A Pulley 1
3040 HW9406261-A Housing 1
3042 HW9406260-1 Housing 1
3044 060S3M273 Belt 1
3045 HW9481967-A Seat 1
3046 HW9483146-A Pulley 1
3047 HW8481521-A Bearing 1
3048 HW9381785-A Gear 1
3049 06S3M300 Belt 1
3050 LP-M5 Plug 1
3051 HW9302840-1 Wrist base 1
3052 HW0400664-A Block 2
3054 HW9201039-1 Cover 2
3055 TA1-S8 Clamp 1
11-6
RE-MTO-A235
11.4 U(R)-axis Driving Unit
4015
4008
4010
4011
4020
4004
4019
4002
4017
4006
4003
4018
4016
4022
4009 4005
4012
4029
4013
4027 4026
4030
4025 4007
4028 4024
4023
4021
4001
4014
2030
2028
2027
2004
2003
2005
2006 2007
2007 2012
2011 2008
2009 2051
2010
2050
2052
2053
2053
2046
2047
11-7
RE-MTO-A235

2008 A-MT6 × 1 Grease nipple 1
2009 HW9482887-A Pulley 1
2011 HW9406282-1 Housing 1
2028 HW9406255-1 Housing 1
2046 HW9302859-A Support 1
2050 M5 Washer 1
2051 M5 × 8 APS bolt 1
2052 CH-16 Saddle 1
Following parts are applied only for YR-UPJ3-B00.

4002 GT-SA M3 × 1 0 Socket screw 8
4003 HW9406275-1 B cover 1
4005 GT-SA M3 ×1 0 Socket screw 6
4006 HW9406276-1 B cover 1
4007 M6 × 6 H set screw 1
4008 HW9406278-1 Washer 1
4009 HW9406285-A Pipe 1
4010 HW9482967-1 Pulley 1
4011 HW9406279-1 Frange 1
4013 GT-LH-4 Spring washer 6
4014 HW9101025-1 Casing 1
4015 GT-SA M3 ×1 0 Socket screw 3
4017 6806LLU Bearing 1
4018 HW9482970-A Bearing 1
4019 HW9381721-A RV reduction 1
gear
4020 6808LLU Bearing 1
4021 06S3M213 Belt 1
4023 ST-SA M3 × 12 Socket screw 1
4024 HW9483148-A Pulley 1
4026 HW9481716-A Motor 1
4027 HW9481967-B Seat 1
4028 HW9481967-A Seat 1
4029 HW9101031-1 U arm 1
4030 LP-M5 Plug 1
11-8
MOTOMAN-UPJ
INSTRUCTIONS
HEAD OFFICE
2-1 Kurosaki-Shiroishi, Yahatanishi-ku, Kitakyusyu-shi, 806-0004, Japan
Phone 81-93-645-7745 Fax 81-93-645-7746
MOTOMAN INC. HEADQUARTERS
805 Liberty Lane West Carrollton, OH 45449, U.S.A.
Phone 1-937-847-6200 Fax 1-937-847-6277
YASKAWA MOTOMAN CANADA LTD.
3530 Laird Road, Unit 3, Mississauga, Ontario, L5L 5Z7, Canada
Phone 1-905-569-6686 Fax 1-905-813-5911
MOTOMAN ROBOTICS EUROPE AB
Franska Vagen 1039854, Kalmar, Sweden
Phone 46-480-417800 Fax 46-480-417999
MOTOMAN ROBOTEC GmbH
Kammerfeld strasse 1, DE-85391 Allershausen, Germany
Phone 49-8166-90100 Fax 49-8166-90103
YASKAWA ELECTRIC KOREA CORPORATION
1F Samyang Bldg. 89-1, Shinchun-dong, Donk-Ku, Daegu, Korea
Phone 82-53-745-7844 Fax 82-2-784-8495
YASKAWA ELECTRIC (SINGAPORE) PTE. LTD.
151 Lorong Chuan, #04-01, New Tech Park, Singapore 556741, Singapore
Phone 65-6282-3003 Fax 65-6289-3003
YASKAWA ELECTRIC (MALAYSIA) SDN. BHD.
No.71, Jalan Bandar Rawang 2, 48000 Rawang, Selangor D.E., Malaysia
Phone 60-3-6092-1377 Fax 60-3-6092-6377
YASKAWA ELECTRIC TAIWAN CORPORATION
9F, 16 Nanking E. Rd., Sec. 3, Taipei, Taiwan
Phone 886-2-2502-5003 Fax 886-2-2505-1280
SHOUGANG MOTOMAN ROBOT CO., LTD.
7,Yongchang-North Road, Beijing Economic & Technological Development Area, Beijing 100076, China
Phone 86-10-6788-0541 Fax 86-10-6788-2878
YASKAWA
Specifications are subject to change without notice MANUAL NO. RE-MTO-A235 1

for ongoing product modifications and improvements. C Printed in Japan June 2006 01-5

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Motoman NXC100 Controller

Part Number: 151562-1CD

1.1 About This Document

1.2 Reference to Other Documentation

1.3 Customer Service Information

It is the purchaser’s responsibility to ensure that all local, county, state,

This safety section addresses the following:

2.2 Standard Conventions

2.3 General Safeguarding Tips

2.4 Mechanical Safety Devices

2.5 Installation Safety

2.6 Programming, Operation, and Maintenance Safety

YASKAWA MANUAL NO.

• The drawings and photos in this manual are representative examples

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

• YASKAWA is not responsible for incidents arising from unauthorized

Notes for Safe Operation

Indicates a potentially hazardous situation which, if not

Indicates a potentially hazardous situation which, if not

Always be sure to follow explicitly the items listed under this

PROHIBITED Must never be performed.

Emergency Stop Button

Injury may result from unintentional or unexpected manipulator motion.

Release of Emergency Stop

Improper operation or unintended manipulator motion may result in injury.

• Confirm that no persons are present in the P-point maximum envelope of

Emergency stop button

SER NO. 44A220-011 DATE 3-2005

Programming pendant NXC100

• Read and understand the Explanation of Warning Labels before operat-

• For safety, operate under the proper lighting.

Definition of Terms Used Often in This Manual

Equipment Manual Designation

NXC100 Controller NXC100

NXC100 Programming Pendant Programming Pendant

Cable between the Manipulator and the Controller Manipulator Cable

Explanation of Warning Labels

Nameplate Warning Label A:

YASKAWA ELECTRIC CORPORAION JAPAN

6 Allowable Load for Wrist Axis and Wrist Flange

8 Electrical Equipment Specification

9 Maintenance and Inspection

10 Recommended Spare Parts

1.1 Contents Confirmation

1.1 Contents Confirmation

Confirm the contents of the delivery when the product arrives.

1.2 Order Number Confirmation

Label (Enlarged View)

THE MANIPULATOR AND THE CONTROLLER

(a) NXC100 (Top View) (b) Manipulator (Top View)

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

• Avoid excessive vibration or shock during transportation.

2.1 Transporting Method

2.1.1 Using a Crane

Fig. 2 Transporting Position

2.1 Transporting Method

2.1.2 Using a Forklift

Forklift claw entry

Fig. 3 Using a Forklift

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

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

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

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

Horizontal rotating maximum torque 294 Nm

Vertical rotating maximum torque 627 Nm

Endurance torque in horizontal operation 59 Nm

Endurance torque in vertical operation 194 Nm