Page 1 Original instructions YAMAHA SCARA ROBOT YK-XE Series Maintenance Manual YK400XE-4 YK510XE-10 / YK610XE-10 / YK710XE-10 EMFV241139 Ver. 1.39 E675...
Page 3: Table Of Contents
4.2 Applying the grease to the ball screw Chapter 4 Adjusting the origin 1. Adjusting the machine reference value 1.1 Stroke end method 1.1.1 Changing the X-axis reference value YK400XE 1.1.2 Changing the Y-axis reference value YK400XE 1.1.3 Changing the Z-axis and R-axis reference values 1.2 Sensor method (X-axis, Y-axis)
Page 4 CONTENTS YK-XE Maintenance Manual Chapter 5 Replacing the harmonic drive 1. Cautions on replacement of the harmonic drive 2. Replacement procedure for harmonic drive YK400XE 2.1 Replacing the X-axis harmonic drive 2.1.1 Preparation 2.1.2 Removal 2.1.3 Replacement and reassembly 2.1.4...
Page 5 2.3 Replacement and reassembly 2.4 Aging 7-10 Chapter 8 Replacing the Z-axis drive unit 1. Replacing the Z-axis drive unit YK400XE 1.1 Replacing the Z-axis motor 1.2 Replacing the Z-axis belt 1.3 Replacing the Z-axis ball screw 1.4 Replacing the Z-axis brake 2.
Page 7: Warranty
9. Pollution, salt damage, condensation; 10. Fires or natural disasters such as earthquakes, tsunamis, lightning strikes, wind and flood damage, etc; 11. Breakdown due to causes other than the above that are not the fault or responsibility of YAMAHA; ■...
Page 9: Introduction
Chapter 1 Introduction Contents Introduction Available manuals Signal symbols Before using the robot (Be sure to read the following notes.)
Page 11: Available Manuals
Available manuals The following manuals are included in the disk that comes supplied with the YAMAHA robot or controller. Safety instructions Describes safe and correct operating method for controller and robot.
Page 12: Signal Symbols
CAUTION Use only the lubricants specified by your distributor. "Harmonic" and "Harmonic drive" are the registered trademarks of Harmonic Drive Systems Inc. Signal symbols The following safety alert symbols and signal words are used to provide safety instructions that must be observed and to describe handling precautions, prohibited actions, and compulsory actions.
Page 13: Before Using The Robot (Be Sure To Read The Following Notes.)
2. Before using the robot (Be sure to read the following notes.) At this time, our thanks for your purchase of this YAMAHA YK-XE series SCARA robot. NOTE In the RCX340 controller, axis names are called using numeric values, like axis-1, axis-2, axis-3, and so on. In this manual, axis names are called using alphabetic characters, like X-axis, Y-axis, Z-axis, and so on.
Page 15 Chapter 2 Attaching, detaching, and replacing the cover Contents Attaching, detaching, and replacing the cover...
Page 17: Attaching, Detaching, And Replacing The Cover
To prevent such troubles, strictly observe this caution. YK400XE Y-axis arm cover (YAMAHA’s part No. KDS-M1314-11) Harness cover (YAMAHA’s part No.KDS-M1312-10) Harness cover mounting bolt Binding head screw M4×10, 3 pcs.
Page 18 M4x6 2 pcs. Base rear cover Base rear cover (YAMAHA’s part No. KFS-M1300-00) (YAMAHA’s part No. KFS-M1300-00) Base rear cover mounting bolt Binding head screw M4x8 2 pcs. (YAMAHA’s part No. 91312-04010) M4x10 2 pcs. (YAMAHA’s part No. 90990-10J003) 23218-FV-00...
Page 19: Chapter 3 Periodic Inspection
Chapter 3 Periodic inspection Contents Overview Daily inspection Six-month inspection Applying the grease Applying the grease to the spline shaft Applying the grease to the ball screw...
Page 21: Overview
Overview Daily and periodic inspection of the YAMAHA robot is essential in order to ensure safe and efficient operation. This chapter describes the periodic inspection items and procedures for the YAMAHA YK-XE series robots. Periodic inspection includes: • Daily inspection •...
Page 22: Daily Inspection
Daily inspection The following is an inspection list that must be performed every day before and after operating the robot. ■ Inspection to be performed with the controller turned off Turn off the controller. Place a sign indicating the robot is being adjusted. Place a sign indicating the robot is being inspected, to keep others from operating the controller switch.
Page 23: Six-Month Inspection
• Do not attempt to weld, heat up, drill holes or cut this container. This might cause the container to explode and the remaining materials inside it to ignite. CAUTION Unless grease specified by YAMAHA is used, the service life of the ball screw and ball spline will shorten.
Page 24 ■ Inspection to be performed with the controller turned off Turn off the controller. Place a sign indicating the robot is being adjusted. Place a sign showing that the robot is being inspected, to keep others from operating the controller switch. Perform the daily inspection.
Page 25 If no cause is found, contact your distributor. • Check the fan cover for contamination. If contaminated, replace the fan filter. (Refer to the User’s Manual for YAMAHA Robot Controller.) ■ Adjustment and parts replacement CAUTION •...
Page 26: Applying The Grease
Applying the grease ■ Applying the grease Name Manufacturer Part No. Remarks L100 THK. Co., Ltd. KDS-M7122-00 Applying the grease to the spline shaft Follow the steps below to apply the grease to the spline shaft. Turn off the controller power. Place a sign indicating the robot is being adjusted.
Page 27: Applying The Grease To The Ball Screw
Remove the cover while referring to "1. Detaching or attaching the covers" in Chapter 2. Remove the old grease with a cloth rag. Apply the grease. Apply the grease to the ball screw. (See the Fig. below.) YK400XE Applying the grease bolt Cover Apply the grease to the groove thinly.
Page 28 YK510XE YK610XE YK710XE Applying the grease Cover Insert grease from grease nipple. Insert grease from grease nipple. Wipe off all grease sticking out from the ball nut. If it is not wiped off, grease will splash on the Z-axis belt. bolt Ball screw nut 53312-FV-01...
Page 29: Adjusting The Origin
Chapter 4 Adjusting the origin Contents Adjusting the machine reference value Stroke end method 1.1.1 Changing the X-axis reference value YK400XE 1.1.2 Changing the Y-axis reference value YK400XE 1.1.3 Changing the Z-axis and R-axis reference values Sensor method (X-axis, Y-axis) 1.2.1...
Page 31: Adjusting The Machine Reference Value
Adjusting the machine reference value The X- and Y-axis origin positions of the YK-XE series are fixed and cannot be changed. Additionally, the machine reference value was correctly adjusted at shipment. The readjustment is not needed during normal operation. However, if the machine reference value exceeds the return-to-origin tolerance range for some reason, follow the steps below to readjust the machine reference value.
Page 32: Changing The X-Axis Reference Value Yk400Xe
Replace the bolts one-by-one and take great care so that the speed reduction gear and arm do not deviate. Bolt M3 x 35, (YAMAHA’s part No.: 91312-03035) 12 pcs. Secure the speed reduction gear. Secure the speed reduction gear while referring to “2.1 Replacing the X-axis harmonic drive” in Chapter 5.
Page 33: Changing The Z-Axis And R-Axis Reference Values
1.1.3 Changing the Z-axis and R-axis reference values Remove the cover. Remove the cover while referring to "12. Detaching or attaching the covers" in Chapter 2. YK400XE YK510XE YK610XE YK710XE Step 7 Step 7 Removing the cover Removing the cover...
Page 34 Loosen the bolts that secure the motor installation plate. YK400XE Step 9 Removing the plate To adjust the Z-axis reference value, Z-axis fixing plate loosen the bolts at 3 locations. Z-axis motor R-axis fixing plate To adjust the R-axis reference value, loosen the bolts at 3 locations.
Page 35 Go out of the safety enclosure. Turn on the controller. Check that no one is inside the safety enclosure, and then turn on the controller. Perform the return-to-origin of the Z-axis. NOTE For details about how to perform the return-to-origin, refer to "2.3 Return-to-origin procedures" in this Chapter. Check the Z-axis machine reference value.
Page 36: Sensor Method (X-Axis, Y-Axis)
Sensor method (X-axis, Y-axis) 1.2.1 Adjusting the X-axis machine reference CAUTION • The origin position may change due to machine reference adjustment. If it occurs, you must set point data again. • When the return-to-origin direction is reversed, the origin position may not be the base front. When using the standard soft limit, the axis may collide with the mechanical stopper.
Page 37 Loosen the hex nut. Step 8-10 Adjusting the X-axis machine reference value Using the wrench, loosen the hex nut that secures the X-axis origin sensor. 23307-FV-00 X-axis origin sensor CAUTION It is enough to loosen the nut. Do not remove the nut completely.
Page 38: Adjusting The Y-Axis Machine Reference
1.2.2 Adjusting the Y-axis machine reference CAUTION The origin position may change due to machine reference adjustment. If it occurs, you must set point data again. Follow the steps below to adjust the Y-axis machine reference value. Prepare a wrench for a width across flat of 13 mm. Turn on the controller.
Page 39 Loosen the hex nut. Step 8-10 Adjusting the Y-axis machine reference value Using the wrench, loosen the hex nut that secures the Y-axis origin sensor. 23308-FV-00 CAUTION It is enough to loosen the nut. Do not remove the nut completely. Move the Y-axis origin sensor as follows.
Page 40: Mark Method Yk400Xe
• When pressing the key on the execution confirmation screen, the execution of the absolute reset is canceled. • For details about how to operate the robot controller, see the "YAMAHA Robot Controller User's Manual". Turn on the controller. Check that no one is inside the safety enclosure, and then turn on the controller.
Page 41 Select an axis whose absolute reset is performed. Use the cursor keys ( ) to select an axis number whose absolute reset is performed, and then press The execution confirmation screen will pop up. Perform the step movement. Press the jog key to perform the step movement of the robot until the origin position marks are matched with each other.
Page 42: Absolute Reset In Servo Off State (Re-Reset)
• When pressing the key on the execution confirmation screen, the execution of the absolute reset is canceled. • For details about how to operate the robot controller, see the "YAMAHA Robot Controller User's Manual". Turn on the controller. Check that no one is inside the safety enclosure, and then turn on the controller.
Page 43 Move the arm to the position where the origin position marks are matched with each other. Press the emergency stop button on the PBX to put the robot in the emergency stop state. WARNING Be sure to press the emergency stop button and move the robot in the state where the servo on cannot be operated from the outside.
Page 44 Select an axis whose absolute reset is performed. Use the cursor keys ( ) to select an axis number whose absolute reset is performed, and then press The execution confirmation screen will pop up. CAUTION • There are multiple discrete positions where the absolute reset can be performed. Move the robot step-by-step while referring to the PBX screen.
Page 45: Absolute Reset In Servo On State (New Reset)
• When pressing the key on the execution confirmation screen, the execution of the absolute reset is canceled. • For details about how to operate the robot controller, see the "YAMAHA Robot Controller User's Manual". Turn on the controller. Check that no one is inside the safety enclosure, and then turn on the controller.
Page 46 Affix the origin position stickers. After the robot has been moved to the all axes "0" pulse position, press the emergency stop button and affix the origin position stickers to legible positions. After that, these origin position stickers are used to perform the absolute reset again at the same position.
Page 47: Absolute Reset In Servo Off State (New Reset)
• When pressing the key on the execution confirmation screen, the execution of the absolute reset is canceled. • For details about how to operate the robot controller, see the "YAMAHA Robot Controller User's Manual". Turn on the controller. Check that no one is inside the safety enclosure, and then turn on the controller.
Page 48 Affix the origin position stickers. After the robot has been moved to the all-axis 0 pulse position, press the emergency stop switch and affix the origin position stickers supplied with the robot to easy-to-identify positions near the R-axis rotation part so that they can be used when the absolute reset is performed again at the same position.
Page 49: Replacing The Harmonic Drive
Chapter 5 Replacing the harmonic drive Contents Cautions on replacement of the harmonic drive Replacement procedure for harmonic drive YK400XE Replacing the X-axis harmonic drive 2.1.1 Preparation 2.1.2 Removal 2.1.3 Replacement and reassembly 2.1.4 Aging 5-10 Replacing the Y-axis harmonic drive 5-11 2.2.1...
Page 51: Cautions On Replacement Of The Harmonic Drive
• Do not attempt to weld, heat up, drill holes or cut this container. This might cause the container to explode and the remaining materials inside it to ignite. CAUTION The harmonic drive service life may shorten if the grease recommended by YAMAHA is not used. ■ Recommended grease Use the following harmonic drive grease.
Page 52: Replacement Procedure For Harmonic Drive Yk400Xe
For the bolt tightening torque in the harmonic drive replacement work, see the Table below. However, when tightening the mounting bolts for the harmonic drive, observe the tightening torque specified in each replacement procedure. Use only YAMAHA genuine bolts. ■...
Page 53 XP in the base, and the round terminal of the X-axis motor. Refer to Chapter 6 "1. Replacing the machine harness YK400XE". Bolt M4 x 8 Cover The round terminal of the X-axis motor is present inside here. So, disconnect...
Page 54 Remove the X-axis motor. Step 6 Removing the X-axis motor 53501-FV-00 Remove the wave generator. 1. Remove the set screw (1 pc.) that secures the wave generator. 2. Remove the wave generator from the motor. 53502-FK-00 O-ring X-axis motor Bolt M5 x 16 Step 7 Removing the wave generator M3 set screw...
Page 55 Remove the X-axis arm. Step 8 Removing the X-axis arm 53503-FV-01 Remove the X-axis harmonic drive from the X-axis arm. 53505-FV-00 O-ring supplied with the harmonic drive NOTE An O-ring is fitted to the X-axis arm. Replace this O-ring with a new one. Bolt M3 x 20 Step 9 Removing the harmonic drive...
Page 56 2.1.3 Replacement and reassembly Follow the steps below to replace the harmonic drive with a new one and reassemble it. Perform the work shown below before reassembling the harmonic drive. 1. Install the bolts on the harmonic drive. 2. Remove the bolts that have been assembled and secured temporarily. Step 1 Preparations before assembling the harmonic drive ...
Page 57 Secure a new harmonic drive to the X-axis arm. 1. Degrease the harmonic drive installation surface of the X-axis arm. Do not apply the grease to the seating part. 2. Fit the O-ring coated with the new harmonic grease into the O-ring groove of the X-axis arm. Since the grease application to the O-ring is intended to prevent the O-ring from coming off, it is accepted to apply a small amount of the grease.
Page 58 Step 4 Installing the harmonic drive Fit the new O-ring coated with the harmonic grease into the O-ring groove of the harmonic drive. 1. Degrease the top surface of the plate where the harmonic drive is to be installed. CAUTION Do not allow the O-ring to get caught out of the Degrease the base top surface groove during reassembly.
Page 59 Fit a new O-ring (3) into the motor Step 7-8 Securing the wave generator flange end face. M3 set screw 53613-FK-00 (Supplied with the harmonic drive.) Apply a small amount of the screw lock. CAUTION Use the tool C. Wave generator Do not allow the O-ring to get caught out of the (Harmonic drive) groove during reassembly.
Page 60 Reattach the base cover. Step 11 Attaching Base Rear Cover 51571-FV-00 Bolt M4×8 Cover Store the wires in the space in front of the X motor. 21243-FV-00 CAUTION Make sure that the wiring does not get caught in the cover. (Make sure that there are no wires in the red frame in the above figure so that the wires are not pinched.) 2.1.4 Aging...
Page 61: Replacing The X-Axis Harmonic Drive
Before starting the work, thoroughly read “1. Attaching, detaching, and replacing the cover” in Chapter 2. The following shows the parts and tools necessary for the Y-axis harmonic drive replacement work. 2.2.1 Preparation Replacement parts Part Name YAMAHA Part No. Part No. / Specs Q'ty Remarks Harmonic drive KDS-M2510-00 O-ring Cross section diameter: 0.8mm...
Page 62: Removal
2.2.2 Removal Step 4 Follow the steps below to remove the Y-axis parts. Removing the cover Turn off the controller. hex socket Place a sign indicating the robot is head bolt being adjusted. Cover Place a sign indicating the robot is being adjusted, to keep others from operating the controller or operation panel.
Page 63 Step 6 Removing the wave generator Remove the wave generator from the motor shaft. Remove the set screws (2 pcs.) that secure the wave generator. 53620-FV-00 Remove the Y-axis harmonic drive from the top surface of the X-axis arm. 1. Remove the Y-axis harmonic drive mounting bolts.
Page 64: Replacement And Reassembly
2.2.3 Replacement and reassembly Follow the steps below to replace the harmonic Step 1 Preparations before assembling the harmonic drive drive with a new one and reassemble it. Perform the work shown below Harmonic drive mounting bolts (7) M3 × 8 (4 pcs) before reassembling the harmonic drive.
Page 65 Step 2 Installing the harmonic drive Secure a new harmonic drive to the X-axis arm. New harmonic drive (1) 1. Degrease the harmonic drive installation Remove the temporarily secured bolt later. surface of the X-axis arm. Do not apply the grease to the seating part. 2.
Page 66 Apply the grease to the inside of Applying the grease to the inside of Step 4-6 the harmonic drive main body. the harmonic drive main body For the Y-axis, apply the grease so that it becomes Apply the grease so that it becomes flat.
Page 67 Step 8 Securing the Y-axis arm Secure the Y-axis arm to the harmonic drive. 1. Degrease the Y-axis arm side where the harmonic drive is to be installed. 2. Apply the harmonic grease 4B No.2 to the tip New Harmonic drive mounting bolt (6) of each bolt so that the roots of at least the M3 ×...
Page 68 Step 9 Tightening the bolts Tighten the bolts in the bolt tightening order shown below. 1. While rotating the Y-axis arm, gradually tighten the bolts <13> <14> <15>, and <16> in an alternating manner, and in the order indicated below (rotate the arm in ultra-low-speed mode (1/10 of turn per second)).
Page 69: Aging
2.2.4 Aging Go out of the safety enclosure. Turn on the controller. Check that no one is inside the safety enclosure, and then turn on the controller. CAUTION After the harmonic drive has been replaced, it is necessary to perform the return-to-origin and set the standard coordinates and point data again.
Page 70: Preparation
For the bolt tightening torque in the harmonic drive replacement work, see the Table below. However, when tightening the mounting bolts for the harmonic drive, observe the tightening torque specified in each replacement procedure. Use only YAMAHA genuine bolts. ■...
Page 71: Removal
Tools(Torque wrench, etc.) CAUTION Use accurately calibrated torque screwdrivers and torque wrenches. Name Part No. Manufacturer Remarks KANON For M5 hex socket head bolt Torque wrench N230QLK (Nakamura Mfg. Co., Ltd.) Tightening torque: 15.2Nm (156kgfcm) KANON Mounting 9.53mm, total length 100mm, Hexagonal width Changeable head 3KH5L (Nakamura Mfg.
Page 72 resolver wire XP in the base, and the round terminal of the X-axis Step 6 Removing the X-axis motor motor. Refer to Chapter 6 “Replacing the machine harness”. Remove the X-axis motor. Place the X-axis arm where it does not apply any Washer force to the harness and does not interfere with the work.
Page 73 Remove the wave generator. Step 9 Remove the wave generator. 53533-FV-00 Remove the set screw (1 pc.) that secures the wave generator. wave generator Removing the harmonic drive Step 10 Removing the harmonic drive 53534-FV-00 Harmonic drive O-ring supplied with the harmonic drive(KN5-M257L-00) Bolt M4 x 20 Removing the ring .
Page 74: Replacement And Reassembly
3.1.3 Replacement and reassembly Follow the steps below to replace the harmonic drive with a new one and reassemble it. Perform the work shown below before reassembling the harmonic drive. 1. Install the bolts on the harmonic drive. 2. Remove the bolts that have been assembled and secured temporarily. Step 1 Preparations before assembling the harmonic drive ...
Page 75 Secure a new harmonic drive to the X-axis arm. 1. Degrease the harmonic drive installation surface of the X-axis arm. Do not apply the grease to the seating part. 2. Fit the O-ring coated with the new harmonic grease into the O-ring groove of the X-axis arm. Since the grease application to the O-ring is intended to prevent the O-ring from coming off, it is accepted to apply a small amount of the grease.
Page 76 Step 4 Install the wave generator. Install the wave generator 53538-FV-00 Wave generator CAUTION Do not allow the O-ring to get caught out of the groove during reassembly. If the robot is operated with the O-ring left caught out of the groove, this may cause a malfunction.
Page 77 Step 8 Motor Unit Mounting Fix the motor unit to the base. Use new fixing bolts. Apply 4BNo. 2 grease to at least 4 threads at the end. Degrease the mating surfaces of the motor holder New bolt 5 and base. M5 x 25 (Tools D) 53543-FV-00 Motor unit...
Page 78 Secure q X shaft arm and harmonic drive. X Secure the axis arm and harmonic drive. Use new fixing bolts. Apply 4BNo. 2 grease to at least 4 threads at the end. Tighten the bolts in the following tightening order. 1.
Page 79: Aging
Reattach the base cover. 51571-FV-00 Step 12 Attaching Base Rear Cover Bolt M4×10 Base rear cover Store the signal wire to the left back side of the X motor and the power wire to the right back side when Bolt M4×6 viewed from the base wiring side.
Page 80: Replacing The Y-Axis Harmonic Drive
Before starting the work, thoroughly read “1. Attaching, detaching, and replacing the cover” in Chapter 2. The following shows the parts and tools necessary for the Y-axis harmonic drive replacement work. 3.2.1 Preparation Replacement parts Part Name YAMAHA Part No. Part No. / Specs Q'ty Remarks Harmonic drive KDS-M2110-00 O-ring(Supplied with the Cross section diameter: 0.99mm...
Page 81: Removal
3.2.2 Removal Step 4 Removing the cover Follow the steps below to remove the Y-axis parts. Turn off the controller. Cover Place a sign indicating the robot is being adjusted. Bolt Place a sign indicating the robot is being adjusted, to keep others from operating the controller or operation panel.
Page 82 Y Remove the shaft motor wiring. Step 6 Y motor removal Y Remove the shaft motor wiring. 53620-FV-00 Remove the motor. Bolted M5x16 O-ring Y Remove the shaft arm. Step 8 Y motor removal 53549-FV-00 Bolt M3×20 CAUTION Washer Y Removing the shaft arm mounting bolts may cause the Y-axis arm to come off.
Page 83 Step 9 Removing the Wave Generator Remove the wave generator from the motor shaft. Remove the set screw that secures the wave generator. 53559-FV-00 Remove the Y-axis harmonic drive Step 10 Removing the Wave Generator from the top surface of the X-axis arm.
Page 84: Replacement And Reassembly
3.2.3 Replacement and reassembly Prepare 40g of harmonic grease 4BNo. 2 and replace it with a new harmonic drive by following the procedures below. Perform the work shown below Step 1 Preparing to Install Harmonic Drives before reassembling the harmonic drive.
Page 85 Step 2 Installing the harmonic drive Secure the new harmonic drive to Ring Ring the X-axis arm. New harmonic drive (1) New harmonic drive (1) 1. X Degrease the mounting surface of the harmonic drive on the shaft arm. New O-ring (4) X Degrease the Do not apply grease to the seating surface.
Page 86 Apply the remaining grease to the Step 4-5 Applying grease inside the harmonic body inside of the harmonic unit. Apply grease so that it is flat. Y On the shaft, apply grease so that it is flat. 53626-FV-00 Harmonic Drive Accessories Harmonic Drive Accessories Install the new harmonic drive O-ring...
Page 87 Step 7 Tightening instructions for bolts Tighten the bolts using the following tightening procedures. 1. Tighten all parts by hand using a wrench in the order of assembling and tightening shown in the figure on the right. 2. In the order shown in the figure on the right, tighten them all at about 50% of the specified torque by the torque driver.
Page 88 Install the harness cover. Step 9 Installing the Harness Cover Bolt M 4 x 10 53558-FV-00 Replacing the Cover Step 10 Reattaching the cover 53631-FV-00 Cover Bolt (0.9Nm) 5-38...
Page 89: Aging
3.2.4 Aging Go out of the safety enclosure. Turn on the controller. Check that no one is inside the safety enclosure, and then turn on the controller. CAUTION After the harmonic drive has been replaced, it is necessary to perform the return-to-origin and set the standard coordinates and point data again.
Page 91: Chapter 6 Replacing The Machine Harness
Chapter 6 Replacing the machine harness Contents Replacing the machine harness YK400XE Removal Assembly Replacing the machine harness YK510XE YK610XE YK710XE 6-7 Removal Assembly 6-12...
Page 93: Replacing The Machine Harness Yk400Xe
• If the bolt tightening torque is not instructed, see the tightening torque stated in "2. Replacement procedure for harmonic drive" "2. Replacement procedure for harmonic drive YK400XE"in Chapter 5. • The return-to-origin needs to be performed after replacing the machine harness.
Page 94: Removal
Removal Step 4 Removing the connector hood Follow the steps below to disconnect the machine harness. Turn off the controller power and air supply. Place a sign indicating the robot is Connector hood being adjusted. Place a sign indicating the robot is being adjusted, to keep others from operating the controller or operation panel.
Page 95 Step 7-9 Removal Disconnect the connector. Disconnect the air tube and round terminal. Air tube joint Disconnect the air tube and round terminal (round terminal for the White and yellow/green wire). Be careful not to drop any lock washer or screw. Air tube (black) エアチューブ(黒) Disconnect the wiring connector.
Page 96 Step11-12 Removing cover, connector hood Remove the cover. Remove the cover while referring to “1. Attaching, detaching, and replacing the cover” in Chapter 2. 53605-FV-00 Connector hood Remove the connector hood. 53606-FV-00 Bolt M4×8 cover Remove the air tubes, connector, Step 13 Removal and round terminal.
Page 97: Assembly
Assembly Assemble a new machine harness in the reverse order of removal. Reconnect the connector, round terminal, and air tubes. NOTE Refer to the separate document “YK-XE Series Installation Manual” for wiring diagrams. Step 1 Assembly Tighten the nut so that the machine harness is not pulled out when stretching it and it does not slip when twisting it 90°.
Page 98 Clamp the machine harness on the Y-axis side. Step 2 Clamping For the machine harness clamp position on the Y-axis side, clamp the machine harness at a specified position while referring to the Fig. 53609-FV-00 L (mm)
Page 99: Replacing The Machine Harness Yk510Xe Yk610Xe Yk710Xe
• If the bolt tightening torque is not instructed, see the tightening torque stated in "3. Replacement procedure for harmonic drive YK510XE YK610XE YK710XE" in Chapter 5. • The return-to-origin needs to be performed after replacing the machine harness. Replacement parts Part Name YAMAHA Part No. Part No. / Specs Q'ty Remarks KFS-M4844-01...
Page 100 Step 6-7 Removal Disconnect the connector. Remove the air tube and round terminal. Remove the air tube and round terminals (black and yellow / green wiring round terminals). Screw with washer Screw with washer Be careful not to drop lock washer, screws, etc. M4×8 M4×8 Round terminal...
Page 101 Remove the harness detent(anti- rotation). Step 8 Harness detent removal Remove the bolt and the anti-rotation. Bolt 53643-FV-00 Anti-rotation Anti-rotation Remove the harness detent(anti- rotation). Step 8 Removal Remove the bolt and the detent. Harness clamp Harness clamp Upper nut Upper nut 53652-FV-00 Step 9...
Page 102 Step10 Remove the base rear cover. Removing the Base Back Cover Refer to Chapter 2 "1. Attaching, detaching, and replacing the cover" and remove the cover. 53604-FV-00 Bolt M4×10 Base rear cover Bolt M4×6 Disconnect the wires on the base Step11 Disconnecting the wires on the base rear cover rear cover.
Page 103 Remove the base side detent.(anti- rotation) Step12 Removing the base side detent 53645-FV-00 Bolt Anti-rotation Step13 Base side clamp removal Remove harness clamp. Harness clamp upper nut Harness clamp upper nut 53655-FV-00 Remove the machine harness on the base side. Step13 Removing the machine harness 53610-FV-00...
Page 104: Assembly
Assembly Assemble a new machine harness in the reverse order of removal. Reconnect the connector, round terminal, and air tubes. NOTE Refer to the separate document “YK-XE Series Installation Manual” for wiring diagrams. Step 1 Assemble Tighten the machine harness so that it does not come out even when pulled, and does not slip when twisted 90 °...
Page 105 Step 2 Clamping Clamp the machine harness on the Y-axis side. For the machine harness clamp position on the Y-axis side, clamp the machine harness at a specified position while referring to the figure. 53609-FV-00 L (mm) YK510XE YK610XE YK710XE NOTE •...
Page 107: Chapter 7 Replacing The X-, Y-Axis Motor
Chapter 7 Replacing the X-, Y-axis motor Contents Motor replacement X-axis motor replacement Y-axis motor replacement Replacing the X-axis base drive assembly Preparation Removal Replacement and reassembly Aging 7-10...
Page 109: Motor Replacement
Hex wrench set Phillips screwdriver Do not use grease if it was purchased 4 or more years Harmonic grease 4B No.2 (*) Harmonic Drive Systems ago. The grease has probably deteriorated. * YK400XE : 27g YK510XE YK610XE YK710XE : 50g...
Page 110: Y-Axis Motor Replacement
Do not use grease if it was purchased 4 or more years Harmonic grease 4B No.2 (*) Harmonic Drive Systems ago. The grease has probably deteriorated. * YK400XE : 27g YK510XE YK610XE YK710XE : 40g Follow the steps below to perform the replacement work. ■ Removal Turn off the controller.
Page 111 Y-axis motor replacement Bolt M4×10 Tool A Motor (1) O-ring (2) Y-axis arm 53701-FV-00 ■ Replacement and reassembly Use the following procedure to replace the motor and reassemble the removed parts. Apply new grease to the harmonic. Wipe off the old grease from the harmonic, then apply new grease as described in Chapter 5 "2.2 Replacing the Y-axis harmonic drive""3.2 Replacing the Y-axis harmonic drive".
Page 112: Replacing The X-Axis Base Drive Assembly
For the bolt tightening torque in the base drive assembly replacement work, see the Table below. However, when tightening the mounting bolts for the base drive assembly, observe the tightening torque specified in each replacement procedure. Use only YAMAHA genuine bolts. Base drive assembly...
Page 113: Preparation
Preparation Replacement parts Part Name YAMAHA Part No. Part No. / Specs Q'ty Remarks Base drive assembly KFS-M2100-00 assembly O-ring KN4-M2143-00 S90(JIS) May deteriorate and must be replaced Base drive assembly mounting bolt 91312-03022 M3 × 22 Must be replaced...
Page 114: Removal
Removal Follow the steps below to remove the X-axis parts. Step 4-5 Remove the base cover Turn off the controller. Place a sign indicating the robot is being adjusted. Place a sign indicating the robot is being Bolt M4 x 10 adjusted, to keep others from operating the controller or operation panel.
Page 115: Replacement And Reassembly
Replacement and reassembly Step 1 Applying grease Apply grease to the base drive assembly. Flatly apply harmonic grease to the flex spline. Grease 19g Grease 19g Grease 19g Grease Grease Grease 53742-FV-00 Do not apply grease to this red surface. CAUTION Make sure that the grease is below the flex spline surface.
Page 116 Secure the ring. Step 3 Fixing the ring 53744-FV-01 Bolt M4×30 (Tools A) Ring Removal of temporary fixing bolt Step 4 Removal of temporary fixing bolt 53745-FV-00 Temporary fixing bolt M3×8...
Page 117 Secure qX-axis arm and base drive assembly. Use new fixing bolts. Apply 4BNo. 2 grease to at least 4 threads at the end. Tighten the bolts in the following tightening order. 1. Tighten all parts by hand using a wrench in the order of assembly tightening shown in the figure below. 2.
Page 118: Aging
Reattach the base cover. 53761-FV-00 Step 6 Attaching Base Rear Cover Bolt M4×10 Base rear cover Store the signal wire to the left back side of the X motor and the power wire to the right back side when Bolt M4×6 viewed from the base wiring side.
Page 119: Chapter 8 Replacing The Z-Axis Drive Unit
Chapter 8 Replacing the Z-axis drive unit Contents Replacing the Z-axis drive unit YK400XE Replacing the Z-axis motor Replacing the Z-axis belt Replacing the Z-axis ball screw Replacing the Z-axis brake Replacing the Z-axis drive unit YK510XE YK610XE YK710XE Replacing the Z-axis motor...
Page 121: Replacing The Z-Axis Drive Unit Yk400Xe
Replacing the Z-axis drive unit YK400XE WARNING Before starting the work, thoroughly read “1. Attaching, detaching, and replacing the cover” in Chapter 2. Replacement parts Part Name YAMAHA Part No. Part No. / Specs Q'ty Remarks Z axis motor KDS-M4881-01...
Page 122: Replacing The Z-Axis Motor
Remove the ground terminal mounting bolts and loosen the Z-axis motor installation plate mounting bolts. Step 5-6 Removing the ground terminal and loosening the motor installation plate mounting bolts Motor installation plate mounting bolt Z-axis motor (YAMAHA’s part No. KDS-M4881-01) Motor installation plate mounting bolt 53801-FV-00 WARNING When loosening the Z-axis motor installation plate, the belt comes off from the pulley and the Z-axis drops.
Page 123: Replacing The Z-Axis Belt
Perform the work from Step 1 to Step 7 stated in “1.1 Replacing the Z-axis motor” of this Chapter to remove the Z-axis motor. Remove the Z-axis belt (YAMAHA’s part No. KDS-M1754-00) from the Y-axis arm and replace it with a new one.
Page 124: Replacing The Z-Axis Ball Screw
Replacing the Z-axis ball screw Follow the steps below to replace the Z-axis ball screw. Remove the Y-axis arm cover. Loosen the Z-axis motor fixing plate mounting bolts. Remove the pulley. Step 1-3 Removing the Y-axis arm cover Y-axis arm upper cover Hex socket head bolt Pulley set screw Pulley...
Page 125: Replacing The Z-Axis Brake
Replacing the Z-axis brake Follow the steps below to replace the Z-axis brake. Perform the work from Step1 to Step7 stated in “1.1 Replacing the Z-axis motor” of this Chapter to remove the Z-axis motor. Remove the brake hub from the pulley. Step 2 Removing the brake hub Brake hub Brake hub installation set screw...
Page 126 Remove the brake unit installation mounting bolts and then the brake. Step 4 Removing the brake Motor installation plate Brake unit (4) (YAMAHA’s part No. KDS-M4890-00) Brake unit installation mounting bolts M3×30 53806-FK-01 Assemble a new brake in the reverse order of removal.
Page 127: Replacing The Z-Axis Drive Unit Yk510Xe Yk610Xe Yk710Xe
Replacing the Z-axis drive unit YK510XE YK610XE YK710XE WARNING Before starting the work, thoroughly read “1. Attaching, detaching, and replacing the cover” in Chapter 2. Replacement parts Part Name YAMAHA Part No. Part No. / Specs Q'ty Remarks Z axis motor KFS-M488E-00...
Page 128: Replacing The Z-Axis Motor
Step 5-6 Removing the ground terminal and loosening the motor installation plate mounting bolts Z-axis motor Motor installation plate mounting bolt Z-axis motor (YAMAHA’s part No. KFS-M4882-00) Motor installation plate mounting bolt 53820-FV-00 WARNING When loosening the Z-axis motor installation plate, the belt comes off from the pulley and the Z-axis drops.
Page 129: Replacing The Z-Axis Belt
Perform the work from Step 1 to Step 7 stated in “2.1 Replacing the Z-axis motor” of this Chapter to remove the Z-axis motor. Remove the Z-axis belt (YAMAHA’s part No. KDS-M1754-00) from the Y-axis arm and replace it with a new one.
Page 130: Replacing The Z-Axis Ball Screw
Replacing the Z-axis ball screw Follow the steps below to replace the Z-axis ball screw. Remove the Y-axis arm cover. Loosen the Z-axis motor fixing plate mounting bolts. Remove the pulley. Step 3 Pulley removal Set screw Set screw for pulley fixing for pulley fixing When setting the pulley, match the When setting the pulley, match the...
Page 131: Replacing The Z-Axis Brake
Assemble in the reverse order of Step 5 Removing the bearing removal. When assembling, it is necessary to adjust the belt tension and machine reference.. 53824-FV-01 2 supplied set screws 4 supplied M4 bolt 4 supplied M5 bolt Ball screw assembly Replacing the Z-axis brake Follow the steps below to replace the Z-axis brake.
Page 132 Motor installation plate Brake unit installation mounting bolts M3×25 Brake unit (4) (YAMAHA’s part No. KFS-M4892-00) 53826-FK-01 CAUTION When assembling, align with the stepped section (spigot) in the motor plate. Assemble a new brake in the reverse order of removal.
Page 133: Chapter 9 Replacing The R-Axis Drive Unit
Chapter 9 Replacing the R-axis drive unit Contents Replacing the R-axis drive unit YK400XE Replacing the R-axis motor Replacing the R-axis belt Replacing the R-axis ball spline Replacing the R-axis drive unit YK510XE YK610XE YK710XE 9-6 Replacing the R-axis motor...
Page 135: Replacing The R-Axis Drive Unit Yk400Xe
Replacing the R-axis drive unit YK400XE WARNING Before starting the work, thoroughly read “1. Attaching, detaching, and replacing the cover” in Chapter 2. Step 1 Serial confirmation The ball splines have two models depending on the manufacturing date of the robot. The old...
Page 136: Replacing The R-Axis Motor
Follow the steps below to replace the R-axis motor. Step 6 Removing the R-axis motor Turn off the controller. R-axis motor (1) (YAMAHA’s part No. KDS-M4881-01) Place a sign indicating the robot is being adjusted. Place a sign indicating the robot is being adjusted, to keep others from operating the controller or operation panel.
Page 137: Replacing The R-Axis Belt
Remove the hex socket head bolts to disassemble the ball spline holder and ball spline. 53910-FV-00 First stage belt (3) (YAMAHA’s part No. Remove the second stage belt. KDS-M1856-00) Make the adjustment. Y-axis arm Follow the work from Step9 stated in “1.1 Replacing the R-axis motor”...
Page 138: Replacing The R-Axis Ball Spline
KDS-M1840-01 Robots with some serial numbers have different ball spline model numbers. See “1.Replacing the R-axis drive unit YK400XE ” in this Chapter. Assemble a new ball spline in the reverse order of removal. When assembling the new ball spline, it is necessary to adjust the belt tension and machine reference.
Page 139: Replacing The R-Axis Drive Unit Yk510Xe Yk610Xe Yk710Xe
2. Replacing the R-axis drive unit YK510XE YK610XE YK710XE WARNING Before starting the work, thoroughly read “1. Attaching, detaching, and replacing the cover” in Chapter 2. Replacement parts Part Name YAMAHA Part No. Part No. / Specs Q'ty Remarks R axis motor...
Page 140: Replacing The R-Axis Motor
Removing the R-axis motor mounting bolt and loosen the R-axis Ground terminal motor installation plate mounting Each location is different. bolts. 53921-FV-01 R-axis motor R-axis motor (YAMAHA’s part No. (YAMAHA’s part No. R-axis motor installation KFS-M488F-00) KFS-M488F-00) plate mounting plate M5×12...
Page 141 Remove the R-axis motor mounting Step 7 bolts. Removing the R-axis motor mounting bolts 53922-FV-00 R-axis motor mounting bolt M5×10 Remove the pulley set screws. Remove the pulley and replace it with a new one. 53904-FK-00 Replace the motor with a new one and assemble this new pulley in the reverse order of removal.
Page 142: Replacing The R-Axis Belt
Replacing the R-axis belt Follow the steps below to replace the R-axis belt. Remove the R-axis motor. Perform the work from Step1 to Step7 stated in “2.1 Replacing the R-axis motor” of this Chapter Step 2 Removing the pulley assembly and first stage belt to remove the R-axis motor.
Page 143: Replacing The R-Axis Ball Spline
Replacing the R-axis ball spline Follow the steps below to replace the R-axis ball Step 1 spline. Removing the Z-axis stopper Remove the Z-axis stopper. 53925-FV-00 Z-axis stopper mounting bolt M5×16 Remove the bolt that secures the R-axis ball spline. Z-axis stopper Step 2 53926-FV-00...
Page 144 Step 4 Removing the R-axis ball spline unit Install the R-axis ball spline. 53929-FV-00 Assemble in the reverse order of removal. When assembling, belt tension adjustment and machine reference adjustment are required. bolts M4×6 bolts M5×4 9-10...
Page 145 Chapter 10 Robot cable replacement Contents Robot cable replacement 10-1...
Page 147 Chapter 5. WARNING Before starting the work, thoroughly read “1. Attaching, detaching, and replacing the cover” in Chapter 2. Replacement parts Part Name YAMAHA Part No. Part No. / Specs Q'ty Remarks Screw for round terminal 97602-04306 M4 ×...
Page 148 ■ Removal YK400XE Disassemble referring to the following procedure. Step 5-6 Disconnecting the robot cable Turn off the controller. Place a sign indicating the robot is Round terminal being adjusted. Screw Robot cable Place a sign indicating the robot is being adjusted, to keep others from operating the controller or operation panel.
Page 149 Secure the round terminal and connect the connector. NOTE Refer to the installation manual, Chapter 8 "1.3 Robot inner wiring diagram". Attach the cover. Step 3 Attaching the base rear cover YK400XE Round terminal Screw Robot cable Store the wires in the space in front of Store the wires in the space in front of the X motor.
Page 151: Chapter 11 Maintenance Parts
Chapter 11 Maintenance parts Contents Consumable parts 11-1 Basic specification 11-2...
Page 153: Consumable Parts
Consumable parts Consumable part Q'ty Remarks KDS-M4843-01 Machine harness YK400XE KFS-M4844-00 Machine harness YK510XE KFS-M4843-10 Machine harness YK610XE KFS-M4843-20 Machine harness YK710XE 11-1...
Page 154: Basic Specification
Basic specification YK400XE-4 YK510XE-10 YK610XE-10 YK710XE-10 225mm 235mm 335mm 435mm Arm length X-axis Rotation ±132° ±134° angle 175mm 275mm Arm length Axis Y-axis Rotation specifications ±150° ±152° angle 150mm 200mm Z-axis Stroke Rotation ±360° R-axis angle 200W 400W X-axis Y-axis...
Page 156 Addition of optional types; Brake release switch type and User wiring/tubing through spline type Ver. 1.31 Feb. 2021 Change of YAMAHA Part No. in Chapter 7 "1. Motor replacement" Ver. 1.32 July 2021 Chapter 5 ”2.2.3 Replacement and reassembly” Ver. 1.33 June 2022 Chapter 8 ”1.
Page 158 Robotics Operations 127 Toyooka, Kita-ku, Hamamatsu, Shizuoka, 433-8103, Japan https://global.yamaha-motor.com/business/robot/ YAMAHA MOTOR CO., LTD.

Yamaha YK510XE Maintenance Manual

Chapter 3 Periodic Inspection

Chapter 6 Replacing the Machine Harness

Chapter 7 Replacing the X-, Y-Axis Motor

Chapter 8 Replacing the Z-Axis Drive Unit

Chapter 9 Replacing the R-Axis Drive Unit

Chapter 11 Maintenance Parts

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