The pendant housing is more than just a plastic container; it is an engineered shield that maintains the IP54/IP64 ingress protection of your robot's HMI. In industrial environments, a hairline crack in a Fanuc iPendant back cover or a worn seal on a Yaskawa DX200 case can allow conductive metal dust and cutting fluids to reach the internal motherboards, leading to catastrophic system failure.
⚠️ Maintenance Alert: If your pendant has been dropped, do not simply tape the cracks. Vacuum-sealed cooling in many pendants relies on the structural integrity of the plastic shell to prevent overheating of the internal CPUs.
Hardware Repair Navigation
- 1. Structural Damage Diagnosis: When to Replace
- 2. Fanuc iPendant & Legacy Case Cross-Reference
- 3. Yaskawa DX/NX/YRC High-Impact Shells
- 4. ABB FlexPendant & KUKA SmartPad Housings
- 5. Technical Guide: Restoring IP Sealing Integrity
1. Structural Damage & Fault Correlation
Before ordering a shell, identify how the physical damage is impacting your robot's performance:
| Damage Location | Physical Symptom | Technical Risk / Correlated Fault |
|---|---|---|
| Bezel/Front Case | Cracks near screen corners | Loss of LCD pressure; Touchscreen drift or rainbow patterns. |
| Back Cover / Rear Shell | Missing screw bosses | Loose internal PCB; Intermittent communication errors (E-Stop). |
| Cable Entry Port | Enlarged/Deformed hole | Oil ingress; Short circuit on the main interface board. |
| Hand-strap Anchors | Snapped plastic loops | Insecure grip; High risk of a second, fatal impact drop. |
2. Detailed Housing & Shell Listings
2.1 ABB FlexPendant Structural Components
Technical Note: ABB IRC5 FlexPendants (DSQC 648 vs. DSQC 679) are externally similar but internally distinct. Standoff heights for the PCBs and joystick apertures are revision-specific.
- 3HAC028357-001 (DSQC679): Housing with integrated rubberized bumpers.
- 3HAC023195-001: Replacement plastic shell for mid-generation IRC5 units.
- 3HNM05345-1: Dedicated housing for legacy S4C+ (Monochrome/Early Color).
2.2 Fanuc iPendant Housing Components
Fanuc housings differ significantly between the R-J3iB (Gray) and R-30iB (Yellow/Black) generations. Note that internal mountings for PCB standoffs vary by suffix.
- A05B-2518-C304: Plastic Front Cover for Fanuc A05B-2518-C202#EMH
- A290-7213-X706: Fanuc Teach Pendant Back Cover Housing (A290-7213-X706)
- A05B-2255-C101: Replacement Plastic Case for Fanuc A05B-2255-C101 iPendant
2.3 Yaskawa Motoman Casing Spares
Yaskawa pendants (JZRCR series) are often sold with integrated membranes. Replacing the shell often requires transferring the internal EMS0702 board.
- DX200 Series: Plastic Cover with Membrane for Yaskawa DX200 Pendant
- NX100 Series: Yaskawa NX100 JZRCR-NPP01B-1 Front Plastic Cover
- XRC Series: Yaskawa XRC JZNC-XPP02B Shell & Membrane Kit
- DX100 Series: Yaskawa DX100 JZRCR-YPP01-1 Back & Front Housing
2.4 KUKA SmartPad & KCP Housing Index
Technical Note: KUKA KCP2 and SmartPad housings utilize high-density industrial plastics to resist welding spatter. For KRC4 SmartPads (00-168-334), the housing features dual-density rubberized grips. If these grips become sticky or peel, it often indicates chemical degradation, and a full shell replacement is required to maintain ergonomic safety.
- SmartPad KRC4 (00-168-334): KUKA 00-168-334 Replacement Shell - Direct replacement for KRC4 SmartPad 1 & 2.
- KCP2 (00-130-547): KUKA KRC2 KCP2 Front/Back Housing Kit - High-impact gray shell for Edition 2005.
- KCP1 (Standard): KUKA KCP1 69-000-399 Housing Spare - Legacy support for KRC1 controllers.
2.5 Panasonic & Kawasaki Specialized Shells
- Panasonic G3: Panasonic AURO1060 Teach Pendant Housing Shell
- Kawasaki: Replacement Casing for Kawasaki Robot Teach Pendants
3. Technical Guide: Restoring IP Sealing Integrity
Replacing the shell is the best time to perform preventative maintenance. Follow these 3 steps to ensure a factory-grade seal:
Step 1: Gasket Inspection
Clean the perimeter groove of the front housing. Even a single hair across the gasket can lead to moisture ingress during high-pressure washdowns.
Step 2: Screw Boss Integrity
Do not over-torque! Most robot pendant cases (like the A05B-2255-C101) use plastic-thread screws. Recommended torque is 0.4 - 0.6 Nm to avoid stripping.
Step 3: Component Transfer
Carefully move the E-Stop switch and Enable switch. Ensure the rubber boots (gaiters) are not pinched between the shell halves.
4. Casing Repair FAQ
Q: Can I use a DX200 shell on a DX100 pendant?
A: No. While they look similar, the internal mounting points for the communication boards and the screw patterns for the back cover are different. Always match the JZRCR or A05B prefix exactly.
Q: Does the housing include the screen protector?
A: Usually, no. The plastic shellis separate from the LCD screen protector (Overlay). We recommend purchasing a new membrane or screen film when replacing the housing for a like-new finish.
Q: My KUKA grip is "sticky." Do I need a new shell?
A: Yes. "Sticky" grips indicate chemical degradation of the dual-density rubber. This can lead to operator fatigue and compromised safetya full shell replacement is the standard corrective action.
5. Related Hardware Directories
- Teach Pendant Membrane & Keypad Index
- Robot Cable & High-Flex Connector Index
- Industrial Robot Bumper & Protective Guard Index