Yaskawa Motoman Alarm 4107 — Out of Range (ABSO Data)

Yaskawa · advanced · 40 min

Motoman alarm 4107 OUT OF RANGE (ABSO DATA) means the controller's stored absolute position no longer matches the encoder — usually an encoder battery, cable, or a robot moved with power off. Recover the absolute data carefully.

⚠️ Recovering absolute data can involve moving the robot and re-establishing its position reference. Work in a manual reduced-speed mode, keep the cell clear, and confirm the correct position before you accept new absolute data — a wrong reference makes the robot move to unexpected places.

What alarm 4107 means

On a Yaskawa Motoman controller (DX100 / DX200 / YRC1000), alarm 4107 OUT OF RANGE (ABSO DATA) means the absolute encoder position read at power-up is outside the allowed range compared with the absolute data stored in the controller. The controller keeps each axis's absolute position; when the value the encoder reports on startup doesn't agree with what was saved, it raises 4107 and will not run programs, because it can no longer trust where the robot is.

Common causes

1. Encoder battery failure — the batteries that retain absolute position data in the manipulator went flat or were disconnected, so the encoder lost its retained count.
2. Encoder / feedback cable disturbed — a disconnected, damaged, or reseated encoder cable between the manipulator and controller.
3. Robot moved while the controller was powered off — the axis physically moved beyond tolerance during maintenance or a power-off, so the encoder count no longer matches the stored position.
4. Encoder or PG (pulse generator) fault on the affected axis.

Step-by-step recovery

1. Identify the axis. Read the alarm detail on the teach pendant — 4107 identifies which axis (and group) is out of range. That's the axis whose absolute data must be recovered.
2. Fix the physical cause first. If the encoder battery is flat, replace it per the manipulator maintenance procedure; if a cable was loose or damaged, reseat/replace it. Do not attempt data recovery until the hardware cause is resolved, or the alarm will return.
3. Confirm the true robot position. Before re-establishing absolute data, verify where the robot actually is versus its known home/reference. Position confidence is essential — the recovery step tells the controller "this is where the axis is."
4. Recover the absolute data. Using the documented ABSO data / position recovery procedure for your controller (accessed through the teach pendant's maintenance/robot position screens under the appropriate security level), re-register the absolute data for the affected axis against the confirmed position. Follow the exact model procedure in the Motoman operator's/maintenance manual for your controller.
5. Verify and test. After recovery, jog the axis in a manual reduced-speed mode and confirm the pendant position readout matches reality across the range. Only then return to automatic operation.

When to escalate

If 4107 returns immediately after a correct recovery with a healthy battery and cable, suspect an encoder/PG hardware fault on that axis and involve Yaskawa service rather than repeatedly recovering data. Never run in automatic with an unverified position reference.