1axis Positioner Maintenance Manual (B-82545EN 02)

FANUC
1-Axis
SERVO
POSITIONER
MECHANICAL UNIT
MAINTENANCE MANUAL
B-82545EN/02
Before using the Robot, be sure to read the "FANUC Robot Safety Manual (B-80687EN)" and
understand the content.
This manual can be used with controllers labeled R-30iA or R-J3iC. If you have a controller
labeled R-J3iC, you should read R-30iA as R-J3iC throughout this manual.
No part of this manual may be reproduced in any form.

All specifications and designs are subject to change without notice.
The products in this manual are controlled based on Japans Foreign Exchange and
Foreign Trade Law. The export from Japan may be subject to an export license by the
government of Japan.
Further, re-export to another country may be subject to the license of the government of
the country from where the product is re-exported. Furthermore, the product may also be
controlled by re-export regulations of the United States government.
Should you wish to export or re-export these products, please contact FANUC for advice.
In this manual we have tried as much as possible to describe all the various matters.
However, we cannot describe all the matters which must not be done, or which cannot be
done, because there are so many possibilities.
Therefore, matters which are not especially described as possible in this manual should be
regarded as impossible.
B-82545EN/02
SAFETY PRECAUTIONS
SAFETY PRECAUTIONS
For the safety of the operator and the system, follow all safety
precautions when operating a robot and positioner and its peripheral
devices installed in a work cell.
s-1
SAFETY PRECAUTIONS
1.1
B-82545EN/02
OPERATOR SAFETY
Operator safety is the primary safety consideration. Because it is very
dangerous to enter the operating space of the robot during automatic
operation, adequate safety precautions must be observed.
The following lists the general safety precautions.
consideration must be made to ensure operator safety.
Careful
(1) Have the robot system operators attend the training courses held
by FANUC.
FANUC provides various training courses. Contact our sales office for details.
(2) Even when the robot and positioner are stationary, it is possible
that the robot is still ready to move state and is waiting for a signal.
In this state, the robot is regarded as still in motion. To ensure
operator safety, provide the system with an alarm to indicate
visually or aurally that the robot is in motion.
(3) Install a safety fence with a gate so that no operator can enter the
work area without passing through the gate. Equip the gate with
an interlock that stops the robot when the gate is opened.
At this time, the positioner as well as the robot must be located
within the fence completely.
The controller is designed to receive this interlock signal. When the gate is
opened and this signal received, the controller stops the robot in an
emergency. For connection, see Fig.1.1 (a).
(4) Provide the peripheral devices with appropriate grounding (Class

1, Class 2, or Class 3).
(5) Try to install the peripheral devices outside the work area.
(6) Draw an outline on the floor, clearly indicating the range of the
robot motion, including the tools such as a hand.
(7) Install a mat switch or photoelectric switch on the floor with an
interlock to a visual or aural alarm that stops the robot and
positioner when an operator enters the work area.
(8) If necessary, install a safety lock so that no one except the operator
in charge can turn on the power of the robot.
The circuit breaker installed in the controller is designed to disable anyone from
turning it on when it is locked with a padlock.
s-2
SAFETY PRECAUTIONS
B-82545EN/02
(9) When adjusting each peripheral device independently, be sure to

turn off the power of the robot.
Note) Terminals FENCE1 and FENCE2

are on the PC board in the
operator's panel.
Panel board
For R-J3iB CONTROLLER

Note) Terminals EAS1,
11 and EAS2, 21 are on the
EAS1,EAS11,
EAS2,EAS21
PC board on the operators panel.
R-J3iC
Refer to the R-30iA CONTROLLER
MAINTENANCE MANUAL.
Panel
board
EAS1
EAS11
EAS2
EAS21
For R-30iA CONTROLLER

Fig. 1.1 (a) Safety fence and gate
s-3
SAFETY PRECAUTIONS
1.1.1
B-82545EN/02
Operator Safety
The operator is a person who operates the robot system. In this sense, a
worker who operates the teach pendant is also an operator. However,
this section does not apply to teach pendant operators.
(1) When the robot and positioner do not need to operate, turn off the
power of the robot controller or press the emergency stop button
before work.
(2) The operator must operate the robot system outside the work area
of the robot or positioner.
(3) Install a safety fence with a safety gate to prevent any worker other
than the operator from entering the work area unexpectedly and
also to prevent the worker from entering a dangerous area.
(4) Install an EMERGENCY STOP button within the operator's
reach.
The robot controller is designed to be connected to an external
EMERGENCY STOP button. With this connection, the controller stops the
robot operation when the external EMERGENCY STOP button is pressed.
See the diagram below for connection.
External
EMERGENCY
STOP button
Panel board
Note) Connect between EMGIN1 and EMGIN 2.

Terminals EMGIN1 and EMGIN2 are on the
Panel board.
Fig.1.1.1 (a) Connection Diagram for External Emergency Stop Switch

(For R-J3iB CONTROLLER)
External
EMERGENCY STOP button
Panel
board
EES1
EES11
EES2
EES21
Note) EES1-EES11
Connect between EES1 EES2-EES21
and EES11 and between EES2 and EES21.
EES1,EES11EES2,EES21
Terminals EES1, EES11, EES2 and EES21 are on the Panel board.
Refer to R-30iA CONTROLLER MAINTENANCE MANUAL.
R-J3iC
Fig.1.1.1 (b) Connection Diagram for External Emergency Stop Switch

(For R-30iA CONTROLLER)
s-4
B-82545EN/02
1.1.2
SAFETY PRECAUTIONS
Safety of the Teach Pendant Operator

When teaching the robot and positioner, the teach pendant operator
needs to enter the work area of the robot or positioner. The teach
pendant operator must give special consideration to safety.
(1) When it is not necessary to enter the work area of the robot or
positioner, perform work outside the work areas.
(2) Before teaching work, check that the robot, positioner, and
peripheral device are not placed in a dangerous or abnormal state.
(3) When it is necessary to enter the work area of the robot or
positioner for teaching work, check the place and state of safety
apparatus such as the emergency stop button and dead man's
switch of the teach pendant.
The teach pendant supplied by FANUC is provided with a teach pendant
enable switch and a deadman's switch in addition to the EMERGENCY STOP
button. The functions of each switch are as follows.
EMERGENCY STOP button
: Pressing this button stops the robot in an
emergency, irrespective to the condition
of the teach pendant enable switch.
Deadman's switch
: The function depends on the state of the
teach pendant enable switch.
When the enable switch is on - Releasing the finger from the dead man's
switch stops the robot in an emergency.
When the enable switch is off-The deadman's switch is ineffective
NOTE
The deadman's switch is provided so that the robot
operation can be stopped simply by releasing finger
from the teach pendant in case of emergency.
s-5
SAFETY PRECAUTIONS
B-82545EN/02
(4) The teach pendant operator needs to exercise special caution to

prevent other people from entering the work area of the robot or
positioner.
NOTE
In addition to the above, the teach pendant enable
switch and the deadman's switch also have the
following function.By pressing the deadman's switch
while the enable switch is on, the emergency stop
factor (normally the safety gate) connected to the
controller is invalidated. In this case, it is possible for
an operator to enter the fence during teach operation
without pressing the EMERGENCY STOP button. In
other words, the system understands that the
combined operations of pressing the teach pendant
enable switch and pressing the deadman's switch
indicates the start of teaching.
The teach pendant operator should be well aware
that the safety gate is not functional under this
condition and bear full responsibility to ensure that no
one enters the fence during teaching.
(5) When entering the work area of the robot or positioner, the teach
pendant operator always needs to enable the teach pendant. In
particular, when the teach pendant enable switch is disabled, the
teach pendant operator needs to exercise caution to prevent the
robot from being started by an operator's panel other than the teach
pendant.
The teach pendant, operator panel, and peripheral device interface send
each robot start signal. However the validity of each signal changes as
follows depending on the ON/OFF switch on the Teach pendant and the
three modes switch on the Operators panel and Remote condition on the
software.
Teach
pendant
Operators
panel
Peripheral
devices
On
Software
remote
condition
Independent
Allowed to start
Not allowed
Not allowed
Off
Off
Remote OFF
Remote ON
Not allowed
Not allowed
Allowed to start
Not allowed
Not allowed
Allowed to start
Operator s panel Teach pendant

Three modes switch ON/OFF switch
T1/T2
AUTO (Except RIA)
AUTO
AUTO
NOTE
When starting the system using the teach pendant in
the RIA specification, the three modes switch should
be T1/T2.
s-6
B-82545EN/02
SAFETY PRECAUTIONS
(6) To start the robot by the operator's panel, confirm that there is no
people near the robot or positioner and that there is no
abnormality.
(7) When a program is completed, be sure to carry out a test run
according to the procedure below.
(a) Run the program for at least one operation cycle in the single
step mode at low speed.
(b) Run the program for at least one operation cycle in the
continuous operation mode at low speed.
(c) Run the program for one operation cycle in the continuous
operation mode at the intermediate speed and check that no
abnormalities occur due to a delay in timing.
(d) Run the program for one operation cycle in the continuous
operation mode at the normal operating speed and check that
the system operates automatically without trouble.
(e) After checking the completeness of the program through the
test run above, execute it in the automatic operation mode.
(8) While operating the system in the automatic operation mode, the
teach pendant operator should leave the robot work area.
s-7
SAFETY PRECAUTIONS
1.1.3
B-82545EN/02
Safety During Maintenance

For the safety of maintenance personnel, pay utmost attention to the
following.
(1) Except when specifically necessary, turn off the power of the
controller while carrying out maintenance. Lock the power switch,
if necessary, so that no other person can turn it on.
(2) When disconnecting the pneumatic system, be sure to reduce the
supply pressure.
(3) Before the start of teaching, check that the robot and positioner
and its peripheral devices are all in the normal operating condition.
(4) When performing maintenance within the work area of the robot
or positioner with the power on, maintenance personnel needs to
indicate that maintenance is in progress and exercise caution to
prevent anyone from starting the robot accidentally.
(5) Do not operate the robot in the automatic mode while anybody is
in the robot work area.
(6) When it is necessary to maintain the robot alongside a wall or
instrument, or when multiple workers are working nearby, make
certain that their escape path is not obstructed.
(7) When a tool is mounted on the robot, or when any moving device
other than the robot is installed, such as belt conveyor, pay careful
attention to its motion.
(8) If necessary, have a worker who is familiar with the robot system
stand beside the operator's panel and observe the work being
performed. If any danger arises, the worker should be ready to
press the EMERGENCY STOP button at any time.
(9) When replacing or reinstalling components, take care to prevent
foreign matter from entering the system.
(10) When handling each unit or printed circuit board in the controller
during inspection, turn off the power of the controller and also turn
off the circuit breaker to protect against electric shock.
(11) When replacing parts, be sure to use those specified by FANUC.
In particular, never use fuses or other parts of non-specified
ratings. They may cause a fire or result in damage to the
components in the controller.
s-8
B-82545EN/02
SAFETY PRECAUTIONS
1.2
SAFETY OF THE TOOLS AND PERIPHERAL DEVICES
1.2.1
Precautions in Programming
(1) Use a limit switch or other sensor to detect a dangerous condition
and, if necessary, design the program to stop the robot when the
sensor signal is received.
(2) Design the program to stop the robot when an abnormal condition
occurs in any other robots or peripheral devices, even though the
robot itself is normal.
(3) In a system in which the robot or positioner operates in sync with
peripheral devices, exercise caution against mutual interference.
(4) The interlock between the robot and peripheral devices is
necessary to check the states of all devices in the system using the
robot or positioner, so that the robot and positioner can be stopped
as needed.
1.2.2
Precautions for Mechanism

(1) Keep the component cells of the robot system clean, and operate
the robot in an environment free of grease, water, and dust.
(2) Employ a limit switch or mechanical stopper to limit the robot
motion so that the robot and the positioner do not come into
contact with its peripheral devices or tools.
s-9
SAFETY PRECAUTIONS
1.3
SAFETY OF THE ROBOT MECHANISM
1.3.1
Precautions in Operation
B-82545EN/02
(1) When operating the robot or positioner in the jog mode, keep an
appropriate speed so that the operator can take a responsive action
in any eventuality.
(2) Before pressing the jog key, be sure to understand in advance how
the robot or positioner operates by the key.
1.3.2
(1) When the work areas of robots overlap, make certain that the
motions of the robots do not interfere with each other.
(2) Be sure to specify a certain work origin in a motion program for
the robot or positioner and make sure that the motion program
starts from and ends at the origin. This makes it clear at a glance
whether the robot has completed work.
1.3.3
Precautions for Mechanisms

(1) Clean the inside of the work area of the robot or positioner to
eliminate the effect of oil, water, and dust.
s-10
B-82545EN/02
SAFETY PRECAUTIONS
1.4
SAFETY OF THE END EFFECTOR
1.4.1
(1) To control the pneumatic, hydraulic and electric actuators,
carefully consider the necessary time delay after issuing each
control command up to actual motion and ensure safe control.
(2) Provide the end effector with a limit switch, and control the robot
system by monitoring the state of the end effector.
1.5
SAFETY IN MAINTENANCE
(1) Never enter the work area of the robot or positioner during
operation. When entering the work area of the robot or positioner
for inspection or maintenance, turn off the power.
(2) If it is necessary to enter the robot work area with the power turned
on, first press the EMERGENCY STOP button on the operator's
box.
(3) When replacing or reinstalling components, take care to prevent
foreign matter from entering the system. When replacing the parts
in the pneumatic system, be sure to reduce the pressure in the
piping to zero by turning the pressure control on the air regulator.
(4) When handling each unit or printed circuit board in the controller
during inspection, turn off the power of the controller and turn off
the circuit breaker to protect against electric shock.
(5) When replacing parts, be sure to use those specified by FANUC.
In particular, never use fuses or other parts of non-specified
ratings. They may cause a fire or result in damage to the
components in the controller.
(6) Before restarting the robot, be sure to check that no one is in the
robot work area and that the robot and its peripheral devices are all
in the normal operating state.
s-11
SAFETY PRECAUTIONS
1.6
B-82545EN/02
WARNING LABEL
(1) Greasing and degreasing label
Fig. 1.6 (a) Greasing and Degreasing Label
Description
When greasing and degreasing, observe the instructions indicated on
this label.
1)
2)
3)
When greasing, be sure to keep the grease outlet open.

Use a manual pump to grease.
Be sure to use a specified grease.
CAUTION
See section I 3.1 GREASE REPLACEMENT for
explanations about specified greases, the amount of
grease to be supplied, and the locations of grease
and degrease outlets for individual models.
s-12
B-82545EN/02
SAFETY PRECAUTIONS
(2) Step-on prohibitive label
Fig. 1.6 (b) Step-on Prohibitive Label
Description
Do not step on or climb the robot or controller as it may adversely affect
the robot and positioner and you may get hurt if you lose your footing as
well.
(3) High-temperature warning label
Fig. 1.6 (c) High-temperature warning label
Description
Be cautious about a section where this label is affixed, as the section
generates
heat. If you have to inevitably touch such a section when it is hot, use a
protective provision such as heat-resistant gloves.
s-13
SAFETY PRECAUTIONS
B-82545EN/02
(4) Transportation label
>200kg
>200kg
>150kg
Fig. 1.6 (d) Transportation label (300kg load capacity type)
Description
When transporting the positioner, observe the instruction on the
transportation label.
The above label includes the following
instructions.
1)
Using a crane
Use a crane having a load capacity of 1960 N (200 kg) or

greater.
Use one sling having a withstand load of 1960 N (200 kgf) or
greater.
Use two M10 eyebolts with a withstand load of 1470 N (150
kgf) or greater. (The eyebolts are attached during shipment.)
s-14
SAFETY PRECAUTIONS
B-82545EN/02
>600kg
>600kg
>450kg
Fig. 1.6 (e) Transportation label (1000kg load capacity type)
Description
When transporting the positioner, observe the instruction on the
transportation label.
The above label includes the following
instructions.
1)
Using a crane
Use a crane having a load capacity of 5880 N (600 kg) or

greater.
Use one sling having a withstand load of 5880 N (600 kgf) or
greater.
Use two M16 eyebolts with a withstand load of 4410 N (450
kgf) or greater. (The eyebolts are attached during shipment.)
WARNING
When a tool or accessory is attached, the center of
gravity of the positioner deviates and the positioner
may become unstable during transportation. If it
becomes unstable, remove the toll or the like and set
the positioner in the transportation posture. This
returns the center of gravity to the normal position. It
is recommended that tools and accessories be
transported separately from the positioner.
To transport the positioner using transportation
equipments, check the fixing bolts of the
transportation equipments in advance and tighten the
loosened bolts.
s-15
PREFACE
B-82545EN/02
PREFACE
This manual describes maintenance and connection work for the servo
positioner. Before replacing parts, check the specifications of the
mechanical unit.
Model name
Mechanical unit specification No.
1-Axis Servo Positioner (300kg)

1-Axis Servo Positioner (1000kg)
A05B-1220-J101
A05B-1220-J102
(1)
(2)
TYPE
NO.
DATE
(3)
(4)
WEIGHT
(5)
OSHINO-MURA.
YAMANASHI PREF.JAPAN
No.
CONTENTS
LETTERS
(1)
MODEL
1-Axis Servo Positioner
(300kg)
1-Axis Servo Positioner
(1000kg)
(2)
TYPE
A05B-1220-J101
A05B-1220-J102
p-1
(3)
No.
(4)
DATE
PRINT
PRODUCTION
PRINT
YEAR AND
SERIAL NO.
MONTH
(5)
WEIGHT
85 kg
280kg
PREFACE
B-82545EN/02
Specification
Item
Specifications
Motion range
Maximum operation
speed
Max. load capacity
Allowable load
moment
Allowable bending
moment
Allowable load inertia
Drive method
Weight
Follower unit (option)
weight
Installation
environment
740 (-370 to +370) 12.9 rad (-6.45 rad to +6.45 rad)

Continuous rotation is available.
160/sec 2.79 rad/sec
120/sec 2.09 rad/sec
300 kg
.
36 kgf m 353 N . m
250 kgf . m
2450 N . m
1000 kg
.
160 kgf m 1,568 N . m
2100 kgf . m
20,580 N . m
2,350 kgf . cm . s2 240 kg . m2

4,700 kgf . cm . s2 460 kg . m2
Electric servo drive by AC servo motor
About 85 kg
About 280kg
About 40 kg
Ambient temperature :
Ambient humidity
:
:
Vibration
0 - 45C
Normally: 75%RH or less
Short time 95%RH or less
(within 1 month)
(No dew or frost allowed)
0.5G (4.9m/s2) or less
* A follower unit (A05B-1220-J151) is available as an option for

300kg load capacity type.
Dust-proof/drip performance
Normal specification
MECHANICAL UNIT
IP54
CAUTION
Definition of IP 54
5=Dust-tight
4=Protection from water immersion
Performance of resistant chemicals and resistant solvents
(1) The positioner (including severe dust/liquid protection model)
cannot be used with the following liquids because there is fear that
rubber parts (packing, oil seal, O ring etc.) will corrode.
(a) Organic solvents
(b) Coolant including chlorine / gasoline
(c) Aminergic detergent
(d) Acid, alkali and liquid causing rust
(e) Other liquids or solutions, that will harm NBR
(2) When the positioner work in the environment, using water or
liquid, complete draining of base must be done. Incomplete
draining of base will make the positioner break down.
p-2
PREFACE
B-82545EN/02
RELATED MANUALS
Safety handbook
For the FANUC Robot series, the following manuals are

available:
B-80687EN
All persons who use the FANUC Robot and system

designer must read and understand thoroughly this
handbook
R-J3iB Mate
Setup and Operations
manual
controller
LR ARC TOOL
B-82094EN
LR HANDLING TOOL
B-81524EN
Maintenance manual
B-81525EN
B-81525EN-1
(European specification)
R-J3iB controller

manual
SPOT TOOL
B-81464EN-1
HANDLING TOOL
B-81464EN-2
ARC TOOL
B-81464EN-3
Maintenance manual
B-81465EN
B-81465EN-1
R-30iA controller
Robot mechanical
unit

manual
SPOT TOOL+
B-82594EN-1
HANDLING TOOL
B-82594EN-2
ARC TOOL
B-82594EN-3
Maintenance manual
B-82595EN
Intended readers :
All persons who use FANUC Robot, system designer
Topics :
Safety items for robot system design, operation, maintenance
Intended readers :
Operator, programmer, maintenance person, system
designer
Topics :
Robot functions, operations, programming, setup, interfaces,
alarms
Use :
Robot operation, teaching, system design
Intended readers :
Maintenance person, system designer
Topics :
Installation, connection to peripheral equipment, maintenance
Use :
Installation, start-up, connection, maintenance
Intended readers :
designer
Topics :
alarms
Use :
Intended readers :
Topics :
Use :
Intended readers :
designer
Topics :
alarms
Use :
Intended readers :
Topics :
Use :
B-82595EN-1
(For Europe)
B-82595EN-2
(RIA)
For the robot mechanical unit, refer to the manual of each robot.
p-3
TABLE OF CONTENTS
B-82545EN/02
TABLE OF CONTENTS
SAFETY PRECAUTIONS............................................................................s-1
PREFACE ....................................................................................................p-1
I
MAINTENANCE
CONFIGURATION .................................................................................. 3
PREVENTIVE MAINTENANCE............................................................... 5
2.1
2.2
2.3
2.4
2.5
PERIODIC MAINTENANCE .................................................................. 11

3.1
3.2
3.3
GENERAL ................................................................................................... 18
PROBLEMS AND CAUSES......................................................................... 19
BACKLASH MEASUREMENT..................................................................... 26
COMPONENT REPLACEMENT AND ADJUSTMENT ITEMS .................... 28
ADJUSTMENTS.................................................................................... 29
5.1
5.2
GREASE REPLACEMENT .......................................................................... 12

PROCEDURE FOR RELEASING THE GREASE RESIDUAL PRESSURE 14
BATTERY REPLACEMENT ........................................................................ 15
TROUBLESHOOTING .......................................................................... 17
4.1
4.2
4.3
4.4
DAILY INSPECTION ..................................................................................... 6

QUARTERLY INSPECTION .......................................................................... 8
ONE-AND HALF-YEAR PERIODIC INSPECTION (5,760 hours).................. 8
THREE-YEAR PERIODIC INSPECTION (11,520 hours) .............................. 8
MAINTENANCE TOOLS ............................................................................... 9
REFERENCE POSITION AND MOVING RANGE....................................... 30

MASTERING ............................................................................................... 32
5.2.1
Resetting Alarms and Preparing for Mastering ......................................................33
5.2.2
Fixture position master...........................................................................................34
5.2.3
Zero Position Mastering .........................................................................................41
5.2.4
Quick Mastering .....................................................................................................44
5.2.5
Mastering Data Entry .............................................................................................45
5.2.6
Mastering Data Entry Method ................................................................................46
5.2.7
Confirming Mastering ............................................................................................48
COMPONENT REPLACEMENT AND ADJUSTMENTS....................... 49

6.1
REPLACING THE MOTOR ......................................................................... 50

c-1
TABLE OF CONTENTS
6.2
6.3
II
POSITIONER OUTLINE DRAWING ..................................................... 65

OUTLINE DRAWING AND OPERATION AREA DIAGRAM ........................ 66
MOUNTING DEVICES ON THE POSITIONER ..................................... 68

2.1
REPLACING CABLES................................................................................. 61
CONNECTION
1.1
WIRING DIAGRAMS ................................................................................... 58

CABLING (WHEN THE HARTING CONNECTOR OPTION IS SELECTED)59
CABLE REPLACEMENT ...................................................................... 60

8.1
REPLACING THE REDUCER ..................................................................... 53

SEALANT APPLICATION............................................................................ 55
PIPING AND WIRING ........................................................................... 57

7.1
7.2
B-82545EN/02
POSITIONER LOAD CONDITION............................................................... 69
TRANSPORTATION AND INSTALLATION ......................................... 71

3.1
3.2
3.3
3.4
3.5
3.6
TRANSPORTATION.................................................................................... 72
STORING THE POSITIONER ..................................................................... 74
INSTALLATION ........................................................................................... 75
MAINTENANCE CLEARANCE.................................................................... 80
ASSEMBLING THE POSITIONER FOR INSTALLATION ........................... 82
INSTALLATION CONDITIONS.................................................................... 83
APPENDIX
A
SPARE PARTS LISTS .......................................................................... 87
CONNECTION DIAGRAMS .................................................................. 89
PERIODIC INSPECTION TABLE.......................................................... 94
MOUNTING BOLT TORQUE LIST ....................................................... 96
c-2
I. MAINTENANCE
B-82545EN/02
1.CONFIGURATION
MAINTENANCE
CONFIGURATION
Fig. 1 shows the configuration of the mechanical unit.
The axis drive mechanism is configured in such a way that the flange
base is rotated by reducing the rotation speed of an AC servo motor
with a reducer.
The flange base is supported on the base through the reducer.
Flange
Reducer
Base
Motor
Fig. 1 Mechanical unit configuration
-3-
1.CONFIGURATION
MAINTENANCE
B-82545EN/02
SPECIFICATIONS OF THE MAJOR MECHANICAL UNIT COMPONENTS

Table 1 (a) Motor
Specification
Name
iS8/4000
A06B-0235-B605#S000
iS22/4000
A06B-0265-B605#S000
Table 1 (b) Reducer
Specification
Weight
A97L-0218-0805#37
A97L-0218-0819
19.5 kg
91kg
Table 1(c) Gear

Specification
Name
A290-7216-X212
A290-7220-X111
-4-
Center gear
Input gear
Load capacity
300kg
1000kg
Load capacity
300kg
1000kg
Load capacity
300kg
300kg
B-82545EN/02
MAINTENANCE
2.PREVENTIVE MAINTENANCE
PREVENTIVE MAINTENANCE
Daily inspection, periodic inspection, and periodic maintenance can
keep the performance of the positioner stable for a long period of time.
NOTE
The annual operating time of the 1-axis servo
positioner is assumed to be 3840 hours.
When using the positioner beyond this annual
operating time, correct the maintenance frequency
in this chapter, which is determined on assumption
that the positioner is used for 3860 hours per year,
and perform maintenance as appropriate.
-5-
2.1
MAINTENANCE
B-82545EN/02
DAILY INSPECTION
Clean and maintain each robot component during everyday system
operations. At the same time, check the components to see if there is a
crack or break in them. Also check and maintain the following items as
required.
a)
Before automatic operation
No.
Inspection item
Pneumatic
pressure check
For
machines
with a
three-piece
pneumatic
option
Check on the
amount of oil
mist
Check on the
amount of oil
Check for
leakage from the
piping
5
6
Whether cables are abnormal

Mechanical unit
Battery voltage check
Whether there is any abnormal

vibration, noise, or heat
generation in motors
Whether there is a change to
positioning precision
-6-
Inspection procedure
Make a pneumatic pressure check,
using the three-piece pneumatic
option shown in Fig. 2.1.
If the measured pneumatic
pressure does not fall in the range
between 0.5 and 0.7 MPa (5 and 7
kg/cm2), make adjustments, using
the regulator pressure setting
handle.
Put the pneumatic pressure system
in operation and check the amount
of oil dripping. If the measured
amount of oil dripping does not
meet the rating (one drop/10 to 20
seconds), make adjustments, using
the oil adjustment knob. The oiler
becomes empty after 10 to 20 days
of normal operation.
Check to see if the amount of oil in
the three-piece option is within the
rated level shown in Fig. 2.1.
Check to see if a joint or hose leaks.
If you find a problem, tighten the
joint or replace any defective
component.
See Chapter 8.
Make sure that when the power is
turned on, the BLAL alarm has not
been raised. If the BLAL alarm has
been raised, replace the battery as
directed in Section 3.4.
Check that each axis is running
smoothly.
Check to see if there is any
displacement from the previous
position and there are variations in
the stop position.
MAINTENANCE
B-82545EN/02
No.
Inspection item
Reliable operation of peripheral

equipment
10
Check on the operation of the

brake.
Check to see if the machine

operates exactly according to
directions from the robot and
peripheral equipment.
See Section 4.2.
Fig. 2.1 Three-piece pneumatic option
b)
After automatic operation

Once you are finished with automatic operation, bring the
positioner to its reference position, and turn it off.
No.
1
Inspection item
Component cleaning
and inspection
-7-
Clean and maintain each component. At the
same time, check the components to see if
there is a crack or break in them.
2.2
MAINTENANCE
B-82545EN/02
QUARTERLY INSPECTION
Inspect the following items at regular intervals of about three months.
Increase the locations and the frequency of inspection if necessary (or
960 hours operating).
No.
2.3
Inspection item
Loose connector
Loose bolt
Debris removal
Check that the motor connectors or other
connectors are not loose.
Check that the cover retaining bolts or
external bolts are not loose. In particular,
check the following three points.
1 axis positioner, Follower unit base fixing
bolts
Bolts fixing jigs to the flange surface
motor cover retaining bolts
Remove any spatter, debris, and dust from
the mechanical unit.
ONE-AND HALF-YEAR PERIODIC INSPECTION

(5,760 hours)
Perform the following inspection/maintenance item at regular intervals
of about one year and half (or 5,760 hours operating).
No.
1
2.4
Inspection item
Battery replacement
Replace the battery in the mechanical
unit. (See Section 3.3.)
THREE-YEAR PERIODIC INSPECTION (11,520 hours)

Perform the following inspection/maintenauce item at regular intervals
of three year.
No.
1
Inspection item
Grease replacement
-8-
See Section 3.1.
MAINTENANCE
B-82545EN/02
2.5
MAINTENANCE TOOLS
You should have the following instruments and tools ready for
maintenance.
a)
Measuring instruments
Instrument
Condition
Dial gauge
1/100mm
Calipers
150mm
b)
Use
For positioning precision and
backlash measurement
Tools
Phillips screwdrivers (large, medium, and small sizes)
Flat-blade screwdrivers (large, medium, and small sizes)
Box wrenches
(M3 to M6)
Allen wrenches
(M3 to M20)
Torque wrench
See Table 2.6.
Long T wrenches
(M5, M6 and M8)
Adjustable wrenches (medium and small sizes)
Pliers
Long-nose pliers
Cutting pliers
Both-ended wrench
Grease gun
C-ring pliers
Flashlight
Seal tape
Loctite No. 242, 262, 675
Sling
Gear puller
NOTE
Prepare torque wrenches that enable the torque
values indicated in Table 2.5 to be set.
NOTE
When applying LOCTITE to the important bolt
tightening points, make sure that it is applied to the
entire longitudinal portion in the engaging section of
the female threads. If it is applied to the male
threads, the bolts may be loosened because
sufficient effects cannot be obtained. Remove the
dust within the bolts and taps and wipe oil off the
engaging section. Make sure that there is no
solvent in the taps.
-9-
MAINTENANCE
B-82545EN/02
Table 2.5
Bolt size
M3
M4
M5
M6
M8
M10
M12
M14
M16
Torque setting value

1.3 Nm (13 kgfcm)
4 Nm (41 kgfcm)
9 Nm (92 kgfcm)
15.6 Nm (159 kgfcm)
37.2 Nm (380 kgfcm)
73.5 Nm (750 kgfcm)
128.4 Nm (1310 kgfcm)
204.8 Nm (2090 kgfcm)
318.5 Nm (3121 kgfcm)
- 10 -
B-82545EN/02
MAINTENANCE
3.PERIODIC MAINTENANCE
PERIODIC MAINTENANCE
- 11 -
3.1
MAINTENANCE
B-82545EN/02
GREASE REPLACEMENT
The grease for the reducers needs to be replaced every three years or
11,520 hours in the procedure shown below. For greasing points, see
Figs. 3.1 (a) and (b).
<1> Remove the seal bolts and plugs of the grease outlets shown in
Figs. 3.1(a) and (b).
<2> Attach the grease nipple supplied with the positioner.
<3> Apply the grease specified in Table 3.1(a) and (b) until the old
grease is replaced and the new grease is output from the grease
outlets. Use grease outlet 1 shown in Figs. 3.1 (a) and (b). Only
when grease outlet 1 cannot be used due to the installation state of
the jig, use grease outlet 2. At this time, confirm that the same
amount of the old grease as that of applied grease has been output
to prevent the grease bath from overflowing.
<4> After applying grease, release the residual pressure in the grease
bath as instructed by the procedure in Section 3.2.
CAUTION
When reusing a grease nipple once used, wind
sealing tape around the screw.
Table 3.1 (a) Grease to be replaced at regular intervals of three years
(11,520 hours) (300kg load capacity)
Specified grease
Amount of grease
to be applied
Kyodo Yushi
Reducer VIGOGREASE RE0
About 980 ml
(Specification:
Gun tip
pressure
Positioner
posture when
greased
0.1 MPa or less Grease outlet 1

(NOTE)
A98L-0040-0174)
is used : 0
Grease outlet 2
is used : free
NOTE When using a hand pump, apply grease approximately once per
two seconds.
Table 3.1 (b) Grease to be replaced at regular intervals of three years
(11,520 hours) (1000kg load capacity)
Specified grease
Amount of grease
to be applied
Kyodo Yushi
Reducer VIGOGREASE RE0
About 5500 ml
Gun tip
pressure
0.15 MPa or
(Specification:
less
A98L-0040-0174)
(NOTE)
Positioner
posture when
greased
Grease outlet 1
is used : 0
Grease outlet 2
is used : free
NOTE When using a hand pump, apply grease approximately twice per
three seconds.
- 12 -
B-82545EN/02
MAINTENANCE
Seal
bolt for grease outlet 2
2
Seal bolt
for grease
outlet 1
1
Plug
for grease inlet
Fig. 3.1 (a) Grease inlet and outlet ( 300kg load capacity)
Seal
bolt for grease outlet 2
2
Seal bolt1
for grease
outlet 1
Plug
for grease inlet
Fig. 3.1 (b) Grease inlet and outlet ( 1000kg load capacity)
- 13 -
MAINTENANCE
B-82545EN/02
CAUTION
If you grease incorrectly, the pressure in the grease
bath will increase, leading to a broken seal, which will
eventually cause grease leakage or malfunction.
When greasing, be sure to follow the cautions stated
below.
1 Before starting greasing, open the grease outlets
(remove bolts and the like from the grease outlets).
2 Using a manual greasing pump, grease gently and
slowly.
3 Avoid using a pneumatic pump driven from a factory
pneumatic line as much as possible.
Even when using a of Table 3.1 (a) and (b) less
during application of grease.
4 Be sure to use the specified grease. Otherwise,
damage to reducers or a similar abnormality may
occur.
5 After applying grease, release the residual pressure
within the grease bath as described in the
procedure in Section 3.2.
6 Wipe off any grease from the floor and positioner
completely, so no one will slip on it.
3.2
PROCEDURE FOR RELEASING THE GREASE RESIDUAL

PRESSURE
After applying grease, to release residual pressure from the grease bath,
perform a repetitive operation with a motion angle of at least 60 degrees
and OVR100% for 10 minutes or more while leaving the grease inlets
and outlets open.
Under the grease inlets and outlets, attach bags for collecting grease so
that grease does not spatter when it comes out of the inlets or outlets.
If the above operation cannot be performed due to the environment of
the positioner, prolong the operating time so that an equivalent
operation can be performed. (If only a motion angle of 30 degrees can
be set, perform an operation for 20 minutes or more.) After completion
of the operation, attach the plugs and seal bolts to the grease inlets and
outlets. When reusing the plugs and seal bolts, be sure to seal them with
seal tape.
- 14 -
MAINTENANCE
B-82545EN/02
3.3
BATTERY REPLACEMENT
A backup battery is used to keep the reference-position data for the
positioner.
The battery needs to be replaced at regular intervals of one year and half.
Follow this procedure for battery replacement.
This section describes the battery replacement procedure to follow
when the HARTING connector option is selected. Replace the battery
on the controller side when the HARTING connector option is not
selected.
1)
Keep the power turned on.

Press the EMERGENCY STOP button of the robot to keep robot
and positioner from moving.
CAUTION
Be sure to turn on the power. If the battery is
replaced when the power is off, the current position
information is lost, so that mastering becomes
necessary.
2)
3)
4)
5)
Uncap the battery case.

Take out the battery from the battery case.
Insert a new battery into the battery case while paying attention to
the polarity of the battery.
Cap the battery case.
Fig. 3.3 (a) Battery replacement 1
- 15 -
MAINTENANCE
B-82545EN/02
Cap
Battery case
Battery specifications: A98L-0031-0005

(1.5V size-D 4 pcs)
Fig. 3.3 (b) Battery replacement 2
- 16 -
B-82545EN/02
MAINTENANCE
TROUBLESHOOTING
- 17 -
4.TROUBLESHOOTING
4.TROUBLESHOOTING
4.1
MAINTENANCE
B-82545EN/02
GENERAL
The source of mechanical unit problems may be difficult to locate
because of overlapping causes. Problems may become further
complicated, if they are not corrected properly. Therefore, it is
necessary to keep an accurate record of problems and to take proper
corrective actions.
- 18 -
B-82545EN/02
4.2
MAINTENANCE
4.TROUBLESHOOTING
PROBLEMS AND CAUSES

Table 4.2(a) shows the main mechanical unit problems and their causes.
If a cause of remedy is unclear, please contact your FANUC service
representative.
Symptom
Vibration
Noise
(Continued)
Table 4.2 (a) Problems and causes

Description
Cause
-The base lifts off the floor plate [Base fastening]
-It is likely that the positioner base is
as the positioner operates.
not securely fastened to the floor plate.
-There is a gap between the
-Probable causes are a loose bolt, an
base and floor plate.
insuffcient degree of surface flatness,
-A base retaining bolt is loose.
or foreign material caught.
-If the positioner is not securely
fastened to the floor plate, the base lifts
the floor plate as the positioner
operates, allowing the base and floor
plates to strike each other wihich, in
turn, leads to vibration.
[Rack or floor]
-The rack or floor vibrates
-It is likely that the rack or floor is not
during operation of the
suffciently rigid.
positioner.
-If the rack or floor is not sufficiently
rigid, reaction from the positioner
deforms the rack or floor, leading to
vibration.
[Overload]
-Vibration becomes more
-It is likely that the load on the
serious when the positioner
positioner is greater than the maximum
adopts a specific posture.
rating.
-If the operating speed of the
positioner is reduced, vibration -It is likely that the positioner control
program is too demanding for the
stops.
positioner hardware.
-Vibration is most noticeable
-It is likely that the ACCELERATION
when the positioner is
value is excessive.
accelerating.
- 19 -
Measure
-If a bolt is loose, apply loctite
and tighten it to the appropriate
torque.
-Adjust the floor plate surface
flatness to within the specified
tolenrance.
-If there is any foreign matter
between the base and floor
plate, remove it.
-Reinforce the rack or floor to

make it more rigid.
-If it is impossible to reinforce
the rack or floor, modify the
robot control program; doing so
might reduce the amount of
vibration.
-Check the maximum load that
the positioner can handle once
more. If the positioner is found
to be overloaded, reduce the
load, or modify the positioner
control program.
-Vibration in a specific portion
can be reduced by modifying
the robot control program while
slowig the positioner and
reducing its acceleration (to
minimize the influenece on the
entire cycle time).
4.TROUBLESHOOTING
Symptom
Vibration
Noise
(Continued)
Description
-Vibration was first noticed after
the positioner collided with an
object or the positioner was
overloaded for a long period.
-The grease has not been
exchanged for a long period.
MAINTENANCE
Cause
[Broken gear, bearing, or reducer]
- It is likely that collision or overload
applied an excessive force on the drive
mechanism, thus damaging the
geartooth surface or rolling surface of a
bearing, or reducer.
- It is likely that prolonged use of the
positioner while overloaded caused
fretting of the gear tooth surface or
rolling surface of a bearing, or reducer
due to resulting metal fatigue.
- It is likely that foreign matter caught in
a gear, bearing, or within a reducer
caused damage on the gear tooth
surface or rolling surface of the
bearing, or reducer.
- It is likely that, because the grease
has not been changed for a long
period, fretting occurred on the gear
tooth surface or rolling surface of a
bearing, or reducer due to metal
fatigue.
These factors all generate cyclic
vibration and noise.
- 20 -
B-82545EN/02
Measure
-Remove the motor, and
replace the gear , the bearing,
and the reducer. For the spec.
of parts and the method of
replacement, contact FANUC.
-Using the positioner within its
maximum rating prevents
problems with the drive
mechanism.
-Regularly changing the grease
with a specified type can help
prevent problems.
MAINTENANCE
B-82545EN/02
Symptom
Vibration
Noise
(Continued)
Description
-The cause of problem cannot
be identified from examination
of the floor, rack, or mechanical
section.
Cause
[Controller, cable, and motor]
-If a failure occurs in a controller circuit,
preventing control commands from
being supplied to the motor normally,
or preventing motor information from
being sent to the controller normally,
vibration might occur.
-If the pulse coder develops a fault,
vibration might occur because
information about the motor position
cannot be transferred to the controller
accurately.
-If the motor becomes defective,
vibration might occur because the
motor cannot deliver its rated
performance.
-If a connection cable between them
has an intermittent break, vibration
might occur.
-If the power cable has an intermittent
break, vibration might occur.
-If the power source voltage drops
below the rating, vibration might occur.
-If a robot control parameter is set to an
invalid value, vibration might occur.
- 21 -
4.TROUBLESHOOTING
Measure
-Refer to the Controller
Maintenance Manual for
troubleshooting related to the
controller and amplifier.
-Replace the pulse coder for
the motor, and check whether
the vibration still occurs.
-Also, replace the motor, and
check whether vibration still
occurs. For the method of
replacement, contact FANUC.
-Check that the positioner is
supplied with the rated voltage.
-Check whether the sheath of
the power cord is damaged. If
so, replace the power cord, and
check whether vibration still
occurs.
-Check whether the sheath of
the cable connecting the
mechanical section
and controller is damaged. If
so, replace the connection
cable, and check whether
vibration still occurs.
-Check that the positioner
control parameter is set to a
valid value. If it is set to an
invalid value, correct it. Contact
FANUC for further information if
necessary.
4.TROUBLESHOOTING
Symptom
Vibration
Noise
(Continued)
Description
-There is some relationship
between the vibration of the
positioner and the operation of
a machine near the positioner.
-There is an unusual sound

after replacement of grease.
after a long period of time.
during operation at low speed.
Rattling
-While the positioner is not

supplied with power, pushing it
with the hand causes part of the
mechanical unit to wobble.
-There is a gap on the mounting
surface of the mechanical unit.
-Backlash is greater than the

tolerance stated in the
applicable maintenance
manual.
(See Table 4.3 (b) and (c).)
MAINTENANCE
Cause
[Noise from a nearby machine]
-If the positioner is not grounded
properly, electrical noise is induced on
the grounding wire, preventing
commands from being transferred
accurately, thus leading to vibration.
-If the positioner is grounded at an
unsuitable point, its grounding
potential becomes unstable, and noise
is likely to be induced on the grounding
line, thus leading to vibration.
-There may be an unusual sound when
using other than the specified grease.
-Even for the specified grease, there
may be an unusual sound during
operation at low speed immediately
after replacement or after a long
period of time.
[Mechanical section coupling bolt]
-It is likely that overloading or a
collision has loosened a mounting bolt
in the positioner mechanical section.
[Increase in backlash]
-It is likely that excessive force applied
to the drive mechanism, due to a
collision or overloading, has broken a
gear or the inside of the reducer,
resulting in an increase in the amount
of backlash.
-It is likely that prolonged use in
overload conditions has caused the
tooth surfaces of a gear and the
reducer to wear out, resulting in an
increase in the amount of backlash.
-It is likely that prolonged use without
changing the grease has caused the
tooth surfaces of a gear and the inside
of the reducer to wear out, resulting in
an increase in the amount of backlash.
- 22 -
B-82545EN/02
Measure
-Connect the grounding wire
firmly to ensure a reliable
ground potential and prevent
extraneous electrical noise.
-Use the specified grease.

-When there is an unusual
sound even for specified
grease, perform operation for
one or two days on an
experiment. Generally, an
usual sound will disappear.
-Check that the following bolts
are tight. If any of these bolts is
loose, apply loctite and tighten
it to the appropriate torque.
-Motor retaining bolt
-Reducer retaining bolt
-Reducer shaft retaining bolt
-Base retaining bolt
-End effecter retaining bolt
-Remove the motor, and check
whether any of its gears are
broken. If any gear is broken,
replace it.
-Check whether any other gear
of the drive mechanism is
damage. If there is no damage
gear, replace the reducer.
-If the reducer is broken, or if a
gear tooth is missing, replace
the relevant component. Also,
remove all the grease from the
gear box and wash the inside of
the gear box.
-After replacing the gear or
reducer, add an appropriate
amount of grease.
-Using the positioner within its
maximum rating prevents
problems with the drive
mechanism.
-Regularly changing the grease
with a specified type can help
prevent problems.
MAINTENANCE
B-82545EN/02
Symptom
Motor
overheating
Description
-The ambient temperature of
the installation location
increases, causing
the motor to overheat.
-After a cover was attached to
the motor, the motor
overheated.
-After the robot control program
or the load was changed, the
motor
overheated.
Cause
[Ambient temperature]
-It is likely that a rise in the ambient
temperature or attaching the motor
cover prevented the motor from
releasing heat efficiently, thus leading
to overheating.
[Operating condition]
-It is likely that the positioner was
operated with the maximum average
current
exceeded.
-After a control parameter was

changed, the motor
overheated.
[Parameter]
-If data input for a workpiece is invalid,
the positioner cannot be accelerated
or decelerated normally, so the
average current increases, leading to
overheating.
[Mechanical section problems]
-It is likely that problems occurred in
the mechanical unit drive mechanism,
thus placing an excessive load on the
motor.
[Motor problems]
-It is likely that a failure of the motor
brake resulted in the motor running
with the brake applied, thus placing an
excessive load on the motor.
-It is likely that a failure of the motor
prevented it from delivering its rated
performance, thus causing an
excessive current to flow through the
motor.
-Symptom other than stated

above
- 23 -
4.TROUBLESHOOTING
Measure
-The teach pendant can be
used to monitor the average
current. Check the average
current when the robot control
program is running. The
allowable average current is
specified for the positioner
according to its ambient
temperature. Contact FANUC
for further information.
-Relaxing the positioner
control program and
conditions can reduce the
average current, thus
preventing overheating.
-Reducing the ambient
temperature is the most
effective means of preventing
overheating.
-Having the surroundings of
the motor well ventilated
enables the motor to release
heat efficiently, thus
preventing overheating. Using
a fan to direct air at the motor
is also effective.
-If there is a source of heat
near the motor, it is advisable
to install shielding to protect
the motor from heat radiation.
-Input an appropriate
parameter as described in
CONTROLLER
OPERATORS MANUAL.
-Repair the mechanical unit

while referring to the above
descriptions of vibration,
noise, and rattling.
-Check that, when the servo
system is energized, the brake
is released.
If the brake remains applied to
the motor all the time, replace
the motor.
-If the average current falls
after the motor is replaced, it
indicates that the first motor
was faulty.
4.TROUBLESHOOTING
MAINTENANCE
Symptom
Grease
leakage
Description
-Grease is leaking from the
mechanical unit.
Cause
[Poor sealing]
-Probable causes are a crack in the
casting, a broken O-ring, a damaged
oil seal, or a loose seal bolt.
-A crack in a casting can occur due to
excessive force that might be caused
in collision.
-An O-ring can be damaged if it is
trapped or cut during disassembling or
re-assembling.
-An oil seal might be damaged if
extraneous dust scratches the lip of
the oil seal.
-A loose seal bolt and grease nipple
might allow grease to leak along the
threads.
Axis rotation
-An axis rotates because the

brake does not function.
-An axis rotates gradually when
it should be at rest.
[Brake drive relay and motor]

-It is likely that brake drive relay
contacts are stuck to each other to
keep the brake current flowing, thus
preventing the brake from operating
when the motor is deenergized.
-It is likely that the brake shoe has
worn out or the brake main body is
damaged, preventing the brake from
operating efficiently.
-It is likely that oil or grease has
entered the motor, causing the
brake to slip.
[Mechanical section problems]
-If the repeatability is unstable,
probable causes are a failure in the
drive mechanism or a loose bolt.
-If the repeatability becomes stable it
is likely that a collision imposed an
excessive load, leading to slipping on
the base surface or the mating surface
of an arm or reducer.
-It is likely that the pulse coder is
abnormal.
Displacement -The positioner operates at a

point other than the taught
position.
-The repeatability is not within
the tolerance.
-Displacement occurs only in a

specific peripheral unit.
[Peripheral unit displacement]

-It is likely that an external force was
applied to the peripheral unit, thus
shifting its position relative to the
positioner.
- 24 -
B-82545EN/02
Measure
-If a crack develops in the
casting, sealant can be used
as a quick-fix to prevent
further grease leakage.
However, the component
should be replaced as soon as
possible, because the crack
might extend.
-O-rings are used in the
locations listed below.
-Motor coupling section
-Reducer (case and shaft)
coupling section
-Oil seals are used in the
locations stated below.
-Inside the reducer
-Seal bolts and nipples are
used in the locations stated
below.
-Grease drain inlet and outlet
-Check whether the brake
drive relay contacts are stuck
to each other. If they are found
to be stuck, replace the relay.
-If the brake shoe is worn out,
if the brake main body is
damaged, or if oil or grease
has entered the motor,
replace the motor.
-If the repeatability is unstable,

repair the mechanical section
by referring to the above
descriptions of vibration,
noise, and rattling.
-If the repeatability is stable,
correct the taught program.
Variation will not occur unless
another collision occurs.
-If the pulse coder is
abnormal, replace the motor
or the pulse coder.
-Correct the setting of the
peripheral unit position.
-Correct the taught program.
MAINTENANCE
B-82545EN/02
Symptom
Description
Displacement -Displacement occurred after a
(Continuted) parameter was changed.
Cause
[Parameter]
-It is likely that the mastering data was
rewritten in such a way that
the positioner origin was shifted.
BZAL alarm
occured
-The voltage of the memory backup

battery may be low.
-The pulse coder cable may be
defected.
-The welding ground cable may be
loosened or broken(NOTE).
-BZAL is displayed on the

controller screen
-Starting of an arc is not good.

Troubles
related to arc -An arc is unstable.
-Beads are irregular.
welding
4.TROUBLESHOOTING
Measure
-Re-enter the previous
mastering data, which is
known to be correct.
-If correct mastering data is
unavailable, perform
mastering again.
-Replace the battery.
-Replace the cable.
-Tighten the connection part of

the ground cable.
-Replace the ground cable.
NOTE
Arc welding troubles may be caused by a welding
unit such as a welding power supply or torch. When
a trouble occurs, see the manual of each unit to find
the cause.
- 25 -
4.TROUBLESHOOTING
4.3
MAINTENANCE
B-82545EN/02
BACKLASH MEASUREMENT
Measurement method
1.
2.
3.
Maintain the positioner in a specified posture. (See Fig. 4.3 (a))

Apply positive and negative loads to each axis as shown in Fig.
4.3(a).
Remove the loads and measure the displacement.
Apply positive and negative loads three times and then remove the
loads. Calculate the average of the displacements in the second and
third measurements as the backlash.
Stop position
0
+10kg
Firtst step
(Do not measure)
-10kg
+10kg
L1
-10kg
0kg
L2
0kg
+10kg
0kg
L3
-10kg
Second step
(B2 =L1+ L2)
Third step
(B3=L 3+ L4)
0kg
L4
Fig. 4.3 (a) BAcklash Measurement Method
Backlash B is calculated using the following expression:

B2 + B3
B=
2
- 26 -
B-82545EN/02
4.TROUBLESHOOTING
MAINTENANCE
Table 4.3 (a) Backlash measurement posture and measurement position

Measured
posture
0
Measurement position (mm)

See fig 4.3(b)
Table 4.3 (b) Backlash allowable rattling of each axis

(300kg load capacity)
Angle conversion (arc-min)
Displacement conversion (mm)
Distance from rotation center to
measurement position (mm)
2.5
0.127
175
Table 4.3 (c) Backlash allowable rattling of each axis

(1000kg load capacity)
Angle conversion (arc-min)
Displacement conversion (mm)
Distance from rotation center to
measurement position (mm)
2.5
0.164
225
NOTE
The displacement conversion value indicates play
in the direction of rotation from the center of the axis
at the distance shown in brackets.
Backlash
measurement
position
Install
the fixture as like this.
Fig. 4.3 (b) Backlash measurement position
- 27 -
4.TROUBLESHOOTING
4.4
MAINTENANCE
B-82545EN/02
COMPONENT REPLACEMENT AND ADJUSTMENT ITEMS

Adjustments are needed after a component is replaced.
The following table lists components and the adjustment items that
must be made after their replacement. After replacing a component,
make necessary adjustments according to this table.
Component replacement or
function change
Adjustment item
Cable replacement
Battery replacement
(The battery should be replaced once
1.5 years.)
Quick mastering
Replace the battery with the power
kept on.
No adjustment is needed.
- 28 -
B-82545EN/02
MAINTENANCE
5.ADJUSTMENTS
ADJUSTMENTS
Each part of the mechanical units of a positioner is set to the best
condition before the positioner is shipped to the customer. The
customer does not need to make adjustments on the positioner when it is
delivered.
If a mechanical unit of the positioner has a large backlash because of a
long-term use or component replacement, make adjustments according
to this section.
- 29 -
5.ADJUSTMENTS
5.1
MAINTENANCE
B-82545EN/02
REFERENCE POSITION AND MOVING RANGE

Zero point and software motion limits are provided for controlled axis.
Exceeding the software motion limit of a controlled axis is called
overtravel (OT). Overtravel is detected at both ends of the motion limit
for each axis. The positioner cannot exceed the software motion limit
unless there is a failure of the system causing loss of zero point position
or there is a system error.
Fig. 5.1(a) shows the zero point and motion limit (stroke).
Fig. 5.1(b) shows the motion direction (+/).
+370
0
-370
(NOTE) There is not a mechanical stopper.

Fig. 5.1(a) Axis swiveling
- 30 -
B-82545EN/02
5.ADJUSTMENTS
MAINTENANCE
740
(370)
Fig. 5.1(b) Axis motion direction
- 31 -
5.ADJUSTMENTS
5.2
MAINTENANCE
B-82545EN/02
MASTERING
Mastering method
There are following five methods of mastering.
Table 5.2 Mastering method
This is performed using a mastering fixture before
the machine is shipped from the factory.
This is performed with all axes set at the 0-degree
position. A zero-position mark (eye mark) is
attached to each positioner axis. This mastering is
performed with all axes aligned to their respective
eye marks.
Simplified mastering
This is performed at a user-specified position. The
corresponding count value is obtained from the
rotation speed of the pulse coder connected to the
relevant motor and the rotation angel within one
rotation. simplified mastering uses the fact that
the absolute value of a rotation angel within one
rotation will not be lost.
One-axis mastering
One-axis mastering is not used.
Mastering data entry
Mastering data is entered directly.
Fixture position
mastering
Zero-position
mastering (eye mark
mastering)
Once mastering is performed, it is necessary to carry out positioning, or

calibration. Positioning is an operation is which the control unit reads
the current pulse count value to sense the current positon of the
positioner.
If the backup batteries for the pulse coder go dead during cable
replacement, simplified mastering can be performed, resetting the
positioner exactly to its initial position by calibration.
If replacement of the motors, reducers, or other parts causes mechanical
changes in the phases of the pulse coder, simplified mastering cannot be
performed. In this case, perform fixture position mastering for accurate
position calibration.
CAUTION
If mastering is performed incorrectly, the positioner
may behave unexpectedly. This is very dangerous.
So, the positioning screen is desinged to apper only
when the $MATER_ENB sytem variable is 1 or 2.
After performing positioning, press F5[DONE] on
the positioning screen. The $MASTER_ENB
system variable is reset to 0 automatically, thus
hiding the positioning screen.
NOTE
It is recommended that you back up the current
mastering data before performing mastering.
- 32 -
MAINTENANCE
B-82545EN/02
5.2.1
5.ADJUSTMENTS
Resetting Alarms and Preparing for Mastering

Before performing mastering because a motor is replaced, it is
necessary to release the relevant alarm and display the positioning
menu.
Alarm displayed
Servo 062 BZAL or Servo 075 Pulse mismatch
Procedure
1
Display the positioning menu by following steps 1 to 6.

1
Press the screen selection key.
2
Press [0 NEXT] and select [6 SYSTEM].
3 Press F1 [TYPE], and select [SYSTEM Variable] from the
menu.
4 Place the cursor on $MASTER_ENB, then key in 1 and
press [ENTER].
5
Press F1 [TYPE], and select[Mater/Cal] from the menu.
6 Select the desired mastering type from the [Master/Cal]
menu.
Toreset the Servo 062 BZAL alarm, follow steps 1 to 5.

1
Press the screen slelection key.
2
Press [0 NEXT] and Select [6 SYSTEM].
3 Press F1 [TYPE], and select [Master/Cal] from the menu.
4 Place the cursor on F3 RES_PCA, then press F4 [TRUE].
5
Switch the controller power off and on again
To reset the Servo 075 Pulse mismatch alarm, follow steps 1 to

3.
1 When the controller power is switched on again, the message
Servo 075 Pulse mismatch appears again.
2 Rotate the axis for which the message mentioned above has
appeared through 10 degrees in either direction.
3
Pree [FAULT RESET]. The alarm is reset.
- 33 -
5.ADJUSTMENTS
5.2.2
MAINTENANCE
B-82545EN/02
Fixture position master

Fixture position mastering is performed using a mastering fixture. This
mastering is carried out in the predetermined fixture position.
Fixture position mastering is accurate because a dedicated mastering
fixture is used. Fixture position mastering is not required in daily
operations because it is factory-performed.
When mastering the positioner, arrange the positioner to meet the
following conditions.
- Make the positioner mounting base horizontal.
(Set the positioner mounting surface so that the levelness of the
entire surface is 1 mm or less.)
- Remove the hand and other parts form the wrist.
- Set the positioner in the condition protected from an external
force.
CAUTION
Be extremely careful in moving the positioner during
mastering because an axis movement range is not
checked.
- 34 -
5.ADJUSTMENTS
MAINTENANCE
B-82545EN/02
Assembling mastering fixtures

Attach the mastering fixture to the positioner as shown in Fig. 5.2.2 (a)
to (e).
Remove the seal from the mastering fixture attaching surface.
Be sure to restore the original condition after completion of mastering.
PIN D
A290-7220-X956
Bolt
M10X20(2pcs)
Mastering fixtureB
A290-7220-X952
PIN C
A290-7220-X955
BOLT
M5X16
CLAMP
A290-7022-X954
MASTERING FIXTURE A
A290-7220-X951
BOLT
M8X20(2pcs)
DIAL GAUGE
PIN B
A290-7220-X953
PIN A
A290-7220-X954
Fig. 5.2.2 (a) Attaching the mastering fixture to the 1-axis positioner (300kg load capacity)
Fig. 5.2.2 (b) Attaching the mastering fixture to the 1-axis positioner (300kg load capacity)
- 35 -
5.ADJUSTMENTS
MAINTENANCE
B-82545EN/02
BOLT
M5X16
MASTERING FIXTURE A
A290-7220-X957
PIN A
A290-7220-X953
CLAMP
A290-7022-X954
PIN B
A290-7220-X954
BOLT
M8X20(2pcs)
Fig. 5.2.2 (c) Attaching the mastering fixture to the 1-axis positioner (1000kg load capacity)
MASTERING FIXTURE B
A290-7220-X958
BOLT
M16X30(2)
PIN D
A290-7220-X956
PIN C
A290-7220-X955
- 36 -
B-82545EN/02
MAINTENANCE
5.ADJUSTMENTS
Fig. 5.2.2 (d) Attaching the mastering fixture to the 1-axis positioner (1000kg load capacity)
THE DIRECTION
OF PIN O 6
THE DIRECTION
OF PIN O10
Fig. 5.2.2 (e) Attaching the mastering fixture to the 1-axis positioner (1000kg load capacity)
- 37 -
5.ADJUSTMENTS
MAINTENANCE
B-82545EN/02
Mastering
1
2
3
4
Press MENUS.
Press NEXT and select SYSTEM.
Press F1, [TYPE].
Select Mater/Cal.
AUTO
SYSTEM Master/Cal
G2
JOINT
1%
TORQUE = [ON ]
1 FIXTURE POSITION MASTER
2 ZERO POSITION MASTER
3 QUICK MASTER
4 SINGLE AXIS MASTER
5 SET QUICK MASTER REF
6 CALIBRATE
Calibrate key select? [NO]

[ TYPE ]
YES
NO
Release brake control, and jog the positioner into a posture for
mastering.
See fig. 5.2.2 (f) and (g) for the mastering posture.
NOTE
Brake control can be released by setting the system
variables as follows:
$PARAM_GROUP.()SSV_OFF_ALL: FALSE
$PARAM_GROUP.()SSV_OFF_ENB[*]: FALSE
(for all axes)
After changing the system variables, switch the
control unit power off and on again.
[*] is the axis number of the positioner.
Slowly move the positioner by axial feed so that the values of dial
indicators shown in Fig. 5.2.2 (a) and (c) are 3 mm.
- 38 -
5.ADJUSTMENTS
MAINTENANCE
B-82545EN/02
Select 1 FIXTURE POSITION MASTER and Press F4, YES.

AUTO
SYSTEM Master/Cal
G2
JOINT
1%
TORQUE = [ON ]
3 QUICK MASTER
6 CALIBRATE
Robot Mastered! Mastering Data :
<
0.0000> <
90.0000> <
0.0000>
<
0.0000> <
0.0000> <
0.0000>
[ TYPE ] LOAD RES_PCA
DONE
Select 6 CALIBRATE and press F4, YES. Mastering will be

performed
Alternatively, switch the power off and on again. Switching the
power on always causes positioning to be performed.
AUTO
SYSTEM Master/Cal
JOINT
1%
TORQUE = [ON ]
3 QUICK MASTER
6 CALIBRATE
Robot Calibrated! Cur Jnt Ang(deg):
<
0.0000> <
0.0000> <
0.0000>
<
0.0000> <
0.0000> <
0.0000>
Quick master ? [NO]

[ TYPE ]
YES
NONE
After positioning is completed, press F5 [DONE].
- 39 -
5.ADJUSTMENTS
MAINTENANCE
B-82545EN/02
Restore
brake
control.
Reset
system
variables
$PARAM_GROUP.$SV_OFF_ALL
and
$PARAM_GROUP.$SV_OFF_ENB to their original values, and
turn the power off and then back on.
10 After mastering, update the mastering data listed in the
factory-supplied data sheet with new mastering data
($DMR_GROUP.$MASTER_COUN [*]).
([*] is the axis number of the positioner.).
Mastering posture
Fig. 5.2.2 (f) Mastering position (300kg load capacity)
Mastering
posture
: 0
:0
Fig. 5.2.2 (g) Mastering position (1000kg load capacity)
- 40 -
5.2.3
5.ADJUSTMENTS
MAINTENANCE
B-82545EN/02
Zero Position Mastering

Zero-position mastering is performed with axes set at the 0-degree
position. A zero-position mark (eye mark) is attached to each positioner
axis. This mastering is performed with all axes set at the 0-degree
position using their respective eye marks.
Zero-position mastering involves a visual check. It cannot be so
accurate. It should be used only as a quick-fix method.
Procedure Mastering to Zero Degrees

Step
1
2
3
4
Press MENUS.
Select NEXT and press SYSTEM.
Press F1, [TYPE].
Select Master/Cal.
AUTO
SYSTEM Master/Cal
G2
JOINT
1%
TORQUE = [ON ]
3 QUICK MASTER
6 CALIBRATE
Calibrate zero position master key select? [NO]

[ TYPE ]
YES
NO
Release brake control, and jog the robot into a posture for
mastering. See Fig. 5.2.3 (a) and (b) for the mastering posture.
NOTE
Brake control can be released by setting the system
variables as follows:
$PARAM_GROUP.SSV_OFF_ALL: FALSE
$PARAM GROUP.SSV OFF ENB[*]: FALSE
(for all axes)
After changing the system variables, switch the
control unit power off and on again.
([*] is the axis number of the positioner.)
- 41 -
5.ADJUSTMENTS
MAINTENANCE
B-82545EN/02
Select Zero Position Master.

AUTO
SYSTEM Master/Cal
G2
JOINT
1%
TORQUE = [ON ]
3 QUICK MASTER
6 CALIBRATE
Robot Mastered! Mastering Data:
<0>
[ TYPE ] LOAD RES_PCA
DONE
Press F4, YES. Mastering will be performed automatically.

Alternatively, turn the power off and then back on. Mastering is
performed.
When the power is turned off and then back on, mastering is
always performed.
AUTO
SYSTEM Master/Cal
G2
JOINT
1%
TORQUE = [ON ]
3 QUICK MASTER
6 CALIBRATE
Robot Calibrated! Cur Jnt Ang(deg):
<
0.0000>
Quick master?
[NO]
[ TYPE ]
YES
NO
After calibration is completed, press F5[DONE].

- 42 -
MAINTENANCE
B-82545EN/02
5.ADJUSTMENTS
Reset the brake control release settings to the original state. Set
system variables $PARAM_GROUP, $SV_OFF_ALL, and
$SV_OFF_ENB to their original values, then turn off then back on
the power.
DETAIL A
Fig. 5.2.3 (a) Marking of the zero-degree for each axis (position mark) (300kg load capacity)
DETAIL B
Fig. 5.2.3 (b) Marking of the zero-degree for each axis (position mark) (1000kg load capacity)
- 43 -
5.ADJUSTMENTS
5.2.4
MAINTENANCE
B-82545EN/02
Quick Mastering
Simplified mastering is performed at a user-specified position. The
corresponding count value is obtained from the rotation speed of the
pulse coder connected to the relevant motor and the rotation angle
within one rotation. Simplified mastering uses the fact that the absolute
value of a rotation angle within one rotation will not be lost.
Simplified mastering is factory-performed at the zero-degree position.
Do not change the setting unless there is a problem.
If it is impossible to set the positioner at the position mentioned above,
it is necessary to re-set the simplified mastering reference position
using the following method. (It would be convenient to set up a marker
that can work in place of the position mark.)
CAUTION
1 Simplified mastering can be used, if the pulse count
value is lost, for example, because a low voltage
has been detected on the backup battery for the
pulse counter.
2 Simplified mastering cannot be used, after the pulse
coder is replaced or after the mastering data is lost
from the robot control unit.
3 This operation cannot be performed if mastering data
is lost as a result of mechanical disassembly or
maintenance. In this case, perform zero position
mastering or fixture position mastering to recover
the mastering data.
Procedure Recording the Quick Master Reference Position

Step
1
2
Select SYSTEM.
Select Master/Cal.
AUTO
SYSTEM Master/Cal
G2
JOINT
1%
TORQUE = [ON ]
3 QUICK MASTER
6 CALIBRATE
Press 'ENTER' or number key to select.
[ TYPE ]
LOAD
- 44 -
RES_PCA
DONE
5.ADJUSTMENTS
MAINTENANCE
B-82545EN/02
3
Set quick master ref? [NO]
Release brake control, and jog the positioner to the simplified

mastering reference position.
Move the cursor to SET QUICK MASTER REF and press
ENTER. Press F4, YES.
Procedure Quick Mastering

Step
Display the Master/Cal screen

AUTO
SYSTEM Master/Cal
JOINT
1%
TORQUE = [ON ]
3 QUICK MASTER
6 CALIBRATE
Robot Not Mastered!
Quick master? [NO]

[ TYPE ]
2
Quick master? [NO]
3
4
5
6
5.2.5
YES
NO
Release brake control, and jog the positioner to the simplified

mastering reference position.
Move the cursor to QUICK MASTER and press ENTER. Press
F4, YES. Quick mastering data is memorized.
Move the cursor to CALIBRATE and press ENTER. Calibration
is executed. Calibration is executed by power on again.
After completing the calibration, press F5, DONE.
Restore
brake
control.
Reset
system
variables
$PARAM_GROUP.$SV_OFF_ALL
and
$PARAM_GROUP.$SV_OFF_ENB to their original values, and
turn the power off and then back on.
After mastering, update the mastering data listed in the
factory-supplied data sheet with new mastering data
($DMR_GROUP[*].$MASTER_COUN ).
([*] is the group number of the positioner.)
Mastering Data Entry

This function enables mastering data values to be assigned directly to a
system variable. It can be used, if mastering data has been lost, but the
pulse count is preserved.
- 45 -
5.ADJUSTMENTS
5.2.6
MAINTENANCE
B-82545EN/02
Mastering Data Entry Method

Step
1
2
Select [6 SYSTEM] and press ENTER.

Select [Variable]. The system variable screen appears.
Change the mastering data.

The
mastering
data
is
saved
to
the
$DMR_GRP().$MASTER_COUN system variable.( is the axis
number of the positioner.)
Select $DMR_GRP. (* is the group number of the postioner.)

SYSTEM
Variables
G2 JOINT
1 %
$DMR_GRP[2]
1 $MASTER_DONE
2 $OT_MINUS
3 $OT_PLUS
4 $MASTER_COUN
5 $REF_DONE
6 $REF_POS
1/25
TRUE
[9] of BOOLEAN
[9] of BOOLEAN
[9] of INTEGER
FALSE
[9] of REAL
7 $REF_COUNT
[9] of INTEGER
8 $BCKLSH_SIGN
[9] of BOOLEAN
9 $EACHMST_DON
10 $SPC_COUNT
[ TYPE
]
- 46 -
[9] of INTEGER
[9] of INTEGER
TRUE
FALSE
5.ADJUSTMENTS
MAINTENANCE
B-82545EN/02
Select $MASTER_COUN, and enter the mastering data you have

recorded.
G2
SYSTEM
Variables
JOINT
1%
$DMR_GRP[2].$MASTER_COUN
1
[1]
95678329
[2]
10223045
0
[3]
[4]
[5]
[6]
[7]
[8]
[9]
1/9
[ TYPE
]
6
7
Press the previous page key.

Set $MASTER_DONE to TRUE.
SYSTEM
Variables

G2
$DMR_GRP[2]
1 $MASTER_DONE
2 $OT_MINUS
3 $OT_PLUS
4 $MASTER_COUN
5 $REF_DONE
6 $REF_POS
1/25
TRUE
[9] of BOOLEAN
[9] of BOOLEAN
[9] of INTEGER
FALSE
[9] of REAL
7 $REF_COUNT
[9] of INTEGER
8 $BCKLSH_SIGN
[9] of BOOLEAN
9 $EACHMST_DON
10 $SPC_COUNT
[ TYPE
]
8
9
10
1%
JOINT
[9] of INTEGER
[9] of INTEGER
TRUE
FALSE
Press F1 [TYPE] and select CALIBRATE.

select [6 CALIBRATE], then press F4 [YES].
After completing positioning, press F5 [DONE].
- 47 -
5.ADJUSTMENTS
5.2.7
MAINTENANCE
B-82545EN/02
Confirming Mastering
1)
2)
Confirming that mastering was performed normally

Usually, positioning is performed automatically when the power is
turned on. To confirm that mastering was performed normally,
check that the current-position display matches the actual position
of the positioner, using this procedure.
a) Replay the taught operation of the positioner to set zero
degrees, and visually check that the zero-degree position
marks shown in Fig. 5.2.3 (a) and (b) are aligned.
b) Replay a specific portion of the program, and check that the
positioner has moved to the taught position.
Possible alarms in positioning
The following paragraphs describe alarms that may occur in
positioning and explain how to handle them.
a) BZAL alarm
This alarm is raised if the voltage of the pulse coder backup
battery becomes 0V when the controller power is off.
Mastering must be performed again because the counter has
already lost data.
b) BLAL alarm
This alarm indicates that the voltage of the pulse coder
backup battery is too low to run the pulse coder. If this alarm
is issued, replace the backup battery soon while keeping the
power on, and check whether the current-position data is
correct, using a method described in item (1).
c) CKAL, RCAL, PHAL, CSAL, DTERR, CRCERR, STBERR,
and SPHAL alarms
If any of these alarms is issued, contact your FANUC service
representative. A motor may have to be replaced.
- 48 -
6. COMPONENT REPLACEMENT AND

ADJUSTMENTS
MAINTENANCE
B-82545EN/02
COMPONENT
REPLACEMENT
ADJUSTMENTS
AND
Adjustments are needed after a component is replaced.

The following table lists components and the adjustment items that
must be made after the components are replaced. After replacing a
component, make necessary adjustments according to this table.
Replacement component
Motor
Reducers
Adjustment item
(a) Mastering
(a) Mastering
NOTE
Be very careful when dismounting and mounting the
heavy components that are listed below.
Component
Motor
Motor
Reducer
Reducer
Flange
Flange
Weight (about)
Load capacity
10kg
22kg
20kg
91kg
16kg
28kg
300kg
1000kg
300kg
1000kg
300kg
1000kg
NOTE
When applying LOCTITE to the important bolt
tightening points, make sure that it is applied to the
entire longitudinal portion in the engaging section of
the female threads. If it is applied to the male
threads, the bolts may be loosened because
sufficient effects cannot be obtained. Remove the
dust within the bolts and taps and wipe oil off the
engaging section. Make sure that there is no
solvent in the taps.
- 49 -

ADJUSTMENTS
6.1
MAINTENANCE
B-82545EN/02
REPLACING THE MOTOR
In the case of 300kg load capacity

1
2
3
4
5
6
7
8
Turn off the power to the controller.

Remove the four M812 bolts and remove the motor cover.
(Only when the motor cover option is selected)
After removing the battery box fixing plate while referencing Fig.
6.1 (b), remove the four M610 bolts and remove the connector
box.
(Only when the HARTING connector option is selected)
Remove the motor connector.
Remove the four M820 motor mounting bolts and washer and
remove the motor.
Attach the input gear to a new motor, and reverse the removal
steps to mount the motor. Replace the O-rings with new ones, and
put the new O-rings in place. See Fig. 6.1 (a) for the tightening
torque and Loctite application.
Supply the grease bath with the specified grease as described in
Section 3.1.
Perform mastering while referencing Chapter 5.
Washer
Nut
Loctite 242
Tightening Torque 16.7Nm
C ring
O ring
Bolt
M8X20,4pcs
Motor cover
(Motor cover option is selected)
Motor
Washer
Bearing
Input Gear
Bolt
M8X12,4pcs
(Harting connector option or
Motor cover option is selected)
Connector box
(Harting connector option is selected)
Plate for fixtation of Battery Box
(Harting connector option is selected)
Fig. 6.1(a) Replacing the motor (300kg load capacity)
- 50 -
MAINTENANCE
B-82545EN/02

ADJUSTMENTS
BATTERY BOX
BOLT
M6X10,4pcs
PLATE FOR FIXATION

OF BATTERY BOX
Fig. 6.1 (b) Removing the connector box (when the HARTING connector option is selected)

1
2

Remove the four M812 bolts and remove the motor cover.
(Only when the motor cover option is selected)
3
After removing the battery box fixing plate while referencing Fig.
6.1 (b), remove the four M610 bolts and remove the connector
box.
(Only when the HARTING connector option is selected)
4 Remove the motor connector.
5 Remove the four M1230 motor mounting bolts and washer and
remove the motor.
6 Attach the input gear to a new motor, and reverse the removal
steps to mount the motor. Replace the O-rings with new ones, and
put the new O-rings in place. See Fig. 6.1 (c) for the tightening
torque and Loctite application.
7
Section 3.1.
8
- 51 -

ADJUSTMENTS
Nut
Loctite
242
242
Tightening
Torque 3.2N.m
3.2N.m
MAINTENANCE
B-82545EN/02
Draw
bolt
242
Loctite
242
118N.m
Tightening Torque 118N.m
O
O
ring
S2
Alvania grease
S2
,4
Washer 4pcs
Bolt
M1230.4pcs
M12X30,4
Motor
Washer
CC
ring
Motor cover
(Motor
cover option is
()
selected.)
Bearing
Input gear
Bolt
Connector box
M8X12,4
M812.4pcs
(Harting connector option(
)
(Harting connector option or
is
setected.)
motor cover option is selected.)
()
Plate for fixation of Battery

()
Box
(Harting connector option

is setected.)
Fig. 6.1 (c) Replacing the motor (1000kg load capacity)
Replacing parts (300kg load capacity)

Part name
Specification
O-ring
JB-OR1A-G105
Motor
A06B-0235-B605#S000
Bearing
A97L-0001-0195#06Z000A
Oil seal
A98L-0040-0047#07010014
Part name
Specification
O-ring
JB-OR1A-G125
Motor
A06B-0265-B605#S000
Bearing
A97L-0001-0196#09Z000A
Oil seal
A98L-0040-0047#13016014
NOTE
Replace the bearing or oil seal only when it is
broken.
- 52 -
6.2

ADJUSTMENTS
MAINTENANCE
B-82545EN/02
REPLACING THE REDUCER

1
2
3
4
5
6
Remove the motor as section 6.1.

Remove the covers, bolts, insulators A and B, collars, flange, and
insulater in that order.
Pull the pipe out of the reducer.
Remove the 11 M10X45 bolts with washers that fasten the reducer
on the base, and remove the reducer.
Remove the gear.
Reverse the removal steps to mount a new reducer. Replace the
O-rings with new ones, and put the new O-rings in place. Be
careful not to damage the oil seal.

7
8
9
Bolt
M1045.11pcs
M10X45,11
Loctite 262
262
Tightening
Torque 73.5N.m
73.5Nm
Washer
See Fig. 6.2 (a) for the tightening torque and Loctite application.
Install the motor as section 6.1.
Section 3.1.
OO
ring
Alvania
grease S2
S2
Flange
Washer
plate 3pcs
,3
Reducer
Bolt M1235.9pcs
M12X35,9
Loctite
262
262
Tightening
Torque
128.4Nm
128.4N.m
Cover
,3
3pcs
collar 9pcs
,9
Insulator
A 3pcs
A,3
Insulator
B
9pcs
B,9
A
(Insert
after the insulator A.)
Gear
Base
O
O
ring
S2
Alvania
grease S2
Pipe

Insulator
C
C
Fig. 6.2 (a) Replacing the reducer (300kg load capacity)

Part name
Specification
O-ring (pipe)
JB-OR1A-G95
O-ring (reducer)
A98L-0040-0041#173
Reducer
A97L-0218-0805#37
- 53 -

ADJUSTMENTS
MAINTENANCE
B-82545EN/02
In the case of 1000 kg load capacity

1
2
3
4
5
6
7
8
Bolt
M1650
15pcs
Loctite M16X50,15
262Nm
262Nm
Tightening
Torque318.5Nm
318.5N.m
,15
Washer
15pcs
Bolt M1285 16pcs
Loctite
262
M12X85,16
Tightening
Torque
262
128.4Nm
128.4N.m
Washer
16pcs
,16
Remove the motor as described in Section 6.1.

Remove the covers, bolts, washers, insulators A and B, flanges,
insulators C in that order.
Remove the 15 bolts (M16 50) that fix the reducer and base and
then remove the reducer and the components ahead of it.
Remove the 16 bolts (M12 85) and washers that secure the
reducer and adapter and remove the reducer from the adapter.
Apply sealant to a new reducer as described in Section 6.3 and
assemble these components in the reverse order. Replace the
O-rings with new ones and put them in place. Be careful not to
damage the oil seal. For the tightening torque and the application
of LOCTITE, see Fig. 6.2 (b).
Mount the motor as described in Section 6.1.
Section 3.1.
Perform mastering as described in Chapter 5.
OO
ring
S2
Alvania
grease S2
Pipe
Insulator B 18pcs
B,18
(Insert
after the insulator A.)
A
Insulator
A,18
A 18pcs
Insulator
C
C
Adapter
Flange
Reducer
Washer
18pcs
,18
Bolt M1235 18pcs
Loctite
262
M12X35,18
262
Tightening
Torque
128.4Nm
128.4N.m
,18
Cover
18pcs
Base
O ring
Alvania grease S2
Fig. 6.2 (b) Replacing the reducer (1000kg load capacity)

Part name
Specification
O-ring (pipe)
JB-OR1A-G125
O-ring (reducer)
A98L-0040-0041#281
Reducer
A97L-0218-0819
- 54 -
MAINTENANCE
B-82545EN/02
6.3

ADJUSTMENTS
SEALANT APPLICATION
Washing and degreasing the surfaces to be sealed

1
2
3
4
After dismounting the reducer from the arm, apply releasant

(Loctite Gasket Remover) to the arms surface from which the
reducer was dismounted, then wait until the sealant (Loctite 518)
becomes softened (for about 10 minutes). Remove the softened
sealant from the surface using a spatula.
Blow air onto the surface to be sealed to remove dust from the
tapped holes.
Sufficiently degrease the reducers surface to be sealed and the
arms surface to be sealed, using a cloth dampened with alcohol.
Polish the arm's surface to be sealed with an oil stone, and
degrease it with alcohol again.
NOTE
Oil may drip from the inside of the reducer. After
degreasing, make sure that no oil is dripping.
Applying sealant
5
6
Make sure that the reducer and the arm are dry (with no alcohol
remaining). If they are still wet with alcohol, wipe them dry.
Apply sealant (Loctite 518) to the surfaces as Fig. 6.3.
Assembling
7
To prevent dust from sticking to the portions to which sealant was

applied, mount the reducer as quickly as possible after sealant
application. Be careful not to touch the applied sealant. If sealant
was wiped off, apply again.
After mounting the reducer, fasten it with bolts and washers
quickly so that the mated surfaces get closer.
NOTE
Do not grease the reducer before the sealant sets, as
it may allow grease to leak. Before greasing, wait
for about at least one hour after the reducer is
mounted.
- 55 -

ADJUSTMENTS
MAINTENANCE
Apply sealant (Loctite No.518) to this area.

(No.518)
Fig. 6.3 Applying sealant to the reducer (1000kg load capacity)
- 56 -
B-82545EN/02
B-82545EN/02
MAINTENANCE
PIPING AND WIRING
- 57 -
7.PIPING AND WIRING
7.PIPING AND WIRING
7.1
MAINTENANCE
B-82545EN/02
WIRING DIAGRAMS
Fig. 7.1 shows the wiring in the mechanical unit when the HARTING
connector option is selected. The controller and motor are directly
connected to each other when the HARTING connector option is not
selected.
Connector panel
K102
Motor
M1BK
M1M
K101
M1P
+
Battery
-
Fig. 7.1 Wiring in the mechanical unit
- 58 -
B-82545EN/02
7.2
MAINTENANCE
7.PIPING AND WIRING
CABLING (WHEN THE HARTING CONNECTOR OPTION IS

SELECTED)
Fig. 7.2 shows the cabling in the mechanical unit when the HARTING
connector option is selected. (There are no cables in the mechanical
unit when the HARTING connector option is not selected.)
K101
K101
Pulse
coder cable
K102
K102
Motor
cable
Fig. 7.2 Wiring in the mechanical unit
- 59 -
8.CABLE REPLACEMENT
MAINTENANCE
B-82545EN/02
CABLE REPLACEMENT
If a cable is broken or damaged, replace it according to the procedure
described in this chapter.
Cautions in handling the pulse coder cable

When transporting, installing, or maintaining the positioner, do not
detach the pulse coder cables carelessly. The cables are provided with
the marking tie shown below. If you detached any cable with the
marking tie, you need to perform mastering for the robot.
Do not detach any connector unless you replace a motor, pulse coder,
reducer, or cable.
BATTERY BACKUP
DON'T
DISCONNECT
Fig. 8 Wire mark
If there is a break in or any other damage to a cable, replace the cable

according to the procedure described in this chapter. If the connector of
a pulse coder cable (K101) is detached, the data about the absolute
position of the positioner is lost. Once any of these cables is replaced,
perform simplified mastering while referencing Section 5.1. If the data
is lost because of a break in a cable, also perform simplified mastering
to calibrate the positioner into the previous absolute position.
- 60 -
MAINTENANCE
B-82545EN/02
8.1
8.CABLE REPLACEMENT
REPLACING CABLES
When the HARTING connector option is not selected, turn off the
power to the controller, directly remove the motor connector, and
replace the cables. When the HARTING connector option is selected,
use the procedure below to replace the cables.
1
2
3
4
5
6
7
8
9
10
11
Make sure that the simple mastering reference point is set with
reference to Section 5.2.4.
Remove the motor cover while referencing Chapter 6.
Remove the four M6X10 bolts from the battery box fixing plate,
and remove the plate together with the battery. Take care not to
break the battery connection cable by excessively pulling it.
Remove the three M8X12 bolts that fasten the connector box, and
remove the connector box.
Remove the motor connector and the cable.
Detach the cables from the connector box. The K101 cable can be
detached from the connector box by removing the four M4X8
bolts, and the K102 cable can be detached by removing the four
M3X8 bolts, housing, and insert.
Remove the battery connection cable.
Remove the ground wire.
Reverse the removal steps to install new cables. Take care not to
cause the cables to be caught and cut in metal plates while
installing them. Also take care not to break the cables by pulling
them.
Perform mastering. Simple mastering is recommended. (see
Chapter 5).
Fig.8.1(a) Replacing cables 1
- 61 -
8.CABLE REPLACEMENT
MAINTENANCE
Fig. 8.1 (b) Replacing cables 2
Fig. 8.1 (c) Replacing cables 3
- 62 -
B-82545EN/02
II. CONNECTION
B-82545EN/02
CONNECTION
1. POSITIONER OUTLINE DRAWING AND

OPERATION AREA DIAGRAM
POSITIONER OUTLINE DRAWING

When installing peripheral equipment, be careful not to cause
interference with the positioner body. For installation, see Section 3.3
and use through holes provided on the base.
- 65 -

1.1
CONNECTION
B-82545EN/02
OUTLINE DRAWING AND OPERATION AREA DIAGRAM

Figs. 1.1 (a) to (c) show the outer dimensions and the operation area of
the positioner, follower unit. (300kg load capacity)
Fig. 1.1 (a) Outline of 1 axis positioner (300kg load capacity)
- 66 -
CONNECTION
B-82545EN/02

4-10H8 +0.022
0
THROUGH
EQUALLY SPECIFIED
343
12-M10
THROUGH
EQUALLY SPECIFIED
360
350
15
185
11
3 H7 +00 .035
6
D E PT
H
30
27
0
65 E
IA M
D

OW
OLL
H
118
231
169
205
Fig. 1.1 (b) Outline of follower unit (option)
MOTOR COVER OPTION

2-10H8
12-M16
+0.022
0
582
25
DEPTH
DEPTH
575
6-M12
EQUALLY SPECIFIED
20
DEPTH
20
EQUALLY SPECIFIED
485
60
160 +0
H7 0.040
8
260
DEP
450
TH
20
1 ER
ET
DIAM
LOW
L
O
H
329.5
654
259
294
HARTING CONNECTOR OPTION
Fig. 1.1 (c) Outline of 1 axis positioner (1000kg load capacity)
- 67 -
2. MOUNTING DEVICES ON THE

POSITIONER
CONNECTION
B-82545EN/02
MOUNTING DEVICES ON THE POSITIONER

NOTE
Wipe oil off the flange surface before mounting the
unit. Otherwise, the unit may be misaligned.
- 68 -
POSITIONER LOAD CONDITION

Fig. 2.2 shows the positioner load conditions.
Use the positioner so that the load condition falls within the range in the
table and the allowable load inertia and allowable load moment in the
table are satisfied.
300
Payload(kg)
2.1

POSITIONER
CONNECTION
B-82545EN/02
250
200
150
120
300
Payload vs Payload C.G

Displacement(mm)
240
180
144
120
Fig. 2.1 (a) Positioner allowable load condition (300kg load capacity)
Allowable load moment (Mr)
300kg load capacity

36 kgf.m (353 N.m)
Allowable bending moment (Mb)

Allowable load inertia (J)
250kgf.m (2450 N.m)

2,350 kgf.cm.s2(240kg.m2)
- 69 -

POSITIONER
CONNECTION
B-82545EN/02
Payload(kg)
1000
800
700
600
500
Payload vs Payload C.G Displacement(mm)
320
267
229
200
160
Fig. 2.1 (b) Positioner allowable load condition (1000kg load capacity)
Allowable load moment (Mr)

Allowable bending moment (Mb)
Allowable load inertia (J)
- 70 -
1000kg load capacity

160 kgf.m (1,568 N.m)
2100kgf.m (20,580 N.m)
4,700 kgf.cm.s2(460kg.m2)
B-82545EN/02
CONNECTION 3.TRANSPORTATION AND INSTALLATION
TRANSPORTATION AND INSTALLATION
- 71 -
3.TRANSPORTATION AND INSTALLATION CONNECTION
3.1
B-82545EN/02
TRANSPORTATION
The positioner can be transported by suspending it. For the 300 kg
load capacity, thread a rope through the M10 eyebolts. For the
1000 kg load capacity, thread a rope through the M16 eyebolts.
(See Figs. 3.1 (a) and (b).) After installation, remove transport
equipment.
CAUTION
When transporting a positioner, be careful not to
damage a motor connector with a sling for lifting the
positioner.
CAUTION
When an end effector and peripherals are installed
on a positioner, the center of gravity of the
positioner changes and the positioner might
become unstable while being transported.
If the positioner becomes unstable, remove the
tooling and place the positioner into the
transportation position. This will position the unit
center of gravity correctly. It is recommended to
transport the end effector and peripherals
separately from the positioner.
Do not pull the eyebolt horizontally.
Do not thread a chain or the like through the
transport member.
Before moving the positioner by using transport
equipment, check and tighten any loose bolts.
- 72 -
B-82545EN/02
NOTE)1.Weight of Positioner
85 kg
2.The eyebolts must conform to JIS B 1168
3.Eyebolt :1pcs
4.When you transport positioner,Take out all works.
Crane weight capacity
:200kg or greater
POSITIONE
R POSTURE ON TRANSPORTATION:Arbitrary
ROBOT
Sling weight capacity

:200kg or greater
>200kg
Transport
equipment
>200kg
>150kg
Fig. 3.1 (a) Carrying the positioner with a crane (300kg load capacity)
NOTE)1.Weight of Positioner
280 kg
2.The eyebolts must conform to JIS B 1168
3.Eyebolt :1pcs
4.When you transport positioner,Take out all works.
Crane weight capacity
:600kg(5800N) or greater
ROBOT POSTURE ON TRANSPORTATION:Arbitrary
Transport
equipment
Sling weight capacity

:600kg(5800N) or greater
>600kg (5880N)
>600kg (5880N)
>450kg (4410N)
Fig. 3.1(b) Carying the positioner with a crane (1000kg load capacity)
- 73 -
3.2
B-82545EN/02
STORING THE POSITIONER

When storing the positioner, keep it in the posture with the following
NOTES.
NOTE
Before storing a positioner for a long term, take
measures for securing the positioner to prevent it
from falling.
NOTE
The flange surface is likely to rust, so apply antirust
oil to the flange surface to save it for a long period of
time.
- 74 -
B-82545EN/02
3.3
INSTALLATION
(1) Before installation
Wipe oil off the flange because it is factory-oiled.
Fig. 3.3 (a) to (c) shows the dimensions of the base of the positioner
main body and the follower unit
.
182
182
6-O14
THROUGH
29
51
47
47
2-O10H8 +0.022
0
THROUGH
207
Fig. 3.3 (a) Dimensions of the base of the positioner main body (300kg load capacity)
- 75 -
B-82545EN/02
6-DIA.18
56
THROUGH
USE M12 BOLTS
31
56
116
M12
2-DIA.10H8 +0.022
0
THROUGH
87
87
118
Fig. 3.3 (b) Dimensions of the base of the positioner follower unit (option for 300kg load capacity)
297.5
297.5
4-O24
THROUGH
32
132
200
2-O10H8 +0.022
0
THROUGH
329.5
Fig. 3.3 (c) Dimensions of the base of the positioner main body (1000kg load capacity)
- 76 -
B-82545EN/02
Fig. 3.3 (d) shows an example of installing the 300kg load capacity type
positioner and the follower unit.(option for 300kg load capacity) In
this example, the sole plate is fixed with four M20 chemical anchors (in
strength category 4.8), and the positioner base is fastened to the sole
plate with six M1240 bolts (in strength category 12.9). The follower
unit base is fastened with six M1270 bolts (in strength category 12.9)
and six GT washers.
When compatibility must be maintained in teaching the positioner
mechanical unit replacement, use the mounting surface.
NOTE
The customer shall arrange for the positioning pin,
anchor bolts, and sole plate.
29 47
47
56
350
56 31
350
4-24THROUGH
FRONT
FRONT
413
(MOUNTING FACE)
174
(MOUNTING FACE)
409
900
364
318
50
INSTALLATION BOARD
(MOUNTING FACE)
(MOUNTING FACE)
50
POSITIONER BASE
BOLT FOR FIXTATION OF POSITONER
M12X40(6pcs)
Strength classification:12.9
128.4 Nm
Tightening Torque:529.2
200
CHEMICAL ANCHOR
M20(4pcs)
Tightening Torque:186.2 Nm
FOLLOWER UNIT BASE

BOLT FOR FIXTATION OF POSITIONER
M1270(6pcs)
Sterngth classification:12.9
128.4 Nm
Tightening Torque:529.2
GT Washer(6pcs) (NOTE 2)
32
2400
Fig. 3.3 (d) Example of installing the positioner (300kg load capacity)
- 77 -
B-82545EN/02
NOTE
- Install the positioner and follower unit so that their
axial centers are aligned. For the installation, follow
the guidelines provided by the contractor and use a
level or three-dimensional measuring instrument to
ensure that the positioner and follower unit are
centered.
The allowable moment for the reducer is 2,450 Nm
(250 kgfm). Install the reducer so as not to exceed
the allowable moment by placing the reducer
off-center.
- Be sure to use the supplied GT washers for the
installation of the follower unit.
Fig. 3.3 (e) shows an example of installing the 1000kg load capacity
type positioner and the follower unit. In this example, the sole plate is
fixed with four M20 chemical anchors (in strength category 4.8), and
the positioner base is fastened to the sole plate with four M2240 bolts
(in strength category 12.9). The follower unit base is necessary for the
customer to be prepared .
When compatibility must be maintained in teaching the positioner
mechanical unit replacement, use the mounting surface.
NOTE
The customer shall arrange for the positioning pin,
anchor bolts, and sole plate.
32 100 100
4-24THROUGH
230
595
900
50
INSTALLATION BOARD
(MOUNTING FACE)
FRONT
FRONT
(MOUNTING FACE)
(MOUNTING FACE)
2400
POSITIONER BASE
BOLT FOR FIXTATION OF POSITIONER
M22X40(4pcs)
FOLLOWER AXIS
(Please prepare by customer.)
200
32
CHEMICAL ANCHOR
M20(4pcs)
50
Fig. 3.3(e) Example of installing the positioner (1000kg load capacity)
- 78 -
B-82545EN/02
NOTE
- When the follower unit is installed in the customer
site, the axial centers of the positioner and follower
unit must be aligned. For the installation, follow the
guidance provided by the contractor and use a level
or three-dimensional measuring instrument to
ensure that the positioner and follower unit are
centered.
The allowable moment for the reducer is 20,580
Nm (2100 kgfm). Install the follower unit so that
the allowable moment is not exceeded because it is
placed off-center.
Fig. 3.3 (c) and Table 3.3(a) and (b) explain what load is put on the base
when the positioner is at a rest, accelerating or decelerating, and at an
emergency stop.
Fig. 3.3 (c) Load and moment applied to the base
State
Table 3.3 (a) Load and moment applied to the base (300kg load capacity)
MV
FV
MH
FH
[Kgm]
(Nm)
[Kgm]
(Nm)
[Kg]
(N)
[Kg]
At rest
Accelerating or
decelerating
At an emergency stop
State
36
353
385
3773
200
334
1961
3276
411
432
4024
4230
24
44
236
430
26
47
251
457
Table 3.3 (b) Load and moment applied to the base (1000kg load capacity)
MV
FV
MH
FH
[Kgm]
(Nm)
[Kgm]
(Nm)
[Kg]
(N)
[Kg]
At rest
Accelerating or
decelerating
At an emergency stop
(N)
(N)
160
1568
1280
12544
407
741
3989
7262
1365
1481
13377
14514
193
455
1891
4459
85
201
833
1970
- 79 -
MAINTENANCE CLEARANCE
Fig. 3.4 (a) and (b) show the layout of maintenance clearances.
600
450
500
450
3.4
B-82545EN/02
Fig. 3.4 (a) Maintenance clearance layout (300kg load capacity)
- 80 -
B-82545EN/02
800
570
570
500
Fig. 3.4(b) Maintenance clearance layout (1000kg load capacity)
- 81 -
3.5
B-82545EN/02
ASSEMBLING THE POSITIONER FOR INSTALLATION

The robot connection cables are detached from the mechanical unit
when the robot is shipped (the cables are connected on the controller
side). When the HARTING connector option is not selected, directly
connect the cable for direct motor connection to the motor connector.
When the HARTING connector option is selected, connect the cables
shown in Fig. 3.5 to the connector box of the mechanical unit. During
the connection, take care not to pull the HARTING connector cable.
In connecting cables between the robot controller and the positioner
body, the customer needs to obtain cable ducts or the like.
PP
Connect the pulse coder cable from the
controller.
PM
Connect the power cable from the controller
Fig. 3.5 Cable connection panel for the positioner mechanical unit
- 82 -
B-82545EN/02
3.6
INSTALLATION CONDITIONS
Table 3.6 lists the installation conditions for the positioner.
Item
Pneumatic
pressure
Table 3.6 Installation conditions

Specification
Supply air
pressure
Consumption
Allowable ambient
temperature
Allowable ambient humidity
Atmosphere
Vibration
0.5 to 0.7 MPa (5 to 7 kg/cm2)

(set at 0.5 MPa (5 kg/cm2))
Maximum instantaneous amount: 150 NI/min
(Note 1)
0 to 45C
Regularly:75%RH or below
Short period (within one month):
95%RH (maximum) or below
No condensation is allowed.
High: Up to 1,000 meters above the sea level
required, no particular provision for attitude.
There shall be no corrosive gas (Note 2).
0.5 G or less
NOTE
1 This is the capacity of the three-piece pneumatic
option. Use the positioner at or below this value.
2 If you cannot avoid using the positioner in an
adverse environment with respect to vibration, dust,
or coolant, contact FANUC.
- 83 -
APPENDIX
B-82545EN/02
A.SPARE PARTS LISTS
APPENDIX
SPARE PARTS LISTS

Table A (a) Cables
(When the HARTING connector option is selected.)
Cable No.
Specifications
Remarks
Load capacity
K101
K102
K101
K102
A660-8016-T096
A660-8016-T097
A660-8016-T241
A660-8016-T243
Pulse coder
Motor power, brake
Pulse coder
Motor power, brake
Table A (b) Motor

Specifications
Model
iS8/4000
A06B-0235-B605#S000
A06B-0265-B605#S000 iS22/4000
Table A (c) Reducer
Specifications
Weight
A97L-0218-0805#37
A97L-0218-0819
19kg
91kg
A97L-0001-0195#06Z000A
A97L-0001-0196#09Z000A
300kg
1000kg
Load capacity
Center gear
Input gear
Table A (e) Bearing

Specifications
Load capacity
300kg
1000kg
Table A (d) Gear

Specifications
Name
A290-7216-X212
A290-7220-X111
Loac capacity
300kg
300kg
Loac capacity
300kg
300kg
Table A (f) O-ring

Specifications
Use position
JB-OR1A-G105
JB-OR1A-G95
A98L-0040-0041#173
JB-OR1A-G125
A98L-0040-0041#281
Motor
Pipe
Reducer
Motor, pipe
Reducer
Table A(g) Oil seal

Specifications
Use position
A98L-0040-0047#07010014
A98L-0040-0047#13016014
- 87 -
300kg
300kg
1000kg
1000kg
Pipe
Pipe
Load capacity
300kg
300kg
300kg
1000kg
1000kg
Load capacity
300kg
1000kg
A.SPARE PARTS LISTS
APPENDIX
B-82545EN/02
Table A (h) Grease

Specifications
A98L-0040-0174#1kg
A98L-0040-0174#4.9kg
Name
Load capacity
VIGOGREASE RE0
300kg
1000kg
Table A (i) Grease nipple

Specifications
Name
A98L-0218-0013#A110
Grease nipple (1/8)
Table A(j) Seal bolt

Specifications
A97L-0218-0417#121515
A97L-0001-0436#2-1D
Use position
Outlet 2 (300kg load capacity)

Outlet 1,2 (1000kg loac capacity)
Outlet 1 (300kg load capacity)
NOTE
For the locations of outlet 1 and 2, see
I.MAINTENANCE 3.1.
Table A (h) Battery
Specifications
Name
A98L-0031-0005
- 88 -
1.5V, size D
Qty
4 pcs
B-82545EN/01
APPENDIX
B. INTRA-MECHANICAL UNIT
CONNECTION DIAGRAMS
CONNECTION DIAGRAMS
Fig. B (a) and (b) show the circuit in the mechanical unit when the HARTING connector option is selected. When the option
is not selected, a direct connection is established from the motor.
- 89 -
CONNECTION DIAGRAMS
APPENDIX
B-82545EN/01
CONNECTOR PANEL
PM
M TYPE
H 15D
(2.5SQ 10A)
K102
B1
B2
B3
B4
B5
G
C1
C2
C3
C4
C5
BKP1
BKM1
A1
A2
A3
A4
A5
J1U
J1V
J1W
J1G
A66L-0001-0401#10
(1.25SQ*10C)11.8
PP
21
22
23
24
H 24DD
(2.5SQ 10A)
M TYPE
9 +5V(A1)
10
11
12
13
14
15
16
17
18
19
20
+6V
BT1
5
6
7
8
0V(A1)
1
2
3 SPRQ J1
4 *SPRQ J1
K101
A66L-0001-0464#1
(0.2SQ*4P)6.7
BATTERY
0V
BT1
Fig. B (a) Connection diagram (300kg load capacity)
- 90 -
B-82545EN/01
CONNECTION DIAGRAMS
APPENDIX
A63L-0001-0648#810SL3SJ
A63L-0001-0653#04A
J1 MOTOR (iS8/4000)
M1 BK 10SL-3P(1.25SQ 13A)
A
BKP1
A63L-0001-0881#1810S
A63L-0001-0881#10C
A
B
A63L-0001-0848#A10SL1
A63L-0001-0850
BKM1
C
D
18-10P
J1W
J1G
M1 M
J1U
J1V
M1 P
8 +5V(A1)
9
10 OV(A1)
10SL1(0.3SQ 3A)
4 +6V(BT1)
5 *SPRQ J1
6 SPRQ J1
7 OV(BT1)
1
2
3
SG
1-axis Servo Positioner(300kg)
:MOVABLE
- 91 -
CONNECTION DIAGRAMS
APPENDIX
B-82545EN/01
CONNECTOR PANEL
PM
M TYPE
H 15D
(2.5SQ 10A)
K102
B1
B2
B3
B4
B5
G
C1
C2
C3
C4
C5
BKP1
BKM1
A1
A2
A3
A4
A5
J1U
J1V
J1W
J1G
A66L-0001-0401#10
(1.25SQ*10C)11.8
PP
21
22
23
24
H 24DD
(2.5SQ 10A)
M TYPE
13
14
15
16
17
18
19
20
+6V
BT1
9 +5V(A1)
10
11
12
5
6
7
8
0V(A1)
1
2
3 SPRQ J1
4 *SPRQ J1
K101
A66L-0001-0464#1
(0.2SQ*4P)6.7
BATTERY
0V
BT1
Fig. B(b) Connection diagram (1000kg load capacity)
- 92 -
B-82545EN/01
CONNECTION DIAGRAMS
APPENDIX
A63L-0001-0648#810SL3SJ
A63L-0001-0653#04A
J1 MOTOR (iS22/4000)
M1 BK 10SL-3P(1.25SQ 13A)
A
BKP1
A
B
J1U
J1V
A63L-0001-0881#1810S
A63L-0001-0881#10C
A63L-0001-0848#A10SL1
A63L-0001-0850
BKM1
C
D
18-10P
J1W
J1G
M1 M
M1 P
8 +5V(A1)
9
10 OV(A1)
10SL1(0.3SQ 3A)
4 +6V(BT1)
5 *SPRQ J1
6 SPRQ J1
7 OV(BT1)
1
2
3
1-axis Servo Positioner(1000kg)
:MOVABLE
- 93 -
SG
C.PERIODIC INSPECTION TABLE
APPENDIX
B-82545EN/02
PERIODIC INSPECTION TABLE
FANUC 1-AXIS SERVO POSITIONER
Working Check
time
time (H)
Item
1
2
years
5760
6720
7680
8640
9600 10560
0.2H
0.2H
0.5H
5 Remove spatter and dust etc.
1.0H
6 Replacing battery. NOTE2)
0.1H
0.3H
980ml
1.0H
5500ml
3
Mechanical unit
Grease First
3
6
9
amount check months months months 1 year
320
960 1920 2880 3840 4800
0.2H
Control unit
Check the mechanical cable.

(damaged or twisted) NOTE1)
Check the motor connector
(tightness).
Tighten the loosened flange
mounting bolts.
Tighten the cover and main
bolt.
PERIODIC INSPECTION TABLE
Replacing grease of reducer.

300kg load capacity NOTE3)
7
Replacing grease of reducer.
1000kg load capacity NOTE3)
Replacing cable of mechanical
8 unit. NOTE1)
Check the robot cable and
9 teach pendant cable.
Cleaning the ventilator.
10 NOTE4)
Check the source voltage.
11 NOTE5)
12 Replacing battery NOTE5)
3.0H
0.2H
0.2H
0.2H
0.1H
NOTE1) Check this when Harting connector option is selected.

The cycle of replacing is necessary to be shortened. Refer to MAINTENANCE 8 in replacing the cable.
NOTE2) Refer to the manual MAINTENANCE 2.4.
NOTE3) Refer to Fig. 3.1 (a) and (b) of the Section 3.1 in MAINTENANCE.
NOTE4) Clean the positioner properly in case of using the positioner under much dust existing.
NOTE5) Refer to the controller maintenance manual.
:Item
for replacing
: Item for checking
- 94 -
C.PERIODIC INSPECTION TABLE
APPENDIX
B-82545EN/02
3
years
4
years
5
years
6
years
7
years
8
years
11520 12480 13440 14400 15360 16320 17280 18240 19200 20160 21120 22080 23040 24000 24960 25920 26880 27840 28800 29760 30720 Items
Overhaul
6
7
8
()
10
11
12
- 95 -
D.MOUNTING BOLT TORQUE LIST
APPENDIX
B-82545EN/02
MOUNTING BOLT TORQUE LIST

If no tightening torque is specified for a bolt, tighten it according to this
table.
Recommended bolt tightening torque
Nominal
diameter
M3
M4
M5
M6
M8
M10
M12
(M14)
M16
(M18)
M20
(M22)
M24
(M27)
M30
M36
Unit: Nm (kgf-cm)
Hexagon socket head bolt

(steel in strength category 12.9)
Hexagon socket head bolt

(stainless)
Tightening torque
Upper limit
Lower limit
Tightening torque
Upper limit
Lower limit
1.8(18)
4.0(41)
7.9(81)
14(140)
32(330)
66(670)
110(1150)
180(1850)
270(2800)
380(3900)
530(5400)
730(7450)
930(9500)
1400(14000)
1800(18500)
3200(33000)
1.3(13)
2.8(29)
5.6(57)
9.6(98)
23(230)
46(470)
78(800)
130(1300)
190(1900)
260(2700)
370(3800)
510(5200)
650(6600)
960(9800)
1300(13000)
2300(23000)
0.76(7.7)
1.8(18)
3.4(35)
5.8(60)
14(145)
27(280)
48(490)
76(780)
120 (1200)
160(1650)
230(2300)
-
- 96 -
0.53(5.4)
1.3(13)
2.5(25)
4.1(42)
9.8(100)
19(195)
33(340)
53(545)
82(840)
110(1150)
160(1600)
-
Hexagon socket head boss

bolt
Hexagon socket head flush
bolt (steel in strength
category 12.9)
Tightening torque
Upper limit
Lower limit
1.8(18)
4.0(41)
7.9(81)
14(140)
32(330)
-
1.3(13)
2.8(29)
5.6(57)
9.6(98)
23(230)
-
INDEX
B-82545EN/02
INDEX
< >
< >
ADJUSTMENTS ............................................................ 29
ONE-AND HALF-YEAR PERIODIC INSPECTION
ASSEMBLING THE POSITIONER FOR
(5,760 hours)..................................................................... 8
INSTALLATION............................................................ 82
OUTLINE DRAWING AND OPERATION AREA

DIAGRAM ..................................................................... 66
< >
BACKLASH MEASUREMENT .................................... 26
< >
PERIODIC INSPECTION TABLE ................................ 94
BATTERY REPLACEMENT ........................................ 15
PERIODIC MAINTENANCE ........................................ 11
< >
PIPING AND WIRING .................................................. 57
CABLE REPLACEMENT.............................................. 60
POSITIONER LOAD CONDITION .............................. 69
CABLING (WHEN THE HARTING CONNECTOR
POSITIONER OUTLINE DRAWING ........................... 65
OPTION IS SELECTED) ............................................... 59
PREFACE...................................................................... p-1
COMPONENT REPLACEMENT AND ADJUSTMENT
PREVENTIVE MAINTENANCE.................................... 5
ITEMS............................................................................. 28
PROBLEMS AND CAUSES.......................................... 19
COMPONENT REPLACEMENT AND ADJUSTMENTS
PROCEDURE FOR RELEASING THE GREASE
........................................................................................ 49
RESIDUAL PRESSURE ................................................ 14
CONFIGURATION ..........................................................3
Confirming Mastering ..................................................... 48
< >
QUARTERLY INSPECTION .......................................... 8
CONNECTION DIAGRAMS......................................... 89
Quick Mastering ............................................................. 44
< >
DAILY INSPECTION ......................................................6
< >
REFERENCE POSITION AND MOVING RANGE ..... 30
< >
REPLACING CABLES.................................................. 61
Fixture position master.................................................... 34
REPLACING THE MOTOR .......................................... 50

REPLACING THE REDUCER...................................... 53
< >
Resetting Alarms and Preparing for Mastering............... 33
GENERAL ...................................................................... 18
GREASE REPLACEMENT ........................................... 12
< >
SAFETY PRECAUTIONS ............................................ s-1
< >
INSTALLATION............................................................ 75
SEALANT APPLICATION ........................................... 55
INSTALLATION CONDITIONS................................... 83
SPARE PARTS LISTS ................................................... 87
< >
MAINTENANCE CLEARANCE................................... 80
STORING THE POSITIONER ...................................... 74
< >
MAINTENANCE TOOLS................................................9
THREE-YEAR PERIODIC INSPECTION (11,520 hours)8
MASTERING ................................................................. 32
TRANSPORTATION..................................................... 72
Mastering Data Entry ...................................................... 45
TRANSPORTATION AND INSTALLATION.............. 71
Mastering Data Entry Method......................................... 46
TROUBLESHOOTING.................................................. 17
MOUNTING BOLT TORQUE LIST ............................. 96

MOUNTING DEVICES ON THE POSITIONER .......... 68
< >
WIRING DIAGRAMS ................................................... 58
- i-1 -
INDEX
B-82545EN/01
< >
Zero Position Mastering .................................................. 41
i-2
Revision Record
FANUC 1-Axis SERVO POSITIONER MECHANICAL UNIT MAINTENANCE MANUAL (B-82545EN)
02
July, 2007
Addition of 1000kg load capacity
01
May,2007
Edition
Date
Contents
Edition
Date
Contents

1axis Positioner Maintenance Manual (B-82545EN 02)

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FANUC

No part of this manual may be reproduced in any form.

(4) Provide the peripheral devices with appropriate grounding (Class

(9) When adjusting each peripheral device independently, be sure to

Note) Terminals FENCE1 and FENCE2

For R-J3iB CONTROLLER

For R-30iA CONTROLLER

Note) Connect between EMGIN1 and EMGIN 2.

Fig.1.1.1 (a) Connection Diagram for External Emergency Stop Switch

Refer to R-30iA CONTROLLER MAINTENANCE MANUAL.

Fig.1.1.1 (b) Connection Diagram for External Emergency Stop Switch

Safety of the Teach Pendant Operator

(4) The teach pendant operator needs to exercise special caution to

Operator s panel Teach pendant

Safety During Maintenance

SAFETY OF THE TOOLS AND PERIPHERAL DEVICES

Precautions for Mechanism

SAFETY OF THE ROBOT MECHANISM

Precautions for Mechanisms

SAFETY OF THE END EFFECTOR

Fig. 1.6 (a) Greasing and Degreasing Label

When greasing, be sure to keep the grease outlet open.

(2) Step-on prohibitive label

Fig. 1.6 (b) Step-on Prohibitive Label

Fig. 1.6 (c) High-temperature warning label

(4) Transportation label

Fig. 1.6 (d) Transportation label (300kg load capacity type)

Use a crane having a load capacity of 1960 N (200 kg) or

Fig. 1.6 (e) Transportation label (1000kg load capacity type)

Use a crane having a load capacity of 5880 N (600 kg) or

Mechanical unit specification No.

1-Axis Servo Positioner (300kg)

740 (-370 to +370) 12.9 rad (-6.45 rad to +6.45 rad)

2,350 kgf . cm . s2 240 kg . m2

* A follower unit (A05B-1220-J151) is available as an option for

For the FANUC Robot series, the following manuals are

All persons who use the FANUC Robot and system

Setup and Operations

Setup and Operations

PERIODIC MAINTENANCE .................................................................. 11

GREASE REPLACEMENT .......................................................................... 12

DAILY INSPECTION ..................................................................................... 6

REFERENCE POSITION AND MOVING RANGE....................................... 30

Resetting Alarms and Preparing for Mastering ......................................................33

Fixture position master...........................................................................................34

Zero Position Mastering .........................................................................................41

Quick Mastering .....................................................................................................44

Mastering Data Entry .............................................................................................45

Mastering Data Entry Method ................................................................................46

Confirming Mastering ............................................................................................48

COMPONENT REPLACEMENT AND ADJUSTMENTS....................... 49

REPLACING THE MOTOR ......................................................................... 50

POSITIONER OUTLINE DRAWING ..................................................... 65

MOUNTING DEVICES ON THE POSITIONER ..................................... 68

WIRING DIAGRAMS ................................................................................... 58

CABLE REPLACEMENT ...................................................................... 60

REPLACING THE REDUCER ..................................................................... 53

PIPING AND WIRING ........................................................................... 57

POSITIONER LOAD CONDITION............................................................... 69

TRANSPORTATION AND INSTALLATION ......................................... 71

SPARE PARTS LISTS .......................................................................... 87

CONNECTION DIAGRAMS .................................................................. 89

PERIODIC INSPECTION TABLE.......................................................... 94