Robot Manipulator

No.
1L11130A-E-10
series
INSTRUCTION MANUAL
MANIPULATOR
NB4 / NB4L / NB15 / NV6 /
( NV6L / NV20 / NV20A / NH5 )
Read and follow these instructions and all safety blocks carefully.
Have only trained and qualified persons install, operate, or service this unit.
Give this manual to the operator.
For help, call your distributor.

Be Sure to Read Instruction Manuals Before Use
Thank you for using the Daihen "Almega" series arc welding robot.
Please be sure to read the instruction manuals listed below (including this manual) and the instruction manuals
provided with the equipment, and use all the products correctly.
In particular, please be sure to read "Chapter 1 Safety Precautions" in the "Quick Start" instruction manual before
starting to use the products in order to ensure your safety and the safety of others. Store the instruction manual in
a safe place for future reference.
Instruction manuals related to the manipulator V/B/H/S series, and the robot control unit FD11 are as follows.
Standard Manuals
Instruction
Instruction Manual Type Main Contents
Manual No.
QUICK START Point on Safety, Transportation and Installation,
1L21700A
Turning the power on/off and manual operation, etc.
SETUP Safety precautions, installing & connecting method,
1L21700B starting up, periodical inspection, solution at the time
of failure
CONTROLLER MAINTENANCE Specifications of controller, explanation of each parts
1L21700K
and maintenance, parts list, etc.
MANIPULATOR Specifications or maintenance of manipulator, parts
NB4 / NB4L / NB15 / NV6 / NV6L / NV20 / NH5 1L11130A list, etc.
/ NV20A
1L11446A
NS3 list, etc.
1L11312A
NV50 list, etc.
1L11306A
NV166 / NV210 list, etc.
BASIC OPERATIONS Explanation of manual operation, teaching, automatic
1L21700C operation, file utilities, backing-up data, basic
operations of Arc/Spot welding application, etc.
EXTERNAL INPUT/OUTPUT Interfacing method with external control device, list of
1L21700H
I/O signals and start/halt the automatic operation, etc.
Software PLC Create program, Input/output relay lists, List of
1L21700J
command words, etc.
CONTROL AND MAINTENANCE Edit logging, User Check, Troubleshooting, etc.
1L21700L
FUNCTION
Application Manuals
Instruction
Instruction Manual Type Main Contents
Manual No.
APPLICATION MANUAL Basic settings, functions for arc welding, teaching
1L21700F
(ARC WELDING) technique, etc.
APPLICATION MANUAL Basic settings, functions for arc welding, teaching
1L21700E
(SPOT WELDING) technique, etc.
Instruction manuals are available other than the above for each optional function that you have purchased.
[Notes] 1. Specifications and information contained in these manuals are subject to change at any time without notice.
2. The screen display of a teach pendant shown in the manual are described as examples, which may be different from the actual
ones.
3. Although we cautiously compiled this standard specification to eliminate as much error as possible, we do not take any
responsibility for damages resulting from neither direct nor indirect errors.
4. The manual is a part of robot products. When transferring or selling off a robot, be sure to append the manual.
5. No part of this manual may be reproduced without permission.
6. Prohibited altering or remodeling
- Do not alter or remodel our products.
- You may get injured or have your equipment damaged because of fire, failure or malfunction caused by altering or
remodeling the product.
- The warranty does not cover any altered or remodeled products.
-1-
Notice
Notes on Safety
The instructions that you are required to obey in order to prevent injury or physical damage to the operator or other
nearby persons are classified and explained as shown below in the provided instruction manuals (including this
manual).
Cases in which death or serious injury are assured if handed incorrectly, and which
avoidance of such dangers is also considered extremely difficult.
DANGER
Cases in which death or serious injury can be expected if handled incorrectly.

WARNING
Cases in which injury or physical damage can be expected if handled incorrectly.

CAUTION
The following symbols are also used for important checkpoints:
A particularly important checkpoint is shown.

IMPORTANT
INFO.
Useful information is shown.
POINT Info for deeper understanding for the main text is shown.
Note that even the matters which are described as CAUTION can result in serious accident depending on the
conditions. Be sure to keep the safety notes since they describe very important matters.
The meanings of Serious injury, Minor injury, and Damage described above are as follows.
Injury which has the aftereffect by loss of eyesight, an injury, the burn (high/low
Serious injury temperature), an electric shock, fracture, poisoning, etc. and that which requires
hospitalization and long-term treatment as an outpatient.
Injury which does not require either hospitalization or long-term treatment as an

Minor injury
outpatient, a burn (high temperature, low temperature), and an electric shock.
Direct and indirect damage in connection with damage of property and

Damage
equipment.
-2-
Table of Contents
Table of Contents
B-type / V-type Manipulator
Chapter 1 Specifications of B-type / V-type Manipulator
1.1 Manipulator model .................................................................................................................. 1-1-2
1.2 Basic Specifications ................................................................................................................ 1-1-4

1.2.1 Basic Specifications of NB4/NB4L/NB15 Manipulator .................................................... 1-1-4
1.2.2 Basic Specifications of NV6/NV6L/NV20/NV20A Manipulator ........................................ 1-1-5
1.3 Outside Dimensions and Working Range ............................................................................... 1-1-7
1.4 Description on Each Part of Manipulator .............................................................................. 1-1-17

1.4.1 Allowable Load on Wrist Axis ........................................................................................ 1-1-17
1.4.2 Flange Dimensions of Wrist Axis .................................................................................. 1-1-22
1.4.3 Mounting Equipment on the Upper Arm ........................................................................ 1-1-25
1.4.4 Restrictions of Working Range ..................................................................................... 1-1-30
1.4.5 Instrument Connecting Cables and Gas (Air) Piping .................................................... 1-1-31
1.4.6 Motion Warning Lamp (option) ..................................................................................... 1-1-36
1.4.7 Holding Brake ............................................................................................................... 1-1-37
1.5 Reference Position of Moving Axis ....................................................................................... 1-1-38
1.5.1 Angular Reference Position of Each Joint in the Working Range................................. 1-1-38
1.5.2 Angular Reference Position of Each Joint in the Starting Area ..................................... 1-1-39
1.6 Motion Direction of Each Axis ............................................................................................... 1-1-40
1.6.1 Motion of Each Axis ...................................................................................................... 1-1-40
1.6.2 Motion in the Cartesian Coordinate .............................................................................. 1-1-40
1.7 Changing Working Range ..................................................................................................... 1-1-46
1.7.1 Changing Working Range of Axis J1 ............................................................................ 1-1-46
1.7.2 Changing Working Range of Axes J2 and J3 (with the option mounted) ..................... 1-1-47
1.8 Option ................................................................................................................................... 1-1-51
Chapter 2 Foundation Work and Installation
2.1 Safety Measures Relating to Installation ................................................................................. 1-2-2
2.2 Installation Locations and Ambient Conditions ....................................................................... 1-2-5
2.3 Notes on Interference by Electromagnetic Noise.................................................................... 1-2-6
2.4 Accessories ............................................................................................................................. 1-2-7
2.5 Transport Method .................................................................................................................... 1-2-8
1
Table of Contents
2.6 Installation of Manipulator ..................................................................................................... 1-2-16

2.6.1 Installation Method ........................................................................................................ 1-2-16
2.6.2 Using Optional Manipulator Stand ................................................................................ 1-2-19
2.6.3 Maximum Manipulator Generative Force ..................................................................... 1-2-20
2.7 Note on Emergency stop of Manipulator ............................................................................... 1-2-21
Chapter 3 Periodic Inspection
3.1 Periodic Inspection .................................................................................................................. 1-3-2

3.1.1 Safety Measures for Inspection, Maintenance, Adjustments and Repairs of the Manipulator ....... 1-3-2
3.1.2 Periodic Inspection Schedule ......................................................................................... 1-3-4
3.1.3 Notes on Periodic Inspection .......................................................................................... 1-3-4
3.1.4 Deadline for Supplying/ Repairing the Robot Maintenance Parts ................................... 1-3-4
3.2 List of Maintenance Items ....................................................................................................... 1-3-5
3.2.1 NB4/NB4L Manipulator ................................................................................................... 1-3-5
3.2.2 NB15 Manipulator ........................................................................................................... 1-3-8
3.2.3 NV6 / NV6L / NV20 / NV20A Manipulator ..................................................................... 1-3-11
Chapter 4 Maintenance
4.1 Tension Adjustments of Timing Belts ...................................................................................... 1-4-4

4.1.1 Tension Adjustments of Timing Belt for NB4/NB4L ......................................................... 1-4-4
4.1.2 Tension Adjustments of Timing Belts of NB15 ................................................................ 1-4-6
4.1.3 Tension Adjustments of Timing Belts of NV6 / NV6L / NV20 / NV20A ............................ 1-4-8
4.2 Replacement and Replenishment of Grease for Reduction Gears ...................................... 1-4-11
4.2.1 Grease Replacement Procedure for Axis J1, J2 and J3 Reduction Gears ....................................... 1-4-11
4.2.2 Grease Replenishment Procedure for Axis J4, J5 and J6 Reduction Gears (NB4/NB4L) .................... 1-4-18
4.2.3 Grease Replenishment Procedure for Axis J4, J5 and J6 Reduction Gears (NB15)........................... 1-4-19
4.2.4 Grease Replenishment Procedure forAxis J4, J5 and J6 Reduction Gears (NV6 / NV6L/ NV20 / NV20A) ..... 1-4-20
4.3 Replenishment of Grease for Gear (NB4/NB4L/NB15) ........................................................ 1-4-21
4.3.1 Grease Replacement Procedure for Axis J4, J5 Gears (NB4/NB4L) ........................... 1-4-21
4.3.2 Grease Replacement Procedure for Axis J4, J5 Gears (NB15) ................................... 1-4-23
4.4 Grease Replenishment for Roller Bearing ............................................................................ 1-4-24

4.4.1 Grease replenishment procedure for Axis J4 cross roller bearing ................................ 1-4-24
4.4.2 Grease replenishment procedure for Axis J5 cross roller bearing (NB15) ................... 1-4-25
4.4.3 Grease replenishment procedure for Axis J6 cross roller bearing (NB4/NB4L) ........... 1-4-26
4.4.4 Grease replenishment procedure for Axis J6 cross roller bearing (NB15) ................... 1-4-27
4.5Battery .................................................................................................................................... 1-4-28
4.5.1 Function of Battery ........................................................................................................ 1-4-28
4.5.2 Specification of Battery ................................................................................................. 1-4-28
4.5.3 Replacing Battery .......................................................................................................... 1-4-28
4.5.4 Notes on Battery Safekeeping ...................................................................................... 1-4-29
4.6 Replacing Internal Wires ....................................................................................................... 1-4-30
2
Table of Contents
Chapter 5 Parts List
5.1 Parts List ................................................................................................................................. 1-5-2

5.1.1 NB4 ................................................................................................................................. 1-5-2
5.1.2 NB4L ............................................................................................................................... 1-5-4
5.1.3 NB15 ............................................................................................................................... 1-5-6
5.1.4 NV6 ................................................................................................................................. 1-5-8
5.1.5 NV6L ............................................................................................................................. 1-5-10
5.1.6 NV20 ............................................................................................................................. 1-5-12
5.1.7 NV20A........................................................................................................................... 1-5-14
5.2 Location and List of Warning Label....................................................................................... 1-5-16
Chapter 6 Internal Wires
6.1 Wiring Connection Figure ....................................................................................................... 1-6-2

6.1.1 Wiring Connection Figure for NB4 .................................................................................. 1-6-2
6.1.2 Wiring Connection Figure for NB4L ................................................................................ 1-6-4
6.1.3 Wiring Connection Figure for NB15 ................................................................................ 1-6-6
6.1.4 Wiring Connection Figure for NV6 .................................................................................. 1-6-8
6.1.5 Wiring Connection Figure for NV6L .............................................................................. 1-6-10
6.1.6 Wiring Connection Figure for NV20 .............................................................................. 1-6-12
6.1.7 Wiring Connection Figure for NV20A ........................................................................... 1-6-14
3
Table of Contents
H-type Manipulator
Chapter 1 Specifications of H-type Manipulator
1.1 Manipulator model .................................................................................................................. 2-1-2
1.2 Basic Specifications ................................................................................................................ 2-1-3
1.3 Outside Dimensions and Working Range ............................................................................... 2-1-4
1.4 Description on Each Part of Manipulator ................................................................................ 2-1-5

1.4.1 Allowable Load on Wrist Axis .......................................................................................... 2-1-5
1.4.2 Flange Dimensions of Wrist Axis .................................................................................... 2-1-6
1.4.3 Mounting Equipment on Upper Arm ................................................................................ 2-1-7
1.4.4 Restrictions of Working Range ....................................................................................... 2-1-8
1.4.5 Instrument Connecting Cables ....................................................................................... 2-1-9
1.4.6 Motion Warning Lamp (option) ..................................................................................... 2-1-12
1.4.7 Holding Brake ............................................................................................................... 2-1-12
1.5 Reference Position of Moving Axis ....................................................................................... 2-1-13
1.5.1 Angular Reference Position of Each Joint in the Working Range................................. 2-1-13
1.5.2 Angular Reference Position of Each Joint in the Starting Area ..................................... 2-1-13
1.6 Motion Direction of Each Axis ............................................................................................... 2-1-14
1.6.1 Motion of Each Axis ...................................................................................................... 2-1-14
1.6.2 Motion in the Cartesian Coordinate .............................................................................. 2-1-14
1.7 Changing Working Range ..................................................................................................... 2-1-15
1.7.1 Changing Working Range of Axis J1 ............................................................................ 2-1-15
1.7.2 Changing Working Range of Axis J2 and J3 ................................................................ 2-1-16
1.8 Option ................................................................................................................................... 2-1-17
2.1 Safety Measures Relating to Installation ................................................................................. 2-2-2
2.2 Installation Locations and Ambient Conditions ....................................................................... 2-2-5
2.3 Notes on Interference by Electromagnetic Noise.................................................................... 2-2-6
2.4 Accessories ............................................................................................................................. 2-2-7
2.5 Transport Method .................................................................................................................... 2-2-8
2.6 Installation of Manipulator ..................................................................................................... 2-2-10

2.6.1 Installation Method ........................................................................................................ 2-2-10
2.6.2 Installing Manipulator and Jigs on Common Frame Base ............................................ 2-2-11
2.6.3 Maximum Manipulator Generative Force ..................................................................... 2-2-11
2.7 Note on Emergency stop of Manipulator ............................................................................... 2-2-12
4
Table of Contents
3.1 Periodic Inspection .................................................................................................................. 2-3-2

3.1.1 Safety Measures for Inspection, Maintenance, Adjustments and Repairs of the Manipulator ....... 2-3-2
3.1.2 Periodic Inspection Schedule ......................................................................................... 2-3-4
3.1.3 Notes on Periodic Inspection .......................................................................................... 2-3-4
3.1.4 Deadline for Supplying/ Repairing the Robot Maintenance Parts ................................... 2-3-4
3.2 List of Maintenance Items ....................................................................................................... 2-3-5
4.1 Tension Adjustments of Timing Belts ...................................................................................... 2-4-4

4.1.1 Tension Adjustments of Timing Belt for Axis J3 .............................................................. 2-4-4
4.1.2 Tension Adjustments of Timing Belts for Axis J4 ............................................................ 2-4-5
4.1.3 Tension Adjustments of Timing Belts for Axis J5 and J6 ................................................. 2-4-6
4.2 Replacement and Replenishment of Grease for Reduction Gears ........................................ 2-4-7
4.2.1 Grease Replacement Procedure for Axis J1, J2 and J3 Reduction Gears ..................... 2-4-7
4.2.2 Grease Replenishiment Procedure for Axis J4, J5 and J6 Reduction Gears ............... 2-4-11
4.3 Grease Replenishment for Cross Roller Bearing.................................................................. 2-4-12
4.3.1 Grease replenishment procedure for Axis J4 cross roller bearing ................................ 2-4-12
4.4 Battery ................................................................................................................................... 2-4-13
4.4.1 Function of Battery ........................................................................................................ 2-4-13
4.4.2 Specification of Battery ................................................................................................. 2-4-13
4.4.3 Replacing Battery .......................................................................................................... 2-4-13
4.4.4 Notes on Battery Safekeeping ...................................................................................... 2-4-14
4.5 Replacing Internal Wires ....................................................................................................... 2-4-15
5.1 Parts List ................................................................................................................................. 2-5-2

5.1.1 NH5 ................................................................................................................................. 2-5-2
5.2 Location and List of Warning Label......................................................................................... 2-5-6
6.1 Wiring Connection Figure ....................................................................................................... 2-6-2

6.1.1 Wiring Connection Figure(Arc welding Specification) ................................................... 2-6-2
6.1.2 Wiring Connection Figure(Handling Specification) ......................................................... 2-6-4
5
B-type/V-type Manipulator
Capter 1 Specifications of B-type/

V-type Manipulator
Capter 2 Foundation Work and Installation
Capter 3 Periodic Inspection
Capter 4 Maintenance
Capter 5 Parts List
Capter 6 Internal Wires

Chapter 1 Specifications of B-type /
V-type Manipulator
This chapter describes the specifications of B-type / V-type manipulator.

1.1 Manipulator model ...................................................................................1-1-2
1.2 Basic Specifications .................................................................................1-1-4

1.2.1 Basic Specifications of NB4/NB4L/NB15 Manipulator ........................1-1-4
1.2.2 Basic Specifications of NV6/NV6L/NV20/NV20A Manipulator ............1-1-5
1.3 Outside Dimensions and Working Range ................................................1-1-7
1.4 Description on Each Part of Manipulator ...............................................1-1-17

1.4.1 Allowable Load on Wrist Axis ...........................................................1-1-17
1.4.2 Flange Dimensions of Wrist Axis ......................................................1-1-22
1.4.3 Mounting Equipment on the Upper Arm ...........................................1-1-25
1.4.4 Restrictions of Working Range .........................................................1-1-30
1.4.5 Instrument Connecting Cables and Gas (Air) Piping ........................1-1-31
1.4.6 Motion Warning Lamp (option) .........................................................1-1-36
1.4.7 Holding Brake ..................................................................................1-1-37
1.5 Reference Position of Moving Axis ........................................................1-1-38
1.5.1 Angular Reference Position of Each Joint in the Working Range.....1-1-38
1.5.2 Angular Reference Position of Each Joint in the Starting Area .........1-1-39
1.6 Motion Direction of Each Axis ................................................................1-1-40
1.6.1 Motion of Each Axis .........................................................................1-1-40
1.6.2 Motion in the Cartesian Coordinate..................................................1-1-40
1.7 Changing Working Range ......................................................................1-1-46
1.7.1 Changing Working Range of Axis J1 ................................................1-1-46
1.7.2 Changing Working Range of Axes J2 and J3 (with the option mounted).......1-1-47
1.8 Option ....................................................................................................1-1-51
1-1-1
1.1 Manipulator model
The following section shows the nomenclature of manipulator model.
1-1-2
1-1-3
1.3 Outside Dimensions and Working Range
1.2 Basic Specifications
1.2.1 Basic Specifications of NB4/NB4L/NB15 Manipulator

Item Specifications
Name NB4 NB4L NB15
Structure Vertical articulated type
Number of axes 6
Max. payload capacity 4 kg 4 kg 15 kg
Positional repeatability +/- 0.08 mm (Note 1) +/- 0.08 mm (Note 1) +/- 0.08 mm (Note 1)
Drive system AC Servo motor
Drive capacity 2550W 4650W 5600W
Position feedback Absolute encoder
J1 (Revolving) +/- 170 (+/-50) (Note 2) +/- 170 (+/-50) (Note 2) +/- 170 (+/-50) (Note 2)
Arm J2(Fore/Back) -155~ +90 -155~ +100 (Note 5) -155~ +100 (Note 5)
J3 (Up/Down) -170~ +180 -170~ +190 -170~ +305 (Note 6)
Working
J4 (Swing) +/- 155 +/- 155 +/- 155

range
Wrist J5 (Bending) -45~ +225(Note 4) -45~ +225(Note 4) -37~ +217(Note 4)

J6 (Twist) +/- 205 (Note 4) +/- 205 (Note 4) +/- 205 (Note 4)
3.66 rad/s {210/s} 3.40 rad/s {195/s} 3.40 rad/s {195/s}
J1 (Revolving) (3.32rad/s{190/s})(Notes (3.05rad/s{175/s})(Notes (2.88rad/s{165/s})(Notes
Arm 2) 2) 2)
Max. velocity
J2(Fore/Back) 3.66 rad/s {210/s} 3.49 rad/s {200/s} 3.05 rad/s {175/s}
J3 (Up/Down) 3.66 rad/s {210/s} 3.49 rad/s {200/s} 3.32 rad/s {190/s}
J4 (Swing) 7.33 rad/s {420/s} 7.33 rad/s {420/s} 6.98 rad/s {400/s}
Wrist J5 (Bending) 7.33 rad/s {420/s} 7.33 rad/s {420/s} 6.11 rad/s {350/s}
J6 (Twist) 10.5 rad/s {600/s} 10.5 rad/s {600/s} 10.5 rad/s {600/s}
J4 (Swing) 10.1 N*m 10.1 N*m 39.0 N*m
Allowable
J5 (Bending) 10.1 N*m 10.1 N*m 39.0 N*m
Moment
Wrist load
J6 (Twist) 2.94 N*m 2.94 N*m 7.36 N*m

Allowable J4 (Swing) 0.38 kg*m2 0.38 kg*m2 1.05 kg*m2
moment of J5 (Bending) 0.38 kg *m2 0.38 kg *m2 1.05 kg*m2
2 2
inertia J6 (Twist) 0.03 kg *m 0.03 kg *m 0.04 kg*m2
Arm operation cross-sectional area 2.94 m2 x 340 6.37 m2 x 340 6.52 m2 x 340
0 ~ 45, 20 ~ 80 %RH
Ambient temperature and humidity
(No condensation)
Mass (weight) 154 kg 277 kg 286 kg
Upper arm payload capacity 10 kg (Note 3) 20 kg (Note 3) 20 kg (Note 3)
Installation type Floor, ceiling or wall hanging type
Paint color White (Munsell 10GY9/1)
Note) 1. The value of the positional repeatability is at the tool center point (TCP) compliant to ISO 9283
2. The value in the parentheses indicates the wall-hung condition. J2 axis may occur the limitation of the
working range.
3. When loading the Max. payload capacity as the end effector.
4. There are occasions where restrictions can be made to the operation range of the J6 axis, depending
on the J5 axiss posture.
5. There are occasions where restrictions can be made to the operation range of the J2 axis.
6. The operation range of the J3 axis is restricted to -170 degrees to +190 degress when floor-based
welding is applied
IMPORTANT
1. The positional repeatability is a measured value obtained when the robot operating conditions are stabilized after
times of the automatic operation.
2. The positional data of absolute encoder is backed up by the battery. The battery backup period with the primary
power OFF is approx. 3 years.
Exceeding this period will require the battery replacement and the absolute offset adjustments.
3. The battery backup period may be shorter depending on the environmental conditions, the use conditions and so on.
4. A holding brake is provided in all axes.
5. The robot itself or peripheral jigs can be cause of interference according to their postures. Please be careful about
any interference when you teach the robot.
6. The above specifications are subject to change without notice.
1-1-4
1.2.2 Basic Specifications of NV6/NV6L/NV20/NV20A Manipulator

Item Specifications
Name NV6 NV6L
Number of axes 6
Max. payload capacity 6 kg 6 kg
Positional repeatability +/- 0.08 mm (Note 1) +/- 0.08 mm (Note 1)
Drive capacity 2600W 5000W
J1 (Revolving)
+/- 170 (+/-50) +/- 170 (+/-50)
(Note 2) (Note 2)
Arm
J2 (Lower arm) -155~ +90 -155~ +100
Working range
J3 (Upper arm) -170~ +190 -170~ +260(Note 3)

J4 (Swing) +/- 180 +/- 180
Wrist J5 (Bending) -50~ +230 -50~ +230
J6 (Twist) +/- 360 +/- 360
3.66 rad/s {210/s} 3.40 rad/s {195/s}
J1 (Revolving) (3.32 rad/s {190/s}) (3.05 rad/s {175/s})
(Note 2) (Note 6)
Max. velocity
Arm
J2 (Lower arm) 3.66 rad/s {210/s} 3.49 rad/s {200/s}
J3 (Upper arm) 3.66rad/s {210/s} 3.49 rad/s {200/s}
J4 (Swing) 7.33 rad/s {420/s} 7.33 rad/s {420/s}
Wrist J5 (Bending) 7.33rad/s {420/s} 7.33 rad/s {420/s}
J6 (Twist) 10.82rad/s {620/s} 10.82 rad/s {620/s}
J4 (Swing) 11.8 N*m 11.8 N*m
Allowable
J5 (Bending) 9.8 N*m 9.8 N*m
Moment
Wrist load
J6 (Twist) 5.9 N*m 5.9 N*m

Allowable J4 (Swing) 0.30 kg*m2 0.30 kg*m2
moment of J5 (Bending) 0.25 kg *m2 0.25 kg *m2
inertia J6 (Twist) 0.06 kg *m2 0.06 kg *m2
Arm operation cross-sectional area 3.14 m2 x 340 7.48 m2 x 340
0 ~ 45, 20 ~ 80 %RH
(No condensation)
Mass (weight) 144 kg 273 kg
Upper arm payload capacity 10 kg (Note 4) 20 kg (Note 4)
2. The value in the parentheses indicates the wall-hung condition. J2 axis may occur the limitation of
the working range.
welding is applied
IMPORTANT
1-1-5
Item Specifications
Name NV20 NV20A
Number of axes 6
Max. payload capacity 20 kg 20 kg
Positional repeatability +/- 0.07 mm (Note 1) +/- 0.07 mm (Note 1)
Drive capacity 5600W 7900W
+/- 170 (+/-50)
J1 (Revolving) +/- 170
(Note 2)
Arm
J2 (Lower arm) -155~ +100 -155~ +100
Working range
J3 (Upper arm) -170~ +260(Note 3) -170~ +260(Note 3)

J4 (Swing) +/- 180 +/- 180
Wrist J5 (Bending) -50~ +230 -50~ +230
J6 (Twist) +/- 360 +/- 360
3.40rad/s {195/s}
J1 (Revolving) (3.05 rad/s {175/s}) 3.40rad/s {195/s}
Arm (Note 2)
Max. velocity
J2 (Lower arm) 3.32rad/s {190/s} 3.32rad/s {190/s}

J3 (Upper arm) 3.14rad/s {180/s} 3.14rad/s {180/s}
J4 (Swing) 6.98 rad/s {400/s} 6.98 rad/s {400/s}
Wrist J5 (Bending) 6.98 rad/s {400/s} 6.98 rad/s {400/s}
J6 (Twist) 10.5 rad/s {600/s} 10.5 rad/s {600/s}
J4 (Swing) 43.7 N*m 43.7 N*m
Allowable
J5 (Bending) 43.7 N*m 43.7 N*m
Moment
Wrist load
J6 (Twist) 19.6N*m 19.6N*m

Allowable J4 (Swing) 1.09 kg*m2 1.09 kg*m2
moment of J5 (Bending) 1.09 kg *m2 1.09 kg *m2
inertia J6 (Twist) 0.24 kg *m2 0.24 kg *m2
2
Arm operation cross-sectional area 5.27 m x 340
0 ~ 45, 20 ~ 80 %RH
(No condensation)
Mass (weight) 278 kg 311 kg
Upper arm payload capacity 20 kg (Note 4) 20 kg (Note 4)
Installation type Floor, ceiling or wall hanging type Floor and ceiling type
2. The value in the parentheses indicates the wall-hung condition. J2 axis may occur the limitation of
the working range.
welding is applied
IMPORTANT
4. A holding brake
Outside is providedand
Dimensions in all axes. Range
Working
(1)NB4
1-1-6

170
300
67
R2
58
300
130
R4
P-Point
18
R1411
P
1210
Fig. 1.3.0.1 Outside Dimensions and Working Range of NB4 (unit : mm)
Note) This figure does not demonstrate the working range of the equipment-mounted robot.
When equipments and tools are mounted, the robot may interfere with itself. Therefore, before
performing operations, be sure that the robot does not come in contact with itself.
Approaching the operating robot may result in a fatal injury. Keep out of the robot
working range whenever the power is ON.
WARNING
1-1-7
170
300
67
4x18
R2
58
300
130
R4
P-Point
18
11
P
R14
212 640
R3
45
1251
530
271
136
1091
Fig. 1.3.0.2 Outside Dimensions and Working Range of NB4 (RT3500H + AF-4012) (unit : mm)
WARNING
1-1-8
(2)NB4L
130
P-Point
P
1505
Fig. 1.3.0.3 Outside Dimensions and Working Range of NB4L (unit : mm)
WARNING
1-1-9
P-Point
P
55
5
5
R2
R37
1823
1040
2370
220
220
TCP
530
760
136
1752
185
525
2299
1638 587 1421

2008
2185 2555
Fig. 1.3.0.4 Outside Dimensions and Working Range of NB4L (RT3500H + AF-4012) (unit : mm)
WARNING
1-1-10
(3)NB15
170
300
17
69.5
R3
4x18
163.5
300
233
R5
15
R1832
170
870
175
1647
760
205
1460
3223
525
185
1576
515 1317
1462 1832
Fig. 1.3.0.5 Outside Dimensions and Working Range of NB15 (unit : mm)
WARNING
1-1-11
170
300
17
69.5
4x18
R3
163.5
38 300
233
R5
0
15
R2
R1832
170
870
175
2195
1647
530
TCP
205
760
1460
140
3223
525
185
2124
1576
515 1317
1462 1832
2010 2380
Fig. 1.3.0.6 Outside Dimensions and Working Range of NB15 (RTWH5000H + AF-4012) (unit : mm)
WARNING
1-1-12
(4)NV6
170
300
4x18
67
134
R2
R3 P-Point
99
P
170
P-Point Working Range
P P-Point Working Range
P
100
650
125
1242
580
P-Point
1135
P
430
160
1188
1082 399 1003

1402
Fig. 1.3.0.7 Outside Dimensions and Working Range of NV6 (unit : mm)
WARNING
1-1-13
(5)NV6L
Fig. 1.3.0.8 Outside Dimensions and Working Range of NV6L (unit : mm)
WARNING
1-1-14
(6)NV20
300
R4 R17
67 10
Fig. 1.3.0.9 Outside Dimensions and Working Range of NV20 (unit : mm)
WARNING
1-1-15
(7)NV20A
Fig. 1.3.0.10 Outside Dimensions and Working Range of NV20A (unit : mm)
WARNING
1-1-16
1.4 Description on Each Part of Manipulator
1.4.1 Allowable Load on Wrist Axis

The payload of manipulator must not exceed each max. payload capacity (NB4 / NB4L :4kg, NV6 / NV6L: 6kg,
NV20 / NV20A : 20kg), including a welding torch, a chucking tool in handling and a workpiece.
Mounting a standard welding torch does not cause any problems to the manipulator, but both the moment and
the moment of inertia must be within the allowance stated in the table below when the manipulator is used for
handling or any other similar purposes.
Also, when a load is imposed not in the form of mass but force, a wrist axis must not be used with these
maximum allowable values exceeded.
Table 1.4.1.1 Allowable Load on Wrist Axis
NB4 / NB4L NB15
Axis
Allowable Allowable Allowable Allowable
Name
Moment Moment of Inertia Moment Moment of Inertia
2 2
J4 10.1 N*m 0.38 kg *m 39.0 N*m 1.05 kg *m
2 2
J5 10.1 N*m 0.38 kg *m 39.0 N*m 1.05 kg *m
2 2
J6 2.94 N*m 0.03 kg *m 7.36 N*m 0.04 kg *m
NV6 / NV6L NV20 / NV20A

Axis
Allowable Allowable Allowable Allowable
Name
Moment Moment of Inertia Moment Moment of Inertia
2 2
J4 11.8 N*m 0.30 kg *m 43.7 N*m 1.09 kg *m
2 2
J5 9.8 N*m 0.25 kg *m 43.7 N*m 1.09 kg *m
2 2
J6 5.9 N*m 0.06 kg *m 19.6 N*m 0.24 kg *m
1-1-17
(1) Allowable Load on Wrist Axis for NB4 /NB4L/NB15 Manipulator
Distance from Axis J6
220
Rotation Center
J6
(mm)
W=4kg
J5
258

300
W=3kg
Rotation Center
345
400
(mm)
(a)NB4 / NB4L
205
Distance from Axis

J6 Rotation Center
J6
(mm)
63 50
Distance from Axis
J5 Rotation Center
J5
W=15kg 260
265
W=10kg
324

(mm)
(b)NB15
Note: Though the center of gravity shown above fully satisfies the allowable load moment, the allowable
moment of inertia is not always satisfied.
Fig.1.4.1.1 Allowable Load on Wrist Axis (NB4 / NB4L / NB15)
1-1-18
(a)NB4 / NB4L
(b)NB15
Fig. 1.4.1.2 Wrist load conditions (NB4 / NB4L / NB15)
1-1-19
(2) Allowable Load on Wrist Axis for NV6 / NV6L / NV20 / NV20A Manipulator

Rotation Center
J6
(mm) 200 144 100
J5
W=6kg
Rotation Center
W=3kg
(mm)
(a) NV6 / NV6L

Rotation Center
J6
(mm)
J5
Rotation Center
(b) NV20 / NV20A
Fig.1.4.1.3 Allowable Load on Wrist Axis (NV6 / NV6L / NV20 / NV20A)
1-1-20
(a)NV6 / NV6L
(b)NV20 / NV20A
Fig. 1.4.1.4 Wrist load conditions (NV6 / NV6L / NV20 / NV20A)
1-1-21
1.4.2 Flange Dimensions of Wrist Axis

(1) Flange Dimensions of Wrist Axis for NB4 / NB4L Manipulator
Fig.1.4.2.1 shows the flange dimensions of wrist axis. Fit a tool using the flange spigot (57H7 or 75h7), and
position it properly using a reamed hole (6H7, 6 deep). To fix the tool in position, use 4XM5 tapping holes.
The length of M5 bolts must be shorter than 10 mm so that it fits the tapping hole of the flange part on wrist axis.
4.5
57 H7

2x6 H7 6 deep
4XM5 10 deep 45 6
10
(equally spaced)
(equally spaced)

P.C.D.67
A View A
A
Fig.1.4.2.1 Flange Dimensions of Wrist Axis (NB4 / NB4L) (unit : mm)
To avoid damaging to the motors or the reduction gears due to overload, be sure to
keep the allowable load on the wrist axis.
CAUTION
Use a specified tightening torque (Strength grade 12.9 : 7.25 N*m) for firmly tightening
M5 bolts so that tools are prevented from falling off or forcibly flown off.
Note that M6 bolts must be fit into a tapping hole (10 mm deep) in the wrist axis flange.
WARNING
1-1-22
(2) Flange Dimensions of Wrist Axis for NB15 Manipulator

Fig.1.4.2.2 shows the flange dimensions of wrist axis. Fit a tool using the flange spigot (83H7 or 105h7), and
6xM6 10 deep
10 2x6 H7 11 deep
(equally spaced) 11
()
.5
A P .C . D .93
View A
A
Fig.1.4.2.2 Flange Dimensions of Wrist Axis (NB15) (unit : mm)
CAUTION
WARNING
1-1-23
(3) Flange Dimensions of Wrist Axis for NV6 / NV6L / NV20 / NV20A Manipulator
Fig.1.4.2.3 , Fig.1.4.2.4 shows the flange dimensions of wrist axis. Fit a tool using the flange spigot (25H7 or
50h7), and position it properly using a reamed hole (6H7, 6 deep). To fix the tool in position, use 4XM6
tapping holes.
7.5
6
(equally spaced)
(equally spaced)

0
.D.4
A P.C
View A
A
Fig.1.4.2.3 Flange Dimensions of Wrist Axis (NV6 / NV6L) (unit : mm)
7
6
equally spaced equally spaced

0
. D.4
P.C
View A
A
A
Fig.1.4.2.4 Flange Dimensions of Wrist Axis (NV20 / NV20A) (unit : mm)
CAUTION
WARNING
1-1-24
1.4.3 Mounting Equipment on the Upper Arm

(1) NB4/NB4L/NB15
On the top, back and side of the upper arm, there are specific areas prepared for devices such as a wire feeding
unit and gas solenoid valve to be mounted. To mount a device, use M8 holes.
(a) Restriction of the maximum mountable mass on the upper arm.

The max. mountable mass on the upper arm depends on the max. wrist axis payload capacity. Calculate it by
the figure below, not exceeding the value C.
A+B1+B2C A : Max. wrist payload capacity (kg)

B1: Mountable mass on the Top of upper arm (kg)
B2: Mountable mass on the Back of upper arm (kg)
C : Max. mountable mass (kg)
NB4 NB4L NB15

A Max. 4kg Max. 15kg
B1 Max. 2kg
B2 Max. 10kg Max. 20kg
C 14kg 24kg 35kg
Suppose that the wrist of NB4 has a mass of 3 kg including a holder. In this case, the upper arm can
be mounted with an equipment of 11 kg (total B1 + B2) or less.
(b) The center-of-gravity position for mounting an equipment on the upper arm must be within the 100-mm pitch
position of 4XM8 tapping holes.
(When mounting the equipment on the back, be careful not to intervene the area of NOT-endurable shown by
hatching in the figure below.)
95 100
40
40
50
117
300
200
105
113
141
133
125
125
110
87
2xM8 16 deep Area of "B 2 " NOT

16 endurable
50 70 B 2 Area of "B 2 " NOT
2xM8 12 deep 9 endurable
12 25 B 2

Fig. 1.4.3.1 Equipment Mounting Position on the Upper Arm (NB4) (unit: mm)
1-1-25
95 100
4xM8 16 deep 40
16
40
50
2xM8 16 deep
16
4xM8 16 deep
16 25
9
117
300
200
110 20 105
121 141 N.P.
133
126
126
107
2xM8 16 deep
16
Area of "B 2 " NOT
endurable
B 2 2xM8 12 deep
12 9 Area of "B 2 " NOT
50 70 25 endurable
B 2

Fig. 1.4.3.2 Equipment Mounting Position on the Upper Arm (NB4L) (unit: mm)
keep the max. mountable mass on the upper arm.
CAUTION
WARNING
1-1-26
(c) Make sure that the centroid position to mount the equipment to the upper arm and rear part is within the
300mm pitch ( part) of J3 axis rotating center. Also, be sure that no any part of the equipment enters the
sphere of mounting unavailable indicated by hatching.
300
100 Axis J3
Rotation Center
217 50 J3
70
7.5
50
40
2xM8 16 deep 2xM8 15 deep

16 15 76.5
Area of "B 2 " NOT

endurable
B 2
50
R5
550
190
97
105
2xM8 15 deep
15
Area of "B 2 " NOT endurable 7.5

206.5 B 2 2 50
Fig. 1.4.3.3 Equipment Mounting Position on the Upper Arm (NB15) (unit: mm)
CAUTION
WARNING
1-1-27
(2) NV6 / NV6L / NV20 / NV20A

The top of the upper arm is provided with the face to mount the equipment such as a wire feeding unit, gas
solenoid valve etc. To mount the equipment, use 4XM8 holes provided in the center.
As for 4XM8 holes (2) provided in the front and 2XM8 (3) holes provided in the back, use them only for
cable clamping or others that the large external force is not applied on.
(a) Restriction of the maximum mountable mass on the upper arm.

The max. mountable mass on the upper arm depends on the max. wrist axis payload capacity. Calculate it by
the figure below, not exceeding the value C.
ABC AMax. wrist payload capacity (kg)

BMountable mass on the upper arm (kg)
CMax. mountable mass (kg)
NV6 NV6L NV20 / NV20A

A Max. 6 kg Max. 6 kg Max. 20 kg
C 16kg 26kg 40kg
Suppose that the wrist of NV6 has a mass of 3 kg including a holder. In this case, the upper arm can
be mounted with an equipment of 13 kg or less.
(b) The center-of-gravity position for mounting an equipment on the upper arm must be within the 140-mm pitch
position (indicated by asterisk in Fig.1.4.3.4, Fig.1.4.3.5) of 4XM8 tapping holes.
(When mounting the equipment on the back, be careful not to intervene the area of NOT-endurable shown by
hatching in the figure below.)
30 108
2
4xM8 12deep
12
40
4xM8 16 deep
16
140
40 60 65
40
84
140
3
2xM8 12 deep 9
12
25
Fig. 1.4.3.4 Equipment Mounting Position on the Upper Arm of NV6 Manipulator (unit: mm)
1-1-28
31 179
7
40
2 4xM8 12 deep 4xM8 16 deep

12 16
76.5
Area of "B "

119 140 NOT endurable

40 60 4
0
550
50
R5
165
105
3
2xM8 12 deep
12
Area of "B "NOT endurable

240
15 25
Fig. 1.4.3.5 Equipment Mounting Position on the Upper Arm of NV6L / NV20 / NV20A Manipulator (unit: mm)
CAUTION
WARNING
1-1-29
1.4.4 Restrictions of Working Range
Each axis of the manipulator has a limit in its working range for safety management and interference prevention.
The limit of working range set by the program in the robot controller is called Soft Limit.
In addition, the manipulator is usually equipped with an overrun limit switch and/or mechanical stoppers in case
that the manipulator moves beyond the Soft Limit.
B-Type / V-Type manipulator has the working range restrictions as shown in the table 1.4.4.1 below.
Table 1.4.4.1 Restrictions of Working Range on Each Axis for V-Type Manipulator
Axis Overrun Limit Mechanical
Soft Limit
Name Switch Stopper
J1
J2
J3
J4 (Note 1)
J5
J6
: Standard equipment
: Optional equipment (Refer to the 1.8 Option)
: Unequipped
Note) 1 . NB15 is unequipped
Fig.1.4.4.1 Limit of Working Range
1-1-30
1.4.5 Instrument Connecting Cables and Gas (Air) Piping

Inside the manipulator, the instrument connecting cables and a gas (air) hose are built in for a wire feeding unit
mounted on top of the upper arm and for driving or signaling instruments such as a gas solenoid valve.
The max allowable pressure of a gas (air) hose is 1.0MPa or less(At 20).
Cable Outlet
Connector (CN29)ELP-06V(J.S.T. Mfg .Co.,Ltd)

Prepare counter-connector Gas (Air) Hose
ELR-06V(J.S.T. Mfg . Co.,Ltd)
Connector (CN28)YLR-01VF(J.S.T. Mfg .Co.,Ltd)
Prepare counter-connector
YLP-01V(J.S.T. Mfg .Co.,Ltd)
Connector (CN27)ELR-02V(J.S.T. Mfg .Co.,Ltd)
ELP-02V(J.S.T. Mfg . Co.,Ltd) Instrument Connection Cables
Connector (CN41)ELP-02V(J.S.T. Mfg .Co.,Ltd) Cable 2 1 NC
Gas (Air) Hose 0.3mm6pcs+ 2
Prepare counter-connector 2 2 Cable [0.3mm ]

0.5mm2pcs+1.25mm4pcs
2
2
ELR-02V(J.S.T. Mfg . Co.,Ltd) 3 Cable [0.3mm ]

+Shield 2
Connector (CN26)ELR-03V(J.S.T. Mfg .Co.,Ltd) Pins

4 Cable [0.3mm ]
Cable0.3mm ]
2
Prepare counter-connector 5
1 2 3 4
ELP-03V(J.S.T. Mfg . Co.,Ltd) 6 NC
5 6 7 8 9 7
2
Cable [0.3mm ]
10 11 12 13 8
2
Cable [0.3mm ]
Gas Connection metal fittings 14 15 16 9 NC
2
10 Cable [0.5mm ]
2
11 Cable [0.5mm ]
2
Gas (Air) inlet 12 Cable [1.25mm ]

2
(9/16-18UNF) 13 Cable [1.25mm ]

2
Removing the adapter 14 Cable [1.25mm ]

2
allows the use of 15 Cable [1.25mm ]

Rc3/8 (PT3/8) Rc3/18(PT3/8) tapperd plug. 16 Shield
9/16-18UNF With shield
Max allowable pressure: 1.0MPa(At 20)
Instrument Cable Connector(CN4)
SRCN2A25-16P 4
<Allocation of CN4 Connector Pins>
(Japanese Aviation Electoronics
industry Ltd.) MAX PRESSURE
1.0 MPa (145psi)
SRCN6A25-16S
industry Ltd.)
J1 Grease filler port
Fig.1.4.5.1 Instrument Connecting Cables and Gas (Air) Piping for NB4 Manipulator
Cable Outlet
Cable
GasAirHose
Instrument Connection Cables

1 NC
0.3mm 2 6pcs+ 2
2 2 Cable [0.3mm ]
0.5mm 2 2pcs+1.25 mm 4pcs 2
3 Cable [0.3mm ]
+Shield 2
Pins 4 Cable [0.3mm ]

2
5 Cable0.3mm ]
1 2 3 4 6 NC
5 6 7 8 9 7
2
Cable [0.3mm ]
10 11 12 13 8
2
Cable [0.3mm ]
14 15 16 9 NC
2
10 Cable [0.5mm ]
2
11 Cable [0.5mm ]
2
12 Cable [1.25mm ]
2
13 Cable [1.25mm ]
2
14 Cable [1.25mm ]
2
15 Cable [1.25mm ]
16 Shield
Allocation of CN4 Connector Pins
MAX PRESSURE
1.0 MPa (145psi)
Welding cable terminal(M10)
Fig.1.4.5.2 Instrument Connecting Cables and Gas (Air) Piping for NB4L Manipulator
1-1-31
Cable Outlet
Rc3/8 (PT3/8) 9/16-18UNF

SRCN2A25-16P
(Japanese Aviation Electronics
industry Ltd.)
SRCN6A25-16S
industory Ltd.)
Fig.1.4.5.3 Instrument Connecting Cables and Gas (Air) Piping for NB15 Manipulator
Cable Outlet
Gas (Air) Hose
Connector (CN29)ELP-06V(J.S.T. Mfg .Co.,Ltd)
ELR-06V(J.S.T. Mfg . Co.,Ltd)
Connector (CN28)YLR-01VF(J.S.T. Mfg .Co.,Ltd)
YLP-01V(J.S.T. Mfg .Co.,Ltd)
Connector (CN27)ELR-02V(J.S.T. Mfg .Co.,Ltd)
Prepare counter-connector Instrument Connection Cables
2 1 NC
ELP-02V(J.S.T. Mfg . Co.,Ltd) 0.3mm6pcs+ 2
2 2 Cable [0.3mm ]
Connector (CN41)ELP-02V(J.S.T. Mfg .Co.,Ltd) 0.5mm2pcs+1.25mm4pcs
2
2
Cable +Shield 3 Cable [0.3mm ]
Prepare counter-connector Gas (Air) Hose 4
2
Cable [0.3mm ]
Pins
ELR-02V(J.S.T. Mfg . Co.,Ltd) 5
2
Cable0.3mm ]
Connector (CN26)ELR-03V(J.S.T. Mfg .Co.,Ltd) 1 2 3 4 6 NC
Prepare counter-connector 5 6 7 8 9 7
2
Cable [0.3mm ]
ELP-03V(J.S.T. Mfg . Co.,Ltd) 10 11 12 13 8
2
Cable [0.3mm ]
14 15 16 9 NC
2
10 Cable [0.5mm ]
Gas Connection metal fittings 2
11 Cable [0.5mm ]
2
12 Cable [1.25mm ]
2
13 Cable [1.25mm ]
2
Gas (Air) inlet 14 Cable [1.25mm ]
2
(9/16-18UNF) 15 Cable [1.25mm ]
Removing the adapter 16 Shield
With shield
allows the use of
Rc3/8 (PT3/8) 9/16-18UNF Rc3/18(PT3/8) tapperd plug. <Allocation of CN4 Connector Pins>
Max allowable pressure: 1.0MPa(At 20)
4
SRCN2A25-16P
MAX PRESSURE
1.0 MPa (145psi)
industry Ltd.)
SRCN6A25-16S
industry Ltd.)
Fig. 1.4.5.4 Instrument Connecting Cables and Gas (Air) Piping for NV6 Manipulator
1-1-32
Connector(CN29)ELP-06V(J.S.T Mfg.Co.Ltd)
ELR-06V(J.S.T.Mfg.Co.Ltd)
Connector(CN28)YLR-01VF(J.S.T Mfg.Co.Ltd)
YLP-01V(J.S.T.Mfg.Co.Ltd)
Connector(CN27)ELR-02V(J.S.T Mfg.Co.Ltd)
ELP-02V(J.S.T.Mfg.Co.Ltd)
Connector(CN41)ELP-02V(J.S.T Mfg.Co.Ltd) Cable
Prepare counter-connector GasAirHose
Gas Connection metal fittings Connector(CN26)ELR-03V(J.S.T Mfg.Co.Ltd)
Instrument Connection Cables
Prepare counter-connector 1 NC
0.3mm 2 6pcs+ 2
ELP-03V(J.S.T.Mfg.Co.Ltd) 2 2 Cable [0.3mm ]
0.5mm 2 2pcs+1.25 mm 4pcs 2
3 Cable [0.3mm ]
+Shield 2

GAS(Air)inlet
5 Cable0.3mm ]
2
(9/16-18UNF) 1 2 3 4 6 NC
Removing the adapter 5 6 7 8 9 2
7 Cable [0.3mm ]
allows the use of 10 11 12 13 2
Rc3/8 (PT3/8) 9/16-18UNF 8 Cable [0.3mm ]
Rc3/8(PT3/8) tapperd plug 14 15 16 9 NC
Max allowable pressure: 2
10 Cable [0.5mm ]
CN1 CN2 CN4 1.0MPa(At 20) 2
11 Cable [0.5mm ]
2
MAX PRESSURE
1.0 MPa (145psi) Instrument Cable Connector(CN4) 12 Cable [1.25mm ]
2
SRCN2A25-16P 13 Cable [1.25mm ]

2
(Japanese Aviation Electronics 14 Cable [1.25mm ]

2
industry Ltd.) 15 Cable [1.25mm ]

16 Shield
SRCN6A25-16S
(Japanese Aviation Electoronics Allocation of CN4 Connector Pins
industory Ltd.)
Fig.1.4.5.5 Instrument Connecting Cables and Gas (Air) Piping for NV6L Manipulator

MS3102A20-29S
industry Ltd.)
MS3106B20-29P
Connector(CN29)ELP-06V(J.S.T Mfg.Co.Ltd) or MS3108B20-29P
(Japanese Aviation
ELR-06V(J.S.T.Mfg.Co.Ltd) Electoronics
Connector(CN28)YLR-01VF(J.S.T Mfg.Co.Ltd) industory Ltd.)
Connector(CN41)ELP-02V(J.S.T Mfg.Co.Ltd)
Prepare counter-connector Cable
ELR-02V(J.S.T.Mfg.Co.Ltd) GasAirHose
Gas Connection metal fittings Connector(CN26)ELR-03V(J.S.T Mfg.Co.Ltd)

Prepare counter-connector Instrument Connection Cables
1 NC
ELP-03V(J.S.T.Mfg.Co.Ltd) 0.3mm 2 6pcs+ 2
2 2 Cable [0.3mm ]
0.5mm 2 2pcs+1.25 mm 4pcs
GAS(Air)inlet 3 Cable [0.3mm ]
2
+Shield
(9/16-18UNF) Pins 4
2
Cable [0.3mm ]
Removing the adapter 5 Cable0.3mm ]
2
allows the use of 1 2 3 4 6 NC

Rc3/8(PT3/8) tapperd plug 5 6 7 8 9 7 Cable [0.3mm ]
2
Rc3/8 (PT3/8) 9/16-18UNF Max allowable pressure: 10 11 12 13 8 Cable [0.3mm ]

2
1.0MPa(At 20) 14 15 16 9 NC
Instrument Cable Connector(CN5) 10 Cable [0.5mm ]
2
MS3102A20-29P 2
11 Cable [0.5mm ]
(Japanese Aviation Electronics 2
12 Cable [1.25mm ]
industry Ltd.) 2
CN1 CN2 CN4 13 Cable [1.25mm ]

14 Cable [1.25mm ]
MS3106B20-29S 2
MAX PRESSURE 15 Cable [1.25mm ]
or MS3108B20-29S
1.0 MPa (145psi)
16 Shield
(Japanese Aviation
Electoronics
industory Ltd.) Allocation of CN4 Connector Pins
Instrument Cable Connector(CN4) Instrument Connection Cables H 0.3 mm

2
SRCN2A25-16P 1.25mm 2 4pcs+0.3mm2 12pcs+ 2

J 0.3 mm
(Japanese Aviation Electronics 1.0mm 2 (0.5mm2 2) 2 K 0.3 mm
2
industry Ltd.) A 1.25 mm

M A B
2
B 1.25 mm
2 L 0.3 mm
Prepare counter-connector L N C 2
P C 1.25 mm
2 M 0.3 mm
K T D
SRCN6A25-16S 2 N 0.3 mm
2
J S R E D 1.25 mm
(Japanese Aviation Electoronics H G F 2 P 0.3 mm
2
E 0.3 mm
industory Ltd.) 2 R 0.3 mm
2
F 0.3 mm 2
G 0.5 mm
2 S 0.3 mm
MS3102A20-29P 2
2 T 0.3 mm
Fig.1.4.5.6 Instrument Connecting Cables and Gas (Air) Piping for NV20 Manipulator
1-1-33

MS3102A20-29S
Prepare counter-connector industry Ltd.)
MS3106B20-29P
Connector(CN29)ELP-06V(J.S.T Mfg.Co.Ltd) or MS3108B20-29P
(Japanese Aviation
ELR-06V(J.S.T.Mfg.Co.Ltd) Electoronics
Connector(CN28)YLR-01VF(J.S.T Mfg.Co.Ltd) industory Ltd.)
Connector(CN41)ELP-02V(J.S.T Mfg.Co.Ltd) Cable
Prepare counter-connector GasAirHose
Connector(CN26)ELR-03V(J.S.T Mfg.Co.Ltd) Instrument Connection Cables
1 NC
Prepare counter-connector 0.3mm 2 6pcs+ 2
2 Cable [0.3mm ]
ELP-03V(J.S.T.Mfg.Co.Ltd) 0.5mm 2 2pcs+1.25 mm 2 4pcs 2
3 Cable [0.3mm ]
GAS(Air)inlet +Shield 2

(9/16-18UNF) 5 Cable0.3mm ]
2
Removing the adapter 1 2 3 4 6 NC

allows the use of 5 6 7 8 9 2
7 Cable [0.3mm ]
Rc3/8(PT3/8) tapperd plug 10 11 12 13 2
8 Cable [0.3mm ]
Max allowable pressure: 14 15 16 9 NC
1.0MPa(At 20) 2
10 Cable [0.5mm ]
Instrument Cable Connector(CN5) 2
11 Cable [0.5mm ]
MS3102A20-29P 2
12 Cable [1.25mm ]
(Japanese Aviation Electronics 2
13 Cable [1.25mm ]
industry Ltd.) 2
CN2 CN3 CN4 14 Cable [1.25mm ]
MS3106B20-29S 15 Cable [1.25mm ]

MAX PRESSURE
1.0 MPa (145psi)
or MS3108B20-29S 16 Shield
(Japanese Aviation
Electoronics Allocation of CN4 Connector Pins
industory Ltd.)
Instrument Connection Cables H 0.3 mm
2
Instrument Cable Connector(CN4) 0.3mm 2 8pcs 2

J 0.3 mm
SRCN2A25-16P 2
A NC K 0.3 mm
M A B
2
B NC L 0.3 mm
industry Ltd.) L
N C 2
P C NC M 0.3 mm
Prepare counter-connector K T D 2
J S R D NC N 0.3 mm
SRCN6A25-16S E
P NC
H G F E 0.3
2
mm
(Japanese Aviation Electoronics R NC
mm
2
industory Ltd.) F 0.3
G NC S NC
MS3102A20-29P
T NC
Fig.1.4.5.7 Instrument Connecting Cables and Gas (Air) Piping for NV20A Manipulator
1-1-34
For welding application, Fig.1.4.5.8 below shows the wiring diagram of the built-in cables in the manipulator.
Base Side Electrical Connection of Manipulator Upper Arm Side
CN4 CN29
White
Red
Yellow,Blue,Green Wire Feed Device(Encorder)
Orange
SRCN6A25-16S
SRCN2A25-16P
CN41
Gray
Black SOL Gas Solenoid Valve
CN26
Yellow
Blue
Others
White
CN27
Red
Black Wire Feed Device(Motor)
CN28
Green
Voltage Detection Line(+)
CN2
MOLEX 58691-0020
Yellow
Blue Warning Lamp
Red
White
Shock Sensor LS
For NB4/NB4L
Base Side Electrical Connection of Manipulator Upper Arm Side Base Side Electrical Connection of Manipulator Upper Arm Side
CN.5 CN.36 CN.5 CN.36

Red
A A A A

White
B Black B B B
C Green C C C
D Yellow D D D
G Blue G G G
Red Red
E Black E E Black E
F Blue F F Blue F
H Brown H H Brown H
J Green J J Green J
K Purple K K Purple K
L White L L White L
M Yellow M M Yellow M
N Skyblue N N N
P Orange P P P
R Grass R R R
S Gray
S S S
T T T T
NV20Electrical Circuit Diagram of CN5 Cables NV20AElectrical Circuit Diagram of CN5 Cables
Fig.1.4.5.8 CN5 Cable Wiring
When using these built-in cables for applications other than welding, prepare the counter-connectors shown from
Fig.1.4.5.1 to Fig.1.4.5.7.
CN5 connector for device connection is prepared into NV20 and NV20A. Please
check the wiring diagram each since wiring is different
IMPORTANT
1-1-35
1.4.6 Motion Warning Lamp (option)

A manipulator is provided with a connector for the motion warning lamp. This warning lamp is optionally available
to indicate Servo ON, Automatic Operation and so on.
Refer to the 1.8 Option for more details.
(1)NB4 (2)NV6
(3)NB4L (4)NV6L / NV20 / NV20A
(5)NB15
Fig.1.4.6.1 Motion Warning Lamp
1-1-36
1.4.7 Holding Brake
All the motors of B-Type / V-Type manipulator have built in holding brakes respectively.
A holding brake is intended to prevent the manipulator arm from falling when the control power is OFF or
when the servo power is OFF due to an emergency stop.
(Note: These brakes will be released only when the servo power is turned on.)
1-1-37
1.5 Reference Position of Moving Axis
The angular reference position of each joint in the working range and the starting area of B-Type / V-Type
manipulator is as follows.
1.5.1 Angular Reference Position of Each Joint in the Working Range
Axis J1 : 0 deg. is at front position.

Axis J2 : 0 deg. is at horizontal position. (The above figure shows 90 deg.)
Axis J3 : Defined as 0 deg. when the angle between the upper and the lower arm is 90 deg.
Axis J4 : 0 deg. is the position where the Axis J3 and J4 are laid in a straight line.
Axis J5 : Defined as -90 deg. when the axis points the direction of a plumb down.
Fig.1.5.1.1 Reference Position of Moving Axis for B-Type / V-Type Manipulator (in the Working Range)
1-1-38
1.5.2 Angular Reference Position of Each Joint in the Starting Area

Axis J2 : 0 deg. is at vertical position.
Axis J3 : Defined as 0 deg. when the upper arm is parallel to the ground.
Fig.1.5.2.1 Reference Position of Moving Axis for B-Type / V-Type Manipulator (in the Starting area)
1-1-39
1.6 Motion Direction of Each Axis

The direction of axis motion when operating B-Type / V-Type manipulators respectively by manual
operation of each axis or the Cartesian coordinate is as follows.
1.6.1 Motion of Each Axis

The axis corresponding to each axis key on Teach pendant can move independently as shown in the
figure.
Axis Name Movement Keys on Teach Pendant
J4 RX-
Z+
Revolving J3
(Left-right) RY+
J5
Lower Arm Z-

RX+ RY-
(Front-Back)
()
Upper Arm RZ+ RZ-
(Up-Down) J6
( Y+ J2
Wrist
(Swing)
()
Wrist
(Bending) X+
()
Y-
Wrist
(Twist)
() X-
J1
Fig.1.6.1.1 Name of the Motion Axis for B-Type / V-Type Manipulator
1.6.2 Motion in the Cartesian Coordinate

The moving directions of each axis for the base coordinate system and the tool coordinate system are as
follows.
The motion in the Cartesian coordinate contains the body axis movement for torch tip position and the
wrist axis movement for torch angle. The wrist axis movement for B-Type / V-Type manipulator has two
kinds: Cartesian coordinate movement by Euler angle and Cartesian coordinate movement by R.P.Y.
(roll-pitch-yaw).
Euler angle or R.P.Y. can be selected by changing the user parameter that sets the system condition
along with other parameters.
(1) Body Axis Movement (Base Coordinate System)
Fig.1.6.2.1 Body Axis Movement in the Base Coordinate System for B-Type / V-Type Manipulator
1-1-40
(2) Wrist Axis Movement

(Euler Angle, Base Coordinate System)
Axis J4 Movement
RX+
The torch rotates around Z-Axis with the torch tip fixed.
RX-
Torch Line
Z-Axis
Z
Fig.1.6.2.2 Axis J4 Moving Direction
Axis J5 Movement
A torch makes a circular movement around the torch tip that

lies on the plane spanned by the torch line and Z-Axis with the
torch tip fixed.
RY-
Torch Line RY+

Z-Axis
Z

Axis J6 Movement
A torch rotates around the torch line at fixed torch angle with the
torch tip fixed.
Z-Axis

Axis J6 Rotation Center
J6

RZ+
RZ-
Torch Line
Z-Axis

Z
Torch Tip Torch Angle

Horizontal Plane

Torch Line

Fig.1.6.2.5 Wrist Axis Moving Direction in the Base Coordinate System
1-1-41
(3) Wrist Axis Movement (Roll-Pitch-Yaw) Z-Axis

Z
Axis J4 Movement
A tool rotates around the X-Axis with the center of the

tool fixed.
RX+
X-Axis
X
RX-
Axis J5 Movement Z-Axis

A tool rotates around the Y-Axis with the center of the
Z
tool fixed.
RY+
Y-Axis
Y RY-
Axis J6 Movement: Z-Axis

A tool rotates around the Z-Axis with the center of the
Z
tool fixed.
RZ+
RZ-
X-Axis
X
1-1-42
(4) Body Axis Movement (Tool Coordinate System)
X- Y+
Z+
Y
Z
Z-
Y- X+
X
Fig.1.6.2.9 Body Axis Movement in Tool Coordinate System
Y X
Fig.1.6.2.10 Body Axis Movement in the Tool Coordinate System when the Posture of the Manipulator Changes
1-1-43
(5) Wrist Axis Movement (Tool Coordinate System)

Axis J4 Movement
A torch rotates around the Z-Axis (torch line) with the torch tip fixed.
Z Z
RX- RX+
Y Y
X X
Axis J4 Moving Direction

J4
Axis J5 Movement
A torch rotates around the Y-Axis with the torch tip fixed.
RY-
Z
RY+ Y
X
J5
Axis J6 Movement
Same as the Axis J4 movement.
RZ-
Y
X RZ+
J6
1-1-44
WARNING
Movement Around the Singular Point in Cartesian Coordinate
Performing the manual operation in Cartesian coordinate or linear/circular interpolation movement around the
singular point may result in danger, causing abrupt movement of an unexpected axis. Therefore, when the
manipulator needs to work around the singular point, be sure to manually operate each axis.
In addition, teach a robot in such a manner that a linear/circular trajectory will not pass near the singular point.
Teaching otherwise provides no guarantee of the set velocity and the trajectory accuracy for the taught point.
B-Type / V-Type have the following two postures referred to as Singular Point.
1. Singular Point for Axis J4 and J6 (see Fig.1.6.2.14)
The posture when the rotation Axis J6 intersects the rotation

Axis J4.
Fig.1.6.2.14 Singular Point for Axis J4 and J6
2. Singular Point for Axis J1 and J5 (see Fig.1.6.2.15)
The posture when the rotation Axis J5 intersects the rotation

Axis J1.
Fig.1.6.2.15 Singular Point for Axis J1 a d J5
1-1-45
1.7 Changing Working Range
1.7.1 Changing Working Range of Axis J1

According to the conditions of the manipulators surrounding area, axis J1 can restrict its working range (add
the optional stopper block Assy. to NB4L, NB15, NV6L, NV20 and NV20A. The stopper block Assy is essential
when changing the installation type of manipulator from the floor-installed or ceiling-hung into the wall-hung
because the motion range of J1 axis is limited to 50. To change the installation type, be sure to contact us.).
Furthermore, by mounting the limit switch (option) limitations can be provided, both electronically and
mechanically.
Axis J1 can be changed its working range according to the ambient condition, which is available by changing
the setting position of stopper bolt as shown in the figure below. Also modify the Soft Limit area at this time.
Stopper

Stopper

2.Install Stopper 1.Remove Stopper

Install StopperOPTION

Fig.1.7.1.1 Changing Working Range of Axis J1 Fig.1.7.1.2 Changing Working Range of Axis J1
(NB4 / NV6) (NB4L / NB15 / NV6L / NV20 / NV20A)
In order to install stopper bolts, select two positions (+ and -) for the desired working range from the positions
shown in Fig.1.6.1.1 or Fig.1.6.1.2 Note that it must be set within +170 ~ -170 since the working range in
excess of +/-170 cannot be set. In addition, the arm must face the front of the robot in the working range.
Select the working range from the + side and the - side in Fig.1.7.1.3, Fig.1.7.1.4
The stopper bolts are mounted at +/-170 at factory shipment.
Stopper (Movable Side)

(Fixed to Frame by the back)
(
Axis J1 -90
Rotary -120 -60
Direction
J1 Arm -150 -30 Stopper Lever

(Fixed Side)
-
-170
Arm Front
Axis J1 Limit SW
+170 J1
Axis J1 (Option)
Rotary
Direction +150 +30
J1 +120
+60
+90
+ Flame

Fig.1.7.1.3 Stopper Bolt Setting Position (NB4 / NV6)
(
(Fixed to Frame by the back)
-80
-110 -50
Axis J1
Rotary Arm
Direction -140 -20 Stopper Lever

(Fixed Side)
-
-170
Arm Front

+170
Axis J1
Rotary
Direction +140 +20

+
+110 +50
+80
Fig.1.7.1.4 Stopper Bolt Setting Position (NB4L / NB15 / NV6L / NV20 / NV20A)
1-1-46
1.7.2 Changing Working Range of Axes J2 and J3 (with the option mounted)
For the axis J2 and J3, the working range can be changed by installing the optional Dog and Limit Switch.
At this time, modify the Soft Limit area as well. The installation position and the adjustment angle of Limit
Switch in each manipulator is shown in the figure below. When setting the dog, select a single position in each
(+) and (-) side in the desired working range.
The limit switch will not operate properly if the dogs installation position of the J3 axiss maximum operation
edge is misplaced. Be sure to install the dog by referring to the following figures shown below.
Axis J2 Rotary Axis J2 Rotary

Direction Direction
J2 J2
+ -
-45
+30 -60
+60 -90
+90 -120
Dog

-155
Fig.1.7.2.1 Dog Setting Position on Axis J2(NB4 / NV6)

Vertical Position
Direction Direction

0
+ -
Axis J2 Limit SW -30

+40
-60
+70
-90
Dog

+100
-120
-155
Fig.1.7.2.2 Dog Setting Position on Axis J2(NB4L / NB15 / NV6L / NV20 / NV20A)
1-1-47
Use the second,a tap of third

from the edge and install Dog.
23 Axis J3 Rotary
Direction
J3
+
The angle contained by Axis J2
Dog
and Axis J3 is 90 degree.

90
0
+90
Axis J3 Rotary
Dog Direction
+60 J3
-
+30 -85
-60
-30
Use the first,a tap of second

12

Fig.1.7.2.3 Dog Setting Position on Axis J3(NB4)
Dog Dog

-85
+90
-50
+60
-20
+30
Fig.1.7.2.4 Dog Setting Position on Axis J3(NB4L)
1-1-48
When floor-based setting is used,

set the dog in a position below 90 degree. Axis J3 Rotary
Dog Direction
90 J3
+
+180+205
+150 and Axis J3 is 90 degree.
90
Dog 0
+120
Axis J3 Rotary
Dog -80 Direction
J3
+90 -
-50
+60
-20
+30
Fig.1.7.2.5 Dog Setting Position on Axis J3(NB15)
Use the first,a tap of second

from the edge and install Dog. Axis J3 Rotary
12 Direction
J3
+
Dog
+100 and Axis J3 is 90 degree.
90
0
Dog Axis J3 Rotary
+60 Direction
J3
-
+30 -80
-60
-30
Use the second,a tap of third

23

Fig.1.7.2.6 Dog Setting Position on Axis J3(NV6)
1-1-49
When floor-based setting is used for welding,

set the dog in a position below 120 degrees.

120 Axis J3 Rotary
Direction
Dog
+180
Dog +150

Dog 90
+120 0

Axis J3 Rotary
Direction
+90

+60
+30
Axis J3 Limit SW

Fig.1.7.2.7 Dog Setting Position on Axis J3(NV6L / NV20 / NV20A)
1-1-50
1.8 Option
1.8 Option
(1) Part to restrict the working area of Axis J1 (electric)
The following part can restrict the working area of Axis J1 electrically.
DAIHEN Part No.. Name Specifications
L10460V00 Cable assembly LS1 Limit switch parts for working restriction of Axis J1.
L10485M Stopper block Assy. Only for NB4L/NB15/NV6L/NV20/NV20A
The stopper block Assy is essential when changing the installation type of manipulator from the
floor-installed or ceiling-hung into the wall-hung because the motion range of J1 axis is limited to 50. To
change the installation type, be sure to contact us.
(2) Part to restrict the working area of Axis J1 (machine)
The working area of axis J1 can be mechanically restricted.
Mechanical stopper parts for axis J1s working
L10485M Stopper block Assy. arearestrictions
(NB4L/NB15/NV6L/NV20/NV20A)
The stopper block Assy is essential when changing the installation type of manipulator from the
floor-installed or ceiling-hung into the wall-hung because the motion range of J1 axis is limited to 50. To
change the installation type, be sure to contact us.
(3) Parts to restrict the workings areas of Axes J2 and J3
The following parts can restrict the working areas of Axes J2 and J3 electrically.
L7400Q00 Cable assembly LS2 Limit switch parts for working restriction of Axes J2 and J3.
For NV6 / NB4
L11130L00 Dog accessories
Dog parts for working restriction of Axes J2 and J3.
For NB4L
L10525N00 Dog accessories
For NV6L / NV20 / NV20A
L10485N00 Dog accessories
For NB15
L10974K00 Dog accessories
(4) Mechanical stoppers for Axis J4

The following parts can restrict the working area of Axis J4 mechanically.
L10470N00 Mechanical stopper J4 Mechanical stopper for Axis J4 of NB4 / NB4L
L10460N00 Mechanical stopper J4 Mechanical stopper for Axis J4 of NV6
Mechanical stopper for Axis J4 of NV6L / NV20 /
L10485P00 Mechanical stopper J4
NV20A
(5) Warning lamp

The warning lamp lights up while the robot is working (the servo power is ON).
This is mounted on top of the upper arm of manipulator.
L6600R00 Warning lamp Coloramber
L6600S Warning lamp Colorred
L10974P00 Lamp installation ASSY Lamp intstallation parts for NB15
For NB15, warning lamp and lamp installation ASSY are necessary
(6) Welding cables and parts mounted
For NV6
The welding cables are mounted along the robot body from its back to Axis J3 passing through the inside of
Axis J1.
L11130S00 Additional power cable ASSY For NV6
For NV6L / NV20 / NV20A
The welding cables are mounted along the robot body from its back to Axis J3 passing through the inside of
Axis J1.
L10485U00 Additional power cable ASSY For NV6L / NV20 / NV20A
1-1-51
1.8 Option
(7) Jig to check the home position
The following jig is a necessary item to check the home position of each axis.
L10725C Mechanical origin checking parts For NB4
L10725B Mechanical origin checking parts For NV6
L10725K Mechanical origin checking parts For NB4L
L10725L Mechanical origin checking parts For NV6L
L10725J Mechanical origin checking parts For NV20 / NV20A
L10725P Mechanical origin checking parts For NB15
The option is not used for Mechanical adjustment(Performing encoder reset and encoder correction)
(8) Manipulator stand
A manipulator stand is available by option.

For details, refer to 2.6.3 Using optional manipulator stand in this instruction manual.
Model Name Specifications
L-3626 Stand Stand height400mm
Do not alter or remodel our products.

You may get injured or have your equipment damaged because of fire, failure or
malfunction caused by altering or remodeling the product.
DANGER The warranty does not cover any altered or remodeled products.
1-1-52
This chapter provides the instructions for the foundation work and installation.
2.1 Safety Measures Relating to Installation ..................................................1-2-2

2.2 Installation Locations and Ambient Conditions.........................................1-2-5
2.3 Notes on Interference by Electromagnetic Noise .....................................1-2-6
2.4 Accessories..............................................................................................1-2-7
2.5 Transport Method.....................................................................................1-2-8
2.6 Installation of Manipulator ......................................................................1-2-16
2.6.1 Installation Method ...........................................................................1-2-16
2.6.2 Using Optional Manipulator Stand....................................................1-2-19
2.6.3 Maximum Manipulator Generative Force .........................................1-2-20
2.7 Note on Emergency stop of Manipulator................................................1-2-21
1-2-1
2.1 Safety Measures Relating to Installation
Measures to Ensure the Safety of Personnel Entering inside the Operating

Range of the Robot
While the robot is operating, there is a danger that the operators will come into contact
with the robot. For this reason, erect a guarding fence to ensure that the operators will
be kept at a distance from the robot. Accidents may occur if operators or other
DANGER individuals gain admittance inside the operating range of the robot by mistake.
Guarding fence
ISO 13857:2008 Safety of machinery - Safety distances to prevent hazard zone
being reached by the upper and lower limbs.
The guarding fence must be constructed in such a way that it cannot be easily climbed
over or easily moved. If the guarding fence is too low, individuals may climb over it and
enter inside the operating range of the robot, leading to accidents.
DANGER
Provide a door in the guarding fence to allow access in and out of the operating range.
Be absolutely sure to install a safety plug in the door, and construct the door in such a
way that it will not open unless the plug is removed. The entry of an individual inside the
CAUTION guarding fence can be detected by means of the signals from the safety plug.
Take steps to provide an interlock so that the servo power (motor power) of the robot
is turned off when the safety plug has been removed or ensure that the motor power
is turned off while the guarding fence is open. The robot can be stopped automatically
when an individual has made an attempt to enter inside the guarding fence. (The
CAUTION robot controller has a safety plug input.)
1-2-2
Provide the emergency stop button of the robot in a location where it can be pressed
immediately by the operator.
Accidents may occur since the emergency stop operation cannot be initiated
CAUTION immediately. (The robot controller has an external emergency stop input.)
If it is not possible to erect a guarding fence, install photoelectric switches, mat switches,
etc. in every location where individuals can enter inside the operating range of the robot
in place of the safety plug. The robot can be stopped automatically when an individual
DANGER has entered inside the operating range of the robot.
Color-code the floor so that the danger area (operating range of the robot) can be easily
identified visually.
CAUTION
Safety measures for positioning the robot and its peripheral devices
Do not position the operation and adjustment controls inside the operating range of the
robot. The robot may cramp the access to these controls.
Place the robot control panel, interlock panel and all other operation panels in positions
DANGER where they can be operated outside the guarding fence.
If an operation stand is to be provided, provide it with an emergency stop button as well.

Emergency stop can be initiated immediately even when fault occurs during operation
using the operation stand.
CAUTION
Do not route the wires and hoses between the robot body and the control panel,
inter-lock panel, etc. in such a way that the operators will trip over them or the forklift
trucks will run straight over them. Otherwise, operators may fall over, wires may break or
WARNING become disconnected, causing accidents.
Do not place the control panel, interlock panel, operation stand, etc. in positions where
the movements of the robot body are not visible.
If the robot movements cannot be seen, the operator will be slow to respond even when
fault has occurred, and this may lead to a serious accident. Accidents may also be
DANGER caused if the presence of the operators cannot be verified.
Place restrictions on the operating range of the robot if the necessary work range of the
robot is smaller than the range in which the robot can be operated. Restrictions can be
placed using limit switches and mechanical stoppers. Even if the robot has moved out of
CAUTION the normal work range due to a fault, for instance, it can be stopped ahead of time.
(Refer to 1.6 Changing Working Range .)
1-2-3
In the range where the movements of the robot body can be seen satisfactorily, install
light-shielding boards, covers, etc. in the directions where operators may be exposed to
spatter while welding is in progress. Operators may be injured by the light emitted during
CAUTION welding, by spatter, etc.
Ensure that the display of the automatic and manual modes indicating the operating
status of the robot is large and conspicuous enough to enable the modes to be easily
recognizable from a distance. The use of a buzzer, alarm or other warning to signal the
start of auto operation is also effective. This will enable the fact that auto operation is
WARNING underway to be easily verified from a distance.
Minimize the number of protruding parts on the devices around the robot.
If necessary, place covers over them. Protruding parts are dangerous when they are
touched by the operator even under normal circumstances, and they constitute a hazard
as well if the robot should suddenly move, surprising and possibly knocking over the
CAUTION operator in the process.
Avoid the kind of layout where operators need to put their hands inside the fenced
area to load and unload the work pieces. The robot may move to the place where an
operator has placed his or her hands inside the fenced area.
DANGER
Safety Precautions for Installation Work
In installing the robot, it is important to position the robot where the operator will not be
cramped. While tools are still installed on the robot, the robot must not be operated in its
maximum operating range so that it touches its peripheral devices.
WARNING
The designated method for installing the robot must be followed without fail. Following a
method which is not designated may cause the robot to move or topple over during
operation which is extremely dangerous.
WARNING
Before proceeding to connect the wires between the robot and the robot controller or
peripheral devices, ensure that the connection methods are thoroughly understood.
Faults may be caused in the operation of the robot by taking the wrong steps.
WARNING
Ensure that the grounding work is done properly. If there are any welders or other
devices that generate significant levels of noise, proceed with the designated
grounding work for them.
WARNING
When moving the robot into position and installing it, be very careful not to damage the
wiring. Furthermore, after having positioned the units, take protective measures such as
providing protective covers to ensure that the wiring will not be damaged by the
WARNING operators and other individuals or by the forklift truck.
1-2-4
2.2 Installation Locations and Ambient Condition
2.2 Installation Locations and Ambient Conditions
(1) The ambient temperature must be in the 0 to 45 degrees Celsius range.

(2) The ambient relative humidity must be in the 20 to 80%RH range, and there must be no condensation.
(3) The amounts of dust, dirt, oily vapors, water, etc. must be minimal.
(4) There must be no flammable or corrosive liquids or gases present.
(5) There must be no major sources of impact or vibration.
(6) No major sources of electrical noise must be in the vicinity of the robot.
2
(7) The vibration level must be less than 0.5G (4.9m/s ).
(8) Avoid direct sunlight.
1-2-5
2.3 Notes on Interference by Electromagnetic Noise

A high-frequency arc starting unit, an inverter-type welding power supply and other units that generate
electromagnetic noises may cause an adverse effect on the robot system, such as malfunction.
To prevent this effect, select a proper installation location and install them in a most appropriate manner.
1-2-6
2.4 Accessories
2.4 Accessories
B-Type / V-Type / manipulator is provided with the following standard accessories.
Table. 2.4.0.1 Standard accessories (L7700D)
Name Specifications Qt. Remarks

Hexagon Socket Head For fixing the main body
M16X50 4
Cap Screw (Strength grade: 10.9)
Spring Washer M16 4 For fixing the main body
B-Type / V-Type manipulator can be provided with the following parts as optional accessories.
Table. 2.4.0.2 Optional accessories

Allen Wrench Set L7096B 1 Tool
Point Mark Assembly L7096C 1 For origin confirmation
Arrow Indicator Plate NB10107A 1set 12 pcs / set
1-2-7
2.5 Transport Method

Use a crane or a forklift to transport the manipulator for unpacking or installing. The manipulator must be
transported at the factory-configured posture as shown in from Fig. 2.5.0.1 to Fig. 2.5.0.14.
When transporting the manipulator with a crane for NB4/NV6, hook a rope on the bracket of manipulator using
shackles and lift it up as shown in from Fig. 2.5.0.1 and Fig.2.5.0.4 by a transport posture with the angle
specified in the Table 2.5.0.1 and Table 2.5.0.4.
When transporting the manipulator with a crane for NB4L/NB15/NV6L/NV20/NV20A, hook a rope on the M12
eyebolts (2 pcs.) bracket of manipulator using shackles and lift it up as shown in from Fig. 2.5.0.2 to Fig.2.5.0.3,
Fig. 2.5.0.5 to Fig.2.5.0.7 by a transport posture with the angle specified in the Table 2.5.0.2 to Table 2.5.0.3 and
Table 2.5.0.5 to Table 2.5.0.7.
When transporting the manipulator with a forklift, secure the manipulator onto a pallet as shown in from Fig.
2.5.0.8 to Fig. 2.5.0.14 in order to prevent it from overturning. The weight of a single NB4 manipulator is 154kg,
and that of NB4L 277kg, and that of NB15 286kg, and that of NV6 144 kg, and that of NV6L 273kg, and that of
NV20 278g, and that of NV20A 311g respectively. Use a pallet strong enough to withstand the load in each case.
Be sure to prevent impacts especially against Section during transport.

WARNING
When transporting or installing the manipulator, take ample care not to apply load by
such as putting your weight on or pulling the End arm part, Axis J6 part, etc.
WARNING
For NB4/NV6, fit the bracket when transporting, and be sure to remove it before the robot
operation. After removing the bracket, keep it with care, and fit two bolts and washers to
tapped holes to prevent from entering trush into the tapped hole or from losing the bolts.
WARNING
Wire Rope

Withstand Load : min.0.8t (1760 lb)
800kg
Length : min. 1.5m (60 in.)
1.5m
Shackles

Prepare shackles that meet the following requirements.
Model :SC-12
Bracket
Withstand Load: 0.9t (1980 lb)
ISO 2415
L11130R01 End arm
Fit this item when transporting the SC-12
robot, and be sure to remove it before 0.9t
the robot operation.After removing the JIS B2801
Hexagon Head Bolt
bracket, keep it with care.
Center of 2xM10x25
Gravity

Spring Washer

W(M10)
(316)
Washer
(8) J6 Unit (52)
J6 W(M10)
Note1) Center of Gravity position is reference.
Fig. 2.5.0.1 Transport Method for NB4 Manipulator (by crane)
Table. 2.5.0.1 NB4 Axis angle in the transport posture by installation type
Installation type Axis J1 Axis J2 Axis J3 Axis J4 Axis J5 Axis J6
Floor or wall hanging type 0 180 -85 -80 -90 0
Ceiling type 0 180 -85 -80 -135 0
1-2-8

WARNING
Wire Rope

800kg
1.5m
Shackles

Prepare shackles that meet
the following requirements.
Model :SC-12
Center of Withstand Load: 0.9t (1980 lb)
Gravity ISO 2415

SC-12
0.9t
JIS B2801
Bracket
Eyebolts (M12)
(L10460T07)
(346)
Pre-installed at our factry. Pre-installed at our factory.

(17) (64)

Fig. 2.5.0.2 Transport Method for NB4L Manipulator (by crane)
Table. 2.5.0.2 NB4L Axis angle in the transport posture by installation type
Ceiling type 0 185 -83 90 135 0
Wire Rope

800kg
1.5m
Shackles

Prepare shackles that meet
the following requirements.
Model :SC-12
Center of ISO 2415
Gravity
SC-12
0.9t
JIS B2801

Eyebolts (M12)

Pre-installed at our factory.
(377)

(18) (62)

Fig. 2.5.0.3 Transport Method for NB15 Manipulator (by crane)
Table. 2.5.0.3 NB15 Axis angle in the transport posture by installation type
Ceiling type 0 180 -80 -30 -60 180
1-2-9

WARNING
Wire Rope

800kg
1.5m
Shackles

Model :SC-12
Bracket

ISO 2415
L11130R01

Fit this item when transporting the SC-12
robot, and be sure to remove it before 0.9t
the robot operation.After removing the
Center of Hexagon Head Bolt
JIS B2801
bracket, keep it with care.
Gravity
2xM10x25
Spring Washer

W(M10)
(296)
Washer
(7) (56)
W(M10)

Fig. 2.5.0.4 Transport Method for NV6 Manipulator (by crane)
Table. 2.5.0.4 NV6 Axis angle in the transport posture by installation type
Floor or wall hanging type 0 180 -80 0 -70 0
Ceiling type 0 180 -80 0 -70 180
Wire Rope


800kg
1.5m
Shackles

Model :SC-12
ISO 2415

SC-12
Center of
0.9t
Gravity
JIS B2801

Eyebolts (M12)

(354)

(17) (60)

Fig. 2.5.0.5 Transport Method for NV6L Manipulator (by crane)
Table. 2.5.0.5 NV6L Axis angle in the transport posture by installation type
Ceiling type 0 180 -80 0 -90 180
1-2-10

WARNING
Wire Rope


800kg
1.5m
Shackles

Model :SC-12
ISO 2415

SC-12
Center of
0.9t
Gravity
JIS B2801

Eyebolts (M12)

(366)

(16) (66)

Fig. 2.5.0.6 Transport Method for NV20 Manipulator (by crane)
Table. 2.5.0.6 NV20 Axis angle in the transport posture by installation type
Ceiling type 0 180 -80 0 -50 180
Wire Rope


800kg
1.5m
Shackles

Model :SC-12
ISO 2415

SC-12
Center of
0.9t
Gravity
JIS B2801

N.P.
Eyebolts (M12)

(370)
(7) (43)

Fig. 2.5.0.7 Transport Method for NV20A Manipulator (by crane)
Table. 2.5.0.7 NV20A Axis angle in the transport posture by installation type
Ceiling type 0 180 -80 0 -50 180
1-2-11
Protector

Fixing Rope or Belt

Pallet Forklift

Fig. 2.5.0.8 Transport Method for NB4 Manipulator (by forklift)
Protector

Fixing Rope or Belt

Pallet Forklift

Fig. 2.5.0.9 Transport Method for NB4L Manipulator (by forklift)
Ensure that the manipulator is moved into position by individuals who have acquired
the permits or licenses needed for carrying out slinging work, operating cranes,
driving forklift trucks, etc. The weights of the robot and the robot controller are given
in the Operation Manual and Maintenance Manual. After checking the weights, adopt
WARNING handling procedures which are commensurate with these weights.
When hoisting the manipulator and/or the robot controller, follow the method set forth
in this manual or in the Maintenance Manual. Moving the robot into position using a
method not specified by the manufacturer may cause the robot to topple over or fall,
WARNING which may lead to accidents.
Take more than enough care to ensure that the wiring is not damaged during the
moving and installation processes. After having positioned the units, take protective
measures such as providing protective covers to ensure that the wiring will not be
WARNING damaged by the operators, other individuals or the forklift trucks.
1-2-12
Protector

Fixing Rope or Belt
Pallet Forklift

Fig. 2.5.0.10 Transport Method for NB15 Manipulator (by forklift)
Protector

Fixing Rope or Belt

Pallet Forklift

Fig. 2.5.0.11 Transport Method for NV6 Manipulator (by forklift)
1-2-13
Protector

Fixing Rope or Belt

Pallet Forklift

Fig. 2.5.0.12 Transport Method for NV6L Manipulator (by forklift)
Protector

Fixing Rope or Belt

Pallet Forklift

Fig. 2.5.0.13 Transport Method for NV20 Manipulator (by forklift)
1-2-14
Protector

Fixing Rope or Belt
Pallet Forklift

Fig. 2.5.0.14 Transport Method for NV20A Manipulator (by forklift)
1-2-15
2.6 Installation of Manipulator
2.6.1 Installation Method

Large reaction force will be applied to the revolving base from all directions when the manipulator works at an
adjustable speed. Considering this mentioned above, the base needs to tolerate not only the static load but also
the reaction force at adjustable speed. Install the manipulator with its revolving base stable.
RP
RP
RP :Reference Plane
(a) NB4 / NV6
RP
RP
RP :Reference Plane
(b) NB4L / NB15 / NV6L / NV20
1-2-16
RP
RP
RP :Reference Plane
A
(c) NV20A
Fig. 2.6.1.1 Manipulator Installation Dimensionsunit : mm
1-2-17
Installing Manipulator and Jigs on Common Frame Base

Movements of the manipulator cause a large force of inertia, requiring the installation floor to be strong and rigid.
Therefore, when the manipulator and jigs are to be mounted together on the same common frame base, the
frame base must be at least 20 mm in thickness and the manipulator must be firmly fixed using four pieces of
hexagon socket head cap screws (M16) and spring washer with a tightening torque of 216 N*m. For the
mounting method of the manipulator on the base, see Fig. 2.6.1.2.
Fig. 2.6.1.2 Installing the Manipulator Directly on Common Frame Base
1-2-18
2.6.2 Using Optional Manipulator Stand

Movements of the manipulator cause a large force of inertia, requiring the installation floor to be strong
and rigid. When the concrete floor thickness is more than 200 mm, use anchor bolts (M16) shown in Fig.
2.6.3.1 for installation.
If the floor is not strong enough, use J-type anchor bolts as shown in Fig. 2.6.3.1 for installation.
The anchor Installation must be in conformity with the manufacturer indicator.
(The concrete anchors, J-type anchor bolts and jack bolts or the like must be prepared by a user.)
If the thickness of a concrete base is 200mm or less, form the foundation in advance after an enough review.
Jack Bolt
(M12)
Anchor Bolt
Lock Nut (M16)
Lock Nut
(M16)
(M12) (Tightening Torque:107.8Nm
107.8Nm
420
Spring Washer
(M16) 4xM12 320
4x18
Flat Washer
(M16)
420
Manipulator Stand

Supporting Plate

500
Foundation View A

Fig. 2.6.2.1 Using an Optional Manipulator Stand for Installation (unit: mm)
1-2-19
2.6.3 Maximum Manipulator Generative Force

Movements of the manipulator may cause a large force as shown in Table 2.6.4.1.
Please design the common frame base that has an enough safety factor to the force shown below.
Table. 2.6.4.1 Maximum manipulator generative force

Maximum vertical Maximum horizontal Maximum vertical Maximum horizontal
Name
generative force FV generative force FH generative moment MV generative moment MH
NB4 4600N 3100N 3400 N*m 2000 N*m
NB4L 7300N 4400N 8600 N*m 2600 N*m
NB15 9700N 6500N 9600 N*m 8100 N*m
NV6 5000N 2600N 4400 N*m 1400 N*m
NV6L 7700N 4800N 6400 N*m 5300 N*m
NV20 10100N 7000N 10000 N*m 8600 N*m
NV20A 10200N 7000N 10000 N*m 8500 N*m
MAX PRESSURE
1.0 MPa (145psi)
Fig. 2.6.3.1 Maximum manipulator generative force
1-2-20
! !
2.7 Note on Emergency stop of Manipulator
Table 2.7.0.1 shows the length of time from Emergency stop SW pressed to the robot stopped and the
angles of each axis to move. For designing a work cell etc., these values shall be considered.
Table 2.7.0.1 Emergency stop of Manipulator

Stop Time Stop Angle
Model Axis No.
ms deg
Axis J1 420 44.8
Axis J2 470 39.1
Axis J3 340 23.4
NV6
Axis J4 310 46.6
Axis J5 260 35.6
Axis J6 300 56.5
Axis J1 510 45.4
Axis J2 450 38.2
Axis J3 450 37.2
NB4
Axis J4 510 56.8
Axis J5 500 57.2
Axis J6 480 61.7
Axis J1 650 52.8
Axis J2 520 57.6
Axis J3 430 23.0
NV6L
Axis J4 480 50.3
Axis J5 460 51.0
Axis J6 470 69.3
Axis J1 660 48.5
Axis J2 480 49.7
Axis J3 540 34.0
NB4L
Axis J4 530 58.8
Axis J5 520 64.7
Axis J6 630 77.6
Axis J1 750 69.1
Axis J2 670 50.0
Axis J3 490 36.1
NB15
Axis J4 490 42.5
Axis J5 500 45.3
Axis J6 540 68.5
Axis J1 690 61.9
Axis J2 680 53.0
Axis J3 480 25.3
NV20
Axis J4 500 51.0
Axis J5 500 48.0
Axis J6 490 71.6
Axis J1 530 55.5
Axis J2 660 55.2
Axis J3 490 25.5
NV20A
Axis J4 500 51.0
Axis J5 500 48.0
Axis J6 490 71.6
1-2-21
This chapter provides the instructions on the periodic inspection.

3.1 Periodic Inspection ..................................................................................1-3-2
3.1.1 Safety Measures for Inspection, Maintenance, Adjustments and Repairs of the Manipulator..... 1-3-2
3.1.2 Periodic Inspection Schedule .............................................................1-3-4
3.1.3 Notes on Periodic Inspection .............................................................1-3-4
3.1.4 Deadline for Supplying/ Repairing the Robot Maintenance Parts ......1-3-4
3.2 List of Maintenance Items ........................................................................1-3-5
3.2.1 NB4/NB4L Manipulator ......................................................................1-3-5
3.2.2 NB15 Manipulator ..............................................................................1-3-8
3.2.3 NV6 / NV6L / NV20 / NV20A Manipulator ........................................ 1-3-11
1-3-1
3.1 Periodic Inspection
3.1.1 Safety Measures for Inspection, Maintenance, Adjustments and Repairs of the Manipulator
To perform inspection, maintenance, adjustments, repairs or other similar work on the manipulator, access to the
robot working range may be required, or work with the primary-side power or the servo power turned on may be
necessary. In any case, be sure to observe the following precautions for inspection, maintenance, adjustments
and repairs.

Whenever the power is ON, never enter the robot working range. Approaching the
operating robot may result in a fatal injury.
WARNING
Never touch any charged parts. Touching any charged part may result in a fatal electric
shock hazard or burn.
WARNING
Never put your hand, finger, hair, clothes or the like close to any rotating section.
Putting your hand, finger, hair or clothes close to the wire feed roll of the wire feed
unit may cause you to get caught, resulting in a serious injury.
Similarly, putting your hand, finger, hair or clothes close to the rotating section of a
WARNING cooling fan may cause you to get caught and hurt.
(1) Prior to carrying out robot inspection, maintenance, adjustments, repairs, etc., be sure to wear a helmet,
safety shoes, gloves and other protective means that may be deemed necessary, as specified by law.
To be more specific, wear clothes that are suited to each specific work.
(2) Prior to initiating work, press the EMERGENCY Stop button or the Stop button to check if the robot system
stops instantly. Furthermore, if a safety plug, a dead man switch or other protective devices are added to the
robot system, they must be checked for proper operation. Should any fault be detected, stop the inspection
work, turn off the primary power immediately, check for causes and take necessary countermeasures
accordingly.
(3) Ensure that personnel who are not operating the robot must not approach the guarding fence.
(4) Prior to starting work, put up a sign Under Inspection

at a visible place to let people around the robot system
know that inspection is now being carried out. Under Inspection
(5) Do not use any equipment that may generate electromagnetic noises, in and around the place where
inspection is being performed.
(6) At least two workers should be involved in the inspection or maintenance work, one performing actual work
and the other serving as a watcher.
(7) Personnel to be involved in robot inspection, maintenance, adjustment and/or repairs should receive
instructions and training on robot functions, operation and maintenance. In addition, if special equipment or
facilities are provided in the robot system, then their entire mechanism must also be fully understood.
(8) Robot inspection, maintenance, adjustment and repairs must be performed by only those who are qualified by
receiving special training. Furthermore, even if they have received such special training, they are not allowed
to perform inspection, maintenance, adjustment or repairs of other machinery that they are not fully familiar
with.
1-3-2
(9) Any sign that may be given to workers, watchmen and/or operators of related machines must be in conformity
with the Customers safety management standards.
(10) The watcher must observe the following. He shall:
(A) Stand at a place that commands a view of the entire robot working range, and devote himself to the duty
of watching the work.
(B) Always hold the EMERGENCY Stop button, and press it immediately whenever any abnormality occurs.
(C) Make sure that people other than those who are involved in inspection, etc. do not come close to the
robot working range.
(11) The workers to be involved in inspection or other work must observe the following.
(A) If work can be carried out outside the robot working range, specify the work details prior to starting the
work. In any case, be sure that work is done outside the robot working range.
(B) In principle, perform inspection, etc., with the robot stopped. However, if such inspection or other work is
inevitably required during robot operation, then be sure to report this to the responsible safety manager,
and with permission obtained, perform the work outside the robot working range.
(C) If the robot is required to be in an operable condition when performing inspection work or the like, specify
the work procedure details beforehand so that safe work can be efficiently proceeded with. Furthermore,
if work is not particularly required to be performed in the robot operable condition, carry out the work with
the robot controller, the welding power supply and/or other input-side power supplies all turned off. If no
special safety procedure is required, be sure to turn off such input-side power supplies for jigs and
peripheral equipment or to make them inactive.
(D) When working in the robot working range, be sure you are always in a ready-to-act posture so that you
can immediately press the EMERGENCY Stop button just in case of robot malfunction.
(E) Carefully check your footing before starting work. Be sure to avoid an unstable scaffold or a scaffold
provided at an elevated position (more than 2 meters high).
(F) When you are in the robot working range, do not perform work with your back facing the manipulator.
(G) To replace PCBs provided in the robot controller or the teach pendant, take anti-static electricity
countermeasures including anti static electricity sheets.
(12) If any abnormal condition has occurred during work, carefully perform the following procedure.
(A) If any malfunction is observed on the robot system, immediately press the EMERGENCY Stop button.
(B) Immediately report this to the watcher, turn off the control power
Do not Switch ON
of the robot controller, then put up a sign Do not switch on.
(C) Be sure to check that all the related machines are stopped.
(D) When necessity arises to go inside the guarding fence, be sure that the person who is going to enter pulls
out the safety plug himself, carries it with him and proceeds with the work concerned.
(E) Even when the robot has automatically stopped due to a fault in supply voltage to the robot system,
hydraulic pressure or air pressure of related equipment, make sure that it is at a complete stop, then
investigate causes to take necessary countermeasures.
(F) If the EMERGENCY Stop switch or other safety devices should have failed to operate, immediately turn
off the primary power, investigate causes and take necessary countermeasures.
(G) To restart the robot after stopping it by pressing the EMERGENCY Stop button, investigate causes, take
necessary countermeasures, replace the safety plug, then restart it from outside the guarding fence.
(13) To end the work, carefully check that the necessary connectors, covers, panels, etc. have been all correctly
mounted and wired.
1-3-3
3.1.2 Periodic Inspection Schedule

The periodic inspection is indispensable in order to continue operating Almega series in a safe and an efficient
manner. Perform the periodic inspection in accordance with the following schedule.
Be sure to overhaul in either a period of whole 6 years or 30,000 cumulative operating hours after delivery,
whichever is shorter.
The inspection and maintenance period is estimated, supposing the manipulator only for Arc welding use. For
more frequent use such as handling operation, that period may be shorter.
Contact to our engineers for details.
3yrs
Maintenance
1yr 1yr 1yr
Inspection Inspection Inspection
3mths 3mths 3mths 3mths 3mths 3mths 3mths 3mths 3mths 3mths 3mths 3mths
Inspection Inspection Inspection Inspection Inspection Inspection Inspection Inspection Inspection Inspection Inspection Inspection
Daily Inspection
0 3mths 6mths 9mths 1yr 15mths 18mths 21mths 2yrs 27mths 30mths 33mths 3yrs
3.1.3 Notes on Periodic Inspection
(1) Periodic inspection must be performed by those who have received the special training program by the
Government or DAIHEN Corporation and maintenance instructions offered by DAIHEN Corporation, or at
their presence.
(2) Prior to performing inspection or maintenance, be sure to turn off the external breaker.
Note that, with turning off only the non-fuse breaker of the robot controller, the primary side of the non-fuse
breaker is still being applied with voltage.
In order to show that inspection or maintenance is underway, hang a noticeable sign on the switch of
the external breaker.
WARNING
ELECTRIC SHOCK
can kill.

Do not touch live electrical
Never touch the charged parts.

parts.
Disconnect all power
before installing or servicing.
WARNING

Multiple sources of voltage

may exist inside this

enclosure.
NK3637
3.1.4 Deadline for Supplying/ Repairing the Robot Maintenance Parts
Deadline for supplying the robot maintenance parts is guaranteed for 7 years from the discontinuation date of the
product, and that for repairing is for 10 years.
For the detailed information about discontinuation date of the product, please see the guidance on the
maintenance parts in our homepage: http://www.daihen.co.jp/ .
Repair of the maintenance parts is provided for the above period of time in principle, however, we will support
our customers as long as the stock is available.
We will make our every effort to secure the required maintenance parts. However, please note that it may be
occasionally unavailable due to the external factors such as the market situation even during the guaranteed
period.
1-3-4
3.2 List of Maintenance Item
3.2 List of Maintenance Items
3.2.1 NB4/NB4L Manipulator

Mainten
Inspection
-ance
No. Location Item Corrective Action
3 1 3 6
Daily
mths yr yrs yrs
Entire Outer Attached spatter, dust
1 Visual check and cleaning
appearance or other foreign matter
2 Matchmark panel Peeling, soiling Visual check
External cable Scratches, soiling and
3 Visual check
Lead wire loose connectors
4 Torch Bracket Cracks, chipping Bending Visual check; Replacing the parts
Visual check with origin
Deviation
checking program.
Confirm that there is no noticeable
5 Torch aiming point
play by checking around 6th axis
Backlash and play
output flange by hand (back/forth,
right/left, up/down).
Looseness at cable
Retightening
connection
Worn tip Replacing tip
6 Welding torch
Attached spatter on nozzle Cleaning or replacing
Attached spatter on torch
Cleaning
mounted section
Visual check, inspection and
Worm feed roll
replacing if needed
7 Wire feed unit
Attached oil or dust on
Cleaning
strainer and feed roll
Coaxial power Scratched or bent cable Visual check, inspection and
cable Worn or bent coil liner replacing if needed.
Gas hose Damaged hose, gas Check with soapy water applied
8
Welding power leakage and replacing
cable Looseness at cable
Conduit cable Retightening
connection
9 Major bolts Looseness Retightening
Connector housing
10 Looseness Retightening
(Base portion)
No noise and vibration by servo
11 Brake Brake operating ON. No falling of the arm with
the servo OFF.
Welding cable Visual check, inspection
12 mounted to the Defects and damage Replace when any abnormality
main body is detected
Damaged cable
Check visually and retighten if
Loose connectors
13 Internal wires necessary.
Bolt for mounting
Replacement Replacement
Grease replacement Grease replacement (See
Reduction gear
14 Abnormality in the Chapter 4.2).Replacing if the
(Axis J1, J2, J3)
reduction gear reduction gear is abnormal.
Grease replenishment Grease replenishment (See
Reduction gear
(Axis J4, J5, J6)
Tension adjustment (See
Timing belt Tension strength of belt
16 Chapter 4.1).Replacing if the
(Axis J5) Abnormality in the belt
tension belt is abnormal.
Gear Grease replenishment
17 Grease replenishment
(Axis J4,J6) (See Chapter 4.3)
Cross roller bearing
(Axis J4,J6)
Cross roller bearing bearing is abnormal.
Replacement (See Chapter
19 Battery Replacement
4.5)
20 Overhaul
Inspection, Replacement
1-3-5
7
J4
15
11 3
J5 1
11
15
16 8
12
14
J3 4
11 4xM16x50
15 9 2
17 19 216N m
J6 6
2
J2 14 5
11
17
13
18
J4
18
J6
10
11
13 13
J1
12
Fig. 3.2.1.1 Check Points of NB4 / NB4LManipulator
WARNING
ELECTRIC SHOCK
can kill.

Never touch live electrical parts.

parts.
WARNING



enclosure.
NK3637
1-3-6
(a) NB4
(b) NB4L
Fig. 3.2.1.2 Check Points on major bolts of NB4 / NB4LManipulator
1-3-7
3.2.2 NB15 Manipulator

Mainten
Inspection
-ance
3 1 3 6
Daily
mths yr yrs yrs
3 Visual check
4 Torch Bracket Cracks, chipping Bending Visual check; Replacing the parts
Deviation
checking program.
Confirm that there is no noticeable
5 Torch aiming point
Backlash and play
Looseness at cable
Retightening
connection
6 Welding torch
Attached spatter on torch
Cleaning
mounted section
Worm feed roll
replacing if needed
7 Wire feed unit
Attached oil or dust on
Cleaning
Gas hose Damaged hose, gas Check with soapy water applied
8
Welding power leakage and replacing
cable Looseness at cable
Conduit cable Retightening
connection
Connector housing
(Base portion)
No noise and vibration by servo
11 Brake Brake operating ON. No falling of the arm with
the servo OFF.
Damaged cable
Check visually and retighten if
Loose connectors
12 Internal wires necessary.
Bolt for mounting
Reduction gear
(Axis J1, J2, J3)
Reduction gear
(Axis J4, J5, J6)
(Axis J5,J6) Abnormality in the belt
tension belt is abnormal.
Gear Grease replenishment
16 Grease replenishment
(Axis J4,J6) (See Chapter 4.3)
Cross roller bearing
(Axis J4,J6)
Cross roller bearing bearing is abnormal.
Replacement (See Chapter
4.5)
19 Overhaul
1-3-8
J4
J5
J3
J6
J2
J6
J6
J4
J1
Fig. 3.2.2.1 Check Points of NB15 Manipulator
WARNING
ELECTRIC SHOCK
can kill.


parts.
WARNING



enclosure.
NK3637
1-3-9
Fig.3.2.2.2 Check Points on major bolts of NB15 Manipulator
1-3-10
3.2.3 NV6 / NV6L / NV20 / NV20A Manipulator

Mainten
Inspection
-ance
3 1 3 6
Daily
mths yr yrs yrs
3 Visual check
Cracks, chipping Visual check; Check with torch
4 Torch mount Bending positioning gauge, replacing the
parts if needed.
Visual check with origin checking
Deviation program; Check with torch
positioning gauge.
5 Torch aiming point Confirm that there is no noticeable
Backlash and play
Looseness at cable Retightening
connection
6 Welding torch Attached spatter on Cleaning or replacing

nozzle
Attached spatter on Cleaning
torch mounted
section
Worm feed roll
replacing if needed.
7 Wire feed unit
Attached oil or dust on Cleaning
Scratched or bent
Coaxial power cable Visual check, inspection and
Gas hose
8 Damaged hose, gas Check with soapy water applied
Welding power
cable leakage and replacing
Conduit cable Looseness at cable
Retightening
connection
Connector housing
(Base portion)
No noise and vibration by
11 Brake Brake operating servo ON. No falling of the arm

with the servo OFF.
Damaged cable
Check visually and
Loose connectors
12 Internal wires retighten if necessary.
Bolt for mounting
Grease replacement
Grease replacement
Reduction gear (See Chapter 4.2)
13 Abnormality in the
(Axis J1, J2, J3) Replacing if the reduction gear is
reduction gear
abnormal
Grease replenishment Grease replenishment
Reduction gear
14 Abnormality in the (See Chapter 4.2).Replacing if the
(Axis J4, J5, J6)
Tension strength of Tension adjustment
Timing belt
15 belt (See Chapter 4.1).Replacing if the
(Axis J5, J6)
Abnormality in the belt tension belt is abnormal.
Grease replenishment
Cross roller Grease replenishment
(See Chapter 4.4)
16 bearing Abnormality in the
Replacing if the cross roller
(Axis J4) Cross roller bearing
bearing is abnormal
17 Battery Replacement Replacement (See Chapter 4.5)

18 Overhaul
1-3-11
J4
14
11 3
J5
11
14
15
13
J3 4
11
14 4xM16x50
15 2
J6 216N m 9
6
4
J2 13 17 5
11
12
16
10
11
13 12
J1
Fig.3.2.3.1 Check Points of NV6 / NV6L /NV20 / NV20A Manipulator
WARNING
ELECTRIC SHOCK
can kill.


parts.
WARNING



enclosure.
NK3637
1-3-12
(a) NV6
(b) NV6L
(c) NV20
1-3-13
(d) NV20A
Fig.3.2.3.2 Check Points on major bolts of NV6/NV6L / NV20 / NV20A Manipulator
1-3-14
This chapter provides the instructions on the maintenance of robots.
4.1 Tension Adjustments of Timing Belts ......................................................1-4-4

4.1.1 Tension Adjustments of Timing Belt for NB4/NB4L ............................1-4-4
4.1.2 Tension Adjustments of Timing Belts of NB15 ....................................1-4-6
4.1.3 Tension Adjustments of Timing Belts of NV6 / NV6L / NV20 / NV20A
.. 1-4-8
4.2 Replacement and Replenishment of Grease for Reduction Gears ................... 1-4-11
4.2.1 Grease Replacement Procedure for Axis J1, J2 and J3 Reduction Gears ........................... 1-4-11
4.2.2 Grease Replenishment Procedure for Axis J4, J5 and J6 Reduction Gears (NB4/NB4L) ...........1-4-18
4.2.3 Grease Replenishment Procedure for Axis J4, J5 and J6 Reduction Gears (NB15).................1-4-19
4.2.4 Grease Replenishment Procedure for Axis J4, J5 and J6 Reduction Gears
(NV6 / NV6L / NV20 /NV20A)........1-4-20
4.3 Replenishment of Grease for Gear (NB4/NB4L/NB15) ........................1-4-21
4.3.1 Grease Replacement Procedure for Axis J4, J5 Gears (NB4 / NB4L) ............... 1-4-21
4.3.2 Grease Replacement Procedure for Axis J4, J5 Gears (NB15)......................1-4-23
4.4 Grease Replenishment for Roller Bearing............................................1-4-24
4.4.1 Grease replenishment procedure for Axis J4 cross roller bearing ...................1-4-24
4.4.2 Grease replenishment procedure for Axis J5 cross roller bearing (NB15) ...........1-4-25
4.4.3 Grease replenishment procedure for Axis J6 cross roller bearing (NB4 / NB4L) 1-4-26
4.4.4 Grease replenishment procedure for Axis J6 cross roller bearing (NB15) ......... 1-4-27
4.5 Battery..................................................................................................1-4-28
4.5.1 Function of Battery ...........................................................................1-4-28
4.5.2 Specification of Battery ....................................................................1-4-28
4.5.3 Replacing Battery.............................................................................1-4-28
4.5.4 Notes on Battery Safekeeping .........................................................1-4-29
4.6 Replacing Internal Wires ......................................................................1-4-30
1-4-1
To perform inspection, maintenance, adjustment, repairs or other similar works on the robot system, access to the
necessary. In any case, be sure to observe the following precautions for inspection, maintenance, adjustments and
repairs.

Whenever the power is ON, never enter the robot working range.Approaching the
WARNING
Never touch any live electrical parts.Touching any live electrical parts may result in a
fatal electric shock hazard or a burn.
WARNING
Bringing hands, fingers, hair or clothes close to the wire feed roll of the wire feed unit
may cause an injury by being caught by it.
Bringing hands, fingers, hair or clothes close to the rotating section of a cooling fan may
WARNING cause an injury by being caught by it.
(1) Before carrying out robot inspection, maintenance, adjustments, repairs, etc., be sure to wear a helmet, safety
shoes, gloves and other protective means that may be deemed necessary, as specified by law.
(2) Before initiating work, press the EMERGENCY Stop button or the Stop button to check if the robot system stops
instantly. Furthermore, if a safety plug, a Deadman switch and/or other protective devices are added to the robot
system, they must be checked for their proper operation. Should any fault be detected, stop the inspection work,
turn off the primary power immediately, check for causes and take necessary measures accordingly.
(4) Before starting work, put up a sign Under Inspection Under Inspection
at a visible place to notify people around the robot system
that the inspection is now underway.
(5) Do not use any devices that may generate electromagnetic noises in and around the place where the inspection
is being conducted.
(6) At least two workers should be involved in the inspection or maintenance work, one performing the actual work
and the other serving as a watchman.
(7) Personnel who are going to conduct the robot inspection, maintenance, adjustment and/or repairs should
receive instructions and training on robot functions, operation and maintenance. In addition, if special devices or
facilities are provided in the robot system, their entire mechanism must also be fully understood.
(8) Robot inspection, maintenance, adjustment and repairs must be performed only by qualified personnel who
have received special training. Furthermore, even if they have received such special training, they are not
allowed to perform inspection, maintenance, adjustment or repairs of machinery other than those they are fully
familiar with.
1-4-2
(10) The watchman has to observe the following.
(A) Stand at a place that commands a view of the entire robot work envelope and concentrate on the duty of
watching the work.
(B) Always hold the EMERGENCY STOP button and press it immediately whenever any abnormality occurs.
(C) Keep personnel except the teaching operator away from the robot work envelope.
(11) The workers to be involved in the inspection or other works must observe the following.
(A) If work can be carried out outside the robot working range, specify the work details before starting the work and
make sure to carry out the work outside the robot working range.
(B) In principle, perform inspection, etc., with the robot stopped. However, if the inspection or other work is inevitably
required while the robot is operating, be sure to report this to the responsible safety manager, and, with
permission obtained, perform the work outside the robot working range.
(C) If the robot is required to be in an operable condition when the inspection work or the like is carried out, specify
the work procedure in detail beforehand so that work can be carried out safely and efficiently. Furthermore, if work
is not particularly required to be performed in the robot operable condition, carry out the work while the robot
controller, the welding power supply and/or other input-side power supplies are all turned off.
If no special safety procedure is required, be sure to turn off such input-side power supplies for jigs and peripheral
equipment or make them inactive.
(D) When working in the robot working range, be sure that you are always in a ready-to-act posture to be promptly
able to press the EMERGENCY Stop button in case of robot malfunction.
(E) Check your footing carefully before initiating work. Be sure to avoid an unstable scaffold or a scaffold provided at
an elevated position (more than 2 meters high).
(G) When replacing PCBs provided in the robot controller or the teach pendant, take countermeasures against static
electricity, for instance by using anti-static electricity sheets.
(12) If any abnormal condition occurs during the work, follow the procedure below carefully.
(A) If any malfunction is observed in the robot system, press the EMERGENCY Stop button immediately.
(B) Report this immediately to the watchman, turn off the control
power of the robot controller, and then put up a sign
Do Not Switch On. Do Not Switch ON
(C) Make sure that all the related machines are stopped.
(D) When necessity arises to go inside the guarding fence, be sure that the person who is going to enter pulls out the
safety plug himself, carries it with him while proceeding with the work concerned.
(E) Even when the robot has automatically stopped due to a fault in supply voltage to the robot system, hydraulic
pressure or air pressure of related equipment, make sure that the robot is at a complete stop. Then, investigate
causes and take necessary countermeasures.
(F) If the EMERGENCY Stop switch or other safety devices should have failed to operate, turn off the primary power
immediately, investigate causes and take necessary countermeasures.
(G) In order to restart the robot after stopping it by pressing the EMERGENCY Stop button, investigate causes, take
necessary countermeasures, replace the safety plug, and then restart it from outside the guarding fence.
(13) To end the work, check carefully that the necessary connectors, covers, panels, etc. have been all
correctly mounted and wired.
1-4-3
4.1 Tension Adjustments of Timing Belts
4.1.1 Tension Adjustments of Timing Belt for NB4/NB4L

To make the timing belts tension adjustments, every year or every 3,000 operating hours, whichever is shorter
period.
To drive Axis J5, timing belt is used between the motor and the reduction gear. Attaining smooth transmission by
the timing belt requires appropriate belt tension. For the adjusting method of timing belt tension of each axis,
read the following instructions.
When making this adjustment, be careful not to allow the timing pulleys to rotate at no load because the origin
point may move out of its position, which will in turn require readjustments.
(1) Removing a cover from the upper arm will reveal the timing belt as shown in Fig.4.1.1.1.
(2) Loosen three motor fixing bolts (M5x10) and turn the motor bracket around the parallel pin to adjust the belt
tension so that it can be coincident with the value specified in Fig 4.1.1.1.
Press the timing belt of Axis J5 with the force and at the location both shown in Table 4.1.1.1 to make the
deflection become coincident with the value specified in Fig 4.1.1.1.
(3) When the specified deflection value is obtained, retighten the motor fixing bolts with a tightening torque of 7.3
N*m, and apply LOCKTITE to the bolts in order to prevent them from loosening.
Twist the upper side of the timing belt round to near side, and then install it the timing pulley on the AC
servomotor.
Table 4.1.1.1 Belt Deflection Values for Tension Adjustments of Timing Belts
Axis NB4 / NB4L
name Pressing force Deflection
J5 9.8 N 56 mm
(29)
Motor Fixing Bolt(3pcs.) Tight
3
L=56mm
PARALLEL PIN
Tightening torque7.25Nm
7.25Nm 9.8N
50
Fig 4.1.1.1 Tension Adjustments of Timing Belt for Axis J5 (Unit : mm) (NB4 / NB4L)
1-4-4
(4) When all the adjustments have been successfully completed, apply an appropriate amount of sealing
agent (Pure Sealant) to the entire circumference of the cover-mounting surface.
And then fix the cover.
Pure Sealant Application Surface(Shaded Area)

Fig 4.1.1.2 Application Surface of Sealing Agent (Pure Sealant)
Do not get your hand caught in the moving section.

Improper adjustment of belt tension may cause damage to the belt.
Then, it may result in the arm falling.
WARNING
1-4-5
4.1.2 Tension Adjustments of Timing Belts of NB15
To make the timing belts tension adjustments, every three years or every 3,000 operating hours, whichever is
shorter period.
To drive Axis J5 and J6, timing belts are used between the motor and the reduction gear. Attaining smooth
transmission by the timing belts requires appropriate belt tension. For the adjusting method of timing belt tension
of each axis, read the following instructions.
Axis J5 and J6(Inside upper arm)

(1) As shown in Fig. 4.1.2.1, the air hose (yellow) is fitted on the pulley cover in which the air pipe is inserted.
Detach the air hose from the one-touch fitting with the pulley cover half opened, remove the air pipe from
the pulley cover, and then uncap the pulley cover. Now, be sure that the air pipe is left on the upper arm
side.To do so, please do not drop your attitude at work and do not remove air pipe at the same time the end
arm pulley cover.
(2) Removing pulley cover will reveal the timing belt (of Axis J5 or Axis J6) as shown in Fig.4.1.2.2.
(3) To make their tension adjustments, loosen four pieces of drive fixing bolts and the lock nut of each drive unit
and adjust the belt tension as described below, using the tension adjusting bolt.
Press the timing belt (of Axis J5 or Axis J6) at the center with a force shown in Table 4.1.2.1 and adjust the
tension by tightening or loosening the adjusting bolt until the deflection obtained becomes the specified
value shown below. When using the tension meter, set the value as specified in Table 4.1.2.2
(4) When the specified deflection value is obtained, lock the adjusting bolt with the lock nut, retighten the drive
fixing bolts with a tightening torque 3.5 N*m, and then apply LOCKTITE to these bolts in order to prevent
them from loosening.
Axis J6(Inside end arm)

(1) As shown in Fig. 4.1.2.1, the air pipe is inserted in the end-arm pulley cover. Detach the air pipe from the
end-arm pulley cover with its half opened, and then uncap the upper cover. To do so, please do not drop
your attitude at work and the air pipe at the same time do not remove the pulley cover.
(2) Removing end arm pulley cover will reveal the timing belt as shown in Fig.4.1.2.3.
(3) To make their tension adjustments, loosen two pieces of idler pulley fixing bolts and the lock nut of each
idler pulley and adjust the belt tension as described below, using the tension adjusting bolt.
Press the timing belt at the center with a force shown in Table 4.1.3.1 and adjust the tension by tightening
or loosening the adjusting bolt until the deflection obtained becomes the specified value shown below.
When using the tension meter, set the value as specified in Table 4.1.2.2
(4) When the specified deflection value is obtained, lock the adjusting bolt with the lock nut, and then apply
LOCKTITE to these bolts in order to prevent them from loosening.
Upper arm

End arm pulley cover End arm

Air pipe

One-touch fitting

Air hose(yellow) Pulley cover

(
Fig 4.1.2.1 Installation State of an Air Hose and the Air Pipe
1-4-6
NB15
Axis name
Pressing force Deflection
J5,J6 (Inside upper arm) 5.05.4N 4.3mm
J6 (Inside end arm) 7.98.3N 1.5mm
Table 4.1.2.2 Belt Tension Values for Tension Adjustments of Timing Belts
NB15
Axis name Unit Mass of Belt
Belt Span Belt Width
Belt Tension
J5,J6 (Inside upper arm) 267.5mm 0.034kg/m 64 ~ 70 N 8mm
J6 (Inside end arm) 92mm 0.035kg/m 87 ~ 93 N 10mm
L=4.3mm
5.05.4N
N
5.05.4
Fig 4.1.2.2 Tension Adjustments of Timing Belts in upper arm for Axis J5 and J6 (NB15) (Unit : mm)
Adjusting Bolt

L=1.5mm
Lock Nut
7.98.3N

Idler pulley Fixing Bolt(2pcs.)
(
Tightning Torque 3.53Nm
3.53Nm
Fig 4.1.2.3 Tension Adjustments of Timing Beltsin in end arm for Axis J6 (NB15) (Unit : mm)

WARNING
1-4-7
4.1.3 Tension Adjustments of Timing Belts of NV6 / NV6L / NV20 / NV20A
To make the timing belts tension adjustments, every three years or every 3,000 operating hours, whichever is
shorter period.
To drive Axis J5 and J6, timing belts are used between the motor and the reduction gear. Attaining smooth
transmission by the timing belts requires appropriate belt tension. For the adjusting method of timing belt tension
of each axis, read the following instructions.
(1) Removing covers from both sides of Axis J5 and J6 Unit will reveal the timing belts of the respective axes as
shown in Fig 4.1.3.1 (for NV6 / NV6L)or Fig 4.1.3.2 (for NV20 / NV20A).
(2) To make their tension adjustments, loosen three pieces of motor fixing bolts (NV6/NV6L:M5x14; NV20 /
NV20A: M6x 20) and the lock nut of each motor unit and adjust the belt tension as described below, using
the tension adjusting bolt.
Press the timing belt (of Axis J5 or Axis J6) at the center with a force shown in Table 4.1.3.1 and adjust the
tension by tightening or loosening the adjusting bolt until the deflection obtained becomes the specified
value shown below. When using the tension meter, set the value as specified in Table 4.1.3.2 and Table
4.1.3.3
(3) When the specified deflection value is obtained, lock the adjusting bolt with the lock nut, retighten the motor
fixing bolts with a tightening torque (NV6/NV6L:7.3 N*m;NV20 / NV20A:11.8 N*m), and then apply
LOCKTITE to these bolts in order to prevent them from loosening.
Axis NV6 / NV6L NV20 / NV20A
name Pressing force Deflection Pressing force Deflection
J5 2.6mm 3.3mm
3.8N 8.6N
J6 4.2mm 5.4mm
Table4.1.3.2 Belt Tension Values for Tension Adjustments of Timing Belts

NV6 / NV6L
Axis
Unit Mass of
name Belt Span Belt Tension Belt Width
Belt
J5 165mm 47.6 ~
0.034kg/m 6mm
J6 265mm 52.0 N
Table4.1.3.3 Belt Tension Values for Tension Adjustments of Timing Belts

NV20 / NV20A
Axis
Unit Mass of
name Belt Span Belt Tension Belt Width
Belt
J5 207.5mm 105.1 ~ 12mm
0.034kg/m
J6 335mm 110 N 12mm
1-4-8
Lock Nut Adjusting Bolt

L=2.6mm
4.9N
Motor Fixing Bolt(3pcs.)

82.5 82.5
3
Tightening Torque7.25Nm
7.25Nm
Adjusting Bolt Lock Nut

L=4.2mm

4.9N
132.5 132.5

3
Tightening Torque7.25Nm
7.25Nm
Fig 4.1.3.1 Tension Adjustments of Timing Belts for Axis J5 and J6 (NV6 / NV6L) (Unit : mm)
Lock Nut Adjusting Bolt

L=3.3mm

8.58.8N
Motor Fixing Bolt(3pcs.) 103.75 103.75

3
11.8Nm
Adjusting Bolt Lock Nut

L=5.4mm
8.58.8N
167.5 167.5
3
11.8Nm
Fig 4.1.3.2 Tension Adjustments of Timing Belts for Axis J5 and J6 (NV20 / NV20A) (Unit : mm)
1-4-9
(4) When all the adjustments have been successfully completed, apply an appropriate amount of sealing
agent (Pure Sealant) to the entire circumference of the cover-mounting surface.
Figl4.1.3.3 Application Surface of Sealing Agent (Pure Sealant) (NV6 / NV6L)
Fig 4.1.3.4 Application Surface of Sealing Agent (Pure Sealant) (NV20 / NV20A)

WARNING
1-4-10
4.2 Replacement and Replenishment of Grease for Reduction Gears

Carry out periodical replacement and replenishment of grease for the reduction gear, referring to Table 4.2.0.1.
Table 4.2.0.1 Period of Replacement and Replenishment Grease
Axis Name Period for Replacement and Replenishment of Grease

Every three years or every 3,000 operating hours,
J1, J2, J3 Replacement
Every one year or every 3,000 operating hours,
J4, J5, J6 Replenishment
If you request us for replacement or replenishment work, you will be charged for the work.
4.2.1 Grease Replacement Procedure for Axis J1, J2 and J3 Reduction Gears
For the location of inlet and outlet, see Fig 4.2.1.4 to Fig4.2.1.8
Use the grease gun with the filling amount check counter function.
If it is not possible to prepare the tool to check the grease filling amount, users are able to measure the difference in
the grease amount before and after the greasing work to see the amount actually injected. Injecting of grease more
than necessary may cause a grease leakage or abnormal robot operation.
When the internal pressure is at the high level such as soon after the manipulator has stopped, it is very dangerous
because the grease may spatter at the moment of removing the plug of grease inlet port and outlet port. Therefore,
take enough care in performing soon after the manipulator has stopped.
(1) Set the posture of manipulator suitable for the work.

Table 4.2.1.1 Posture at the grease replacement
Axis J1 Axis J2 Axis J3
Any 90 0
TP display angle of Axis J2 and J3 is the one of the Axis J2 and J3 displayed when the
axis monitor is started with the teach pendant.
(2) Remove a plug from each outlet (Axis J1 and J2) and a grease nipple (Axis J3).
(3) Replace the grease nipple on Axis J3 (or A-PT 1/8 type) with a plug on each axis inlet.
(4) Make sure that neither grease inlet port nor outlet port has a choke. Inject the grease for some 50mm from the
tip of the outlet hose [85, Max. length 100mm].Attach the air equipment fitting [Rc1/8,8] and the outlet
hose to the outlet port.
As the outlet port for the J1 axis is located inside the frame, attach the air equipment fitting and the hose to
the outlet port and lay it outside the frame. (for NB4L/NB15/NV6L/NV20)
.
Fig.4.2.1.1 Air equipment fitting and outlet hose for choke checking
1-4-11
(5) Prepare the grease catch container under the outlet part. Use the grease gun to inject the grease of 1.4ml
from the grease inlet port at the rate of 1.6ml/sec. or lower. And make sure that the grease comes out from the
tip of outlet hose. If not, eliminate a choke from the hole of inlet and outlet port.
Fig.4.2.1.2 Grease catch container
(6) Use the grease gun to inject the given amount of grease at the rate of 1.6ml/sec. or lower. At this time, make
sure that the color of grease come out is gradually going to change. In addition, be sure to observe the
injecting rate. If not, it may cause a abnormal robot operation.
Grease to use is VIGOGREASE RE0 (except NV20A), and the filling amount is as follows.
Table.4.2.1.2 Amount of Grease

NB4 / NV6 250ml 220ml 120ml
NB4L / NB15 / NV6L / NV20 620ml 580ml 305ml
The density of VIGOGREASE RE0 is 0.9g/ml.
Grease to use to NV20A is Multemp FZ No.00, and the filling amount is as follows.
Table.4.2.1.3 Amount of Grease(NV20A)

NV20A 860ml 690ml 345ml
The density of Multemp FZ No.00is 0.9g/ml.
(7) Check the amount of grease injected and discharged when the actual injecting amount reaches the given
filling amount. As for the actual injecting amount, check the grease gun counter or the difference in the amount
before and after the greasing work. For the discharged amount on the other hand, check the grease catch
container to see the difference in the amount before and after the greasing work. When the amount of injected
and discharged becomes equal, it is considered that the grease replacement has been completed. Then, go to
the procedure (12).
(8) If the discharged amount is less than the injected amount, the difference indicates the surplus. In that case,
discharge the surplus by applying push-out air into the outlet port so that the injected and discharged amount
becomes equal.
(9) Remove the grease nipple from the inlet port, and attach the air equipment fitting [Rc1/8,8] and the outlet
hose [85, Max. length 100mm] to the inlet port.
(10) Prepare the grease catch container as shown in Fig.4.2.1.2.
(11) Make the pressure of push-out air lower than the maximum of 0.025MPa using the precision regulator.
If the grease does not come out but only air even if applying push-out air, operate the target axis at the low
speed with the posture shown in Table.4.2.1.3 and within the working range shown in Fig.4.2.1.3, applying
push-out air at the same time, to discharge the surplus. When the amount of injected and discharged
becomes equal, it is considered that the grease replacement has been completed. Then, go to the procedure
(12).
1-4-12
Table.4.2.1.4 Recommended posture
Recommended Recommended Recommended

Axis posture with posture with posture with
J1 axis at motion J2 axis at motion J3 axis at motion
Axis J1 Any Any Any
Axis J2 Any 90 90
Axis J3 Any Any 0
(a) Low speed working range of J1 axis
(b) Low speed working range of J2 axis
(c) Low speed working range of J3 axis
Fig.4.2.1.3 Low speed working range in applying push-out air
1-4-13
(12) Wipe off grease adhered to the body, and attach the plug. To attach it, wrap the seal tape around the screw
part.
Refer to Table 4.2.1.5, and attach the plug correctly according to the setup posture.
On completion of replacement, be sure to attach the plug to the grease inlet port of every axis and fit the
removed grease nipple to the outlet port of J3 axis.
Table 4.2.1.5 Installation posture and plug type (NB4L/NB15/NV6L/NV20)
Installation type
Axis
Plug location Floor-installed / Wall-hung Ceiling-hung
name
Inside of Frame Orifice plugOutlet PlugOutlet
J1
Connector Plate PlugInlet Orifice plug (Inlet)
Backside of Frame (Upper) Orifice plugOutlet Plug
J2 Backside of Frame (Lower) Plug Orifice plugOutlet
Downside of Lower-arm PlugInlet PlugInlet
Backside of Upper-Arm (Upper) Grease nippleOutlet Plug
J3 Backside of Upper-Arm (Lower) Plug Grease nippleOutlet
Upside of Lower-arm PlugInlet PlugInlet
Note) 1. The grease inlet and outlet of Axis J1, J2 and J3 all differ depending on the installation posture
of manipulator as well as the plug type. Mounting a wrong plug may cause grease leakage,
therefore, comply with the prescription shown in Table 4.2.1.5.
2. Also when modifying the installation posture of manipulator after delivery, be sure to see Table
4.2.1.5 and check the plug type.
3. The initial installation posture of manipulator at shipment is the floor-installation type.
4. When operating after grease replenishment, grease may leak from the outlet. This is just
remains from the outlet, not an abnormal thing. Wipe off leaked grease.
5. The Rc1/8 grease nipple, orifice plug and plug are tightened by torques of 8 N*m.
Do not enter the robot work area while the power is ON.
Also, never apply grease while the robot is operating.
Be sure to take out a plug and grease nipple in the outlet port, otherwise grease
may flow into the motor inside to result in damage of the motor.
Carry out the proper replacement/refill of grease, otherwise the reduction gear may
WARNING be damaged.
When the internal pressure is at the high level such as soon after the manipulator
has stopped, it is very dangerous because the grease may spatter at the moment of
removing the plug of grease inlet port and outlet port. Therefore, take enough care
in performing soon after the manipulator has stopped.
1-4-14
)
(Outlet)()
View A
A
(Outlet)()
Note) The description (Inlet) and (Outlet) in the diagram are opposite at ceiling-hung type.
Fig 4.2.1.4 Location of grease inlet and outlet in Axis J1, J2 and J3 reduction gears. (NB4) (Floor-installed / Wall-hung type)
(Outlet)()
View A
A
(Outlet)()
Note) The description Inlet and Outlet in the diagram are oppsite at ceiling-hung type.
Fig 4.2.1.5 Location of grease inlet and outlet in Axis J1, J2 and J3 reduction gears. (NV6) (Floor-installed / Wall-hung type)
1-4-15
Axis J3
Backside of Upper-arm (Upper)
J3
Grease Nipple
(Rc 1/8)
Axis J3 Axis J3
Backside of Upper-arm (Lower) Upside of Lower-arm
J3 J3
Plug Plug
(Rc 1/8) (Rc 1/8)
Axis J2
Backside of Frame (Upper)
J2 Axis J1 Axis J2
Orifice Plug Inside of Frame Downside of Lower-arm
(Rc 1/8) J1 J2
Orifice Plug Plug
Axis J2 (Rc 1/8) (Rc 1/8)
Backside of Frame (Lower)
J2
Plug
(Rc 1/8)
Axis J1
Connector Plate
J1
Plug
(Rc 1/8)
The grease inlet and outlet all differ depending on the installation posture of manipulator as well as the plug type. For
more details, please refer to Table 4.2.1.5.
Note) The description (Upper) and (Lower) in the diagram are the names based on the relation at floor-installation,
however these names do not change even at hanging installation type.
Fig 4.2.1.6 Location of grease inlet and outlet in Axis J1, J2 and J3 reduction gears (NB4L )
Axis J3
J3
Grease Nipple
(Rc 1/8)
Axis J3
Backside of Upper-arm (Lower) Axis J3
J3 Upside of Lower-arm
Plug J3
Plug
(Rc 1/8)
(Rc 1/8)
Axis J2
J2 Axis J2
Orifice Plug Downside of Lower-arm
(Rc 1/8) Axis J1 J2
Inside of Frame Plug
Axis J2 J1 (Rc 1/8)
Backside of Frame (Lower) Orifice Plug
J2 (Rc 1/8)
Plug
(Rc 1/8)
Axis J1
Connector Plate
J1
Plug
(Rc 1/8)
Fig 4.2.1.7 Location of grease inlet and outlet in Axis J1, J2 and J3 reduction gears (NB15)
1-4-16
Axis J3
J3
Grease Nipple
(Rc 1/8)
Axis J3
Backside of Upper-arm (Lower) Axis J3
J3 Upside of Lower-arm
Plug J3
(Rc 1/8) Plug
(Rc 1/8)
Axis J2
J2 Axis J2
Orifice Plug Axis J1
Downside of Lower-arm
(Rc 1/8) Inside of Frame
J2
J1
Plug
Orifice Plug
Axis J2 (Rc 1/8)
(Rc 1/8)
Backside of Frame (Lower)
J2
Plug
(Rc 1/8)
Axis J1
Connector Plate
J1
Plug
(Rc 1/8)
Fig 4.2.1.8 Location of grease inlet and outlet in Axis J1, J2 and J3 reduction gears (NV6L / NV20)
Axis J3
Backside of Upper-arm
J3
Grease Nipple
(Rc 1/8)
(Outlet)()
Axis J3
Upside of Lower-arm
J3
Plug
(Rc 1/8)
Axis J2
Backside of Frame
J2 Axis J1
Axis J2
Plug Side of Frame
Downside of Lower-arm
(Rc 1/8) J1
J2
(Outlet)() Plug
Plug
(Rc 1/8)
(Rc 1/8)
(Inlet)()
Axis J1
Connector Plate
J1
Plug
(Rc 1/8)
Fig 4.2.1.9 Location of grease inlet and outlet in Axis J1, J2 and J3 reduction gears (NV20A)
1-4-17
4.2.2 Grease Replenishment Procedure for Axis J4, J5 and J6 Reduction Gears (NB4/NB4L)
Table 4.2.2.1 Amount of Grease

NB4 / NB4L Axis J4 Axis J5 Axis J6
Grease Multemp AC-N Multemp AC-N Harmonic SK-2
Amount 5ml 3ml 2ml
(1) Remove two pieces of plugs each from Axis J4, J5 and J6.
As for the plugs of grease filler port for the axis J6, take out the axis-J6 motor cover.
(2) Apply grease (Multemp AC-N) to the Axis J4, J5 and J6 using a sharpened-point tool such as an injector.
Comply with the prescription as shown in Table 4.2.2.1.
(3) After replenishment, remount the plugs (2 positions each). To mount it, apply seal agent such as a sealant
to the screw part.
Fig. 4.2.2.1 Location of plug in Axis J4, J5 and J6 reduction gears (NB4 / NB4L)
WARNING be damaged.
1-4-18
4.2.3 Grease Replenishment Procedure for Axis J4, J5 and J6 Reduction Gears (NB15)

NB15 5ml 5ml 5ml
(2) Apply grease (Harmonic SK-2) to the Axis J4, J5 and J6 using a sharpened-point tool such as an injector.
Comply with the prescription as shown inTable4.2.3.1.
(3) After filling grease, attach the plugs (2 places each) using the tightening torque 2.5Nm.
In attaching the plugs, wrap a sealing tape around the screw part.
Fig. 4.2.3.1 Location of plug in Axis J4, J5 and J6 reduction gears (NB15)
WARNING be damaged.
1-4-19
(NV6 / NV6L / NV20 / NV20A)
Table4.2.4.1 Amount of Grease

NV6 / NV6L 5ml 3ml 3ml
NV20 / NV20A 5ml 5ml 5ml
Comply with the prescription as shown inTable.4.2.4.1.
(3) After filling grease, attach the plugs (2 places each) using the tightening torque 2.5Nm.
In attaching the plugs, wrap a sealing tape around the screw part.
Axis J4 Plug
(Air vent hole)

(M6x0.75)
Axis J4 Plug
(Grease filler port)

(M6x0.75)
Axis J5 Plug NV6L/NV20/NV20A Axis J4 Plug

(Air vent hole) (Air vent hole)

(M6x0.75) (M6x0.75)
Axis J5 Plug Axis J4 Plug

(Grease filler port) (Grease filler port)

Axis J6 Plug (M6x0.75)
(M6x0.75)
(Air vent hole)

Axis J6 Plug
(M6x0.75)
(Grease filler port)

(M6x0.75)
NV6
Fig.4.2.4.1 Location of plug in Axis J4, J5 and J6 reduction gears (NV6 / NV6L / NV20 / NV20A)
WARNING be damaged.
1-4-20
4.3 Replenishment of Grease for Gear (NB4/NB4L/NB15)

Carry out periodical replenishment of grease for the gear, referring to Table 4.3.0.1.
Table 4.3.0.1 Period of Replenishment Grease
Axis Name Period for Replenishment of Grease

J4, J6 Every one year or every 3,000 operating hours, whichever is shorter
If you request us for replenishment work, you will be charged for the work.
4.3.1 Grease Replacement Procedure for Axis J4, J5 Gears (NB4 / NB4L)
Axis J4 Axis J6
NB4 / NB4L ml ml
(1) Remove the plugs of grease filler port on the axis J4 (1 location) and J6 (2 locations on the sides).
(2) Apply grease (Albania EP-2) using a sharpened-point tool such as an injector.
To apply grease carefully in all the teeth of the gear, slightly shift the axis for greasing, moving the teeth, and
apply grease little by little. Before greasing, in addition, make sure that the manipulator is servo OFF.
Do not apply it with the manipulator ON.
(3) After replenishment, remount the plugs. To mount it, apply seal agent such as a sealant to the screw part.
The tightening torque for each plug of Rc1/8 is specified to be 8 N*m.
Axis J4 Grease filler port

(Rc 1/8)
Axis J6 Grease filler port

(Rc 1/8)
Fig. 4.3.1.1 Location of plug in Axis J4, J6 Gears(NB4)
1-4-21
Fig. 4.3.1.2 Location of plug in Axis J4, J6 Gears(NB4L)
WARNING Also, never apply grease while the robot is operating.
1-4-22
4.3.2 Grease Replacement Procedure for Axis J4, J5 Gears (NB15)
Axis J4 Axis J6
NB15 ml ml
(1) Remove the plugs of grease filler port on the axis J4 (1 location) and J6 (1 locations on the sides).
(2) Apply grease (Albania EP-2) using a sharpened-point tool such as an injector.
To apply grease carefully in all the teeth of the gear, slightly shift the axis for greasing, moving the teeth, and
apply grease little by little. Before greasing, in addition, make sure that the manipulator is servo OFF.
Do not apply it with the manipulator ON.
(3) After replenishment, remount the plugs. To mount it, apply seal agent such as a sealant to the screw part.
The tightening torque for each plug of Rc1/8 is specified to be 8 N*m.
Fig. 4.3.2.1 Location of plug in Axis J4, J6 Gears(NB15)
WARNING Also, never apply grease while the robot is operating.
1-4-23
4.4 Grease Replenishment for Roller Bearing

Replenish the cross roller bearing with grease according to the cycle shown in Table 4.4.0.1.
Table 4.4.0.1 Grease replenishment cycle
Axis name Cycle of replenishment

J4
J5(NB15)
Every one year or every 3,000 operating hours, whichever is shorter.
J6 (NB4/NB4L
/NB15)
4.4.1 Grease replenishment procedure for Axis J4 cross roller bearing
Table 4.4.1.1 Amount of grease

TP display angle of Amount of
Type
Axis J4 grease
-90
0
NB4 / NB4L / NB15 1ml each
90
150
-90
0
NV6 / NV6L / NV20 / NV20A 1ml each
90
180
You are recommended to use a manual grease gun with a displacement of 1ml.
When the amount of grease is more than the specified one, the operation will not be
hindered, while the grease may leak from the rotating section.
TP display angle of Axis J4 is the one of the Axis J4 displayed when the axis monitor is
started with the teach pendant.
Apply grease using a grease gun. Grease to be used is Daphne Multilex WR No.2.
Operate the Axis J4 to the TP display angle shown in Table 4.4.1.1 to apply the amount of grease shown in the
table.
Before greasing, make sure that the manipulator is servo OFF.
After greasing, shake down the Axis J4 after the application to have grease spread.
NB4/NB4L NV6/NV6L/NV20/NV20A NB15
Fig.4.4.1.1 Location of grease inlet plug of Axis J4 cross roller bearing
WARNING Carry out the proper replacement/refill of grease, otherwise the bearing may be
damaged.
1-4-24
4.4.2 Grease replenishment procedure for Axis J5 cross roller bearing (NB15)

Type
Axis J5 grease
-90
NB15 0 1ml each
90
(1) Remove a plug to take out a rubber stopper inside.

(2) Then, replace it with a grease nipple (A-M6F).
(3) Apply grease using a grease gun. Grease to be used is Harmonic 4B No.2.
table.
(4) After filling grease, take out a grease nipple and put a rubber stopper once removed in (1) back on a filler port of
the cross roller bearing. Then, attach a plug. In attaching the plugs, wrap a sealing tape around the screw part.
The tightening torque for each plug of Rc1/8 is specified to be 2.5 N*m.
damaged.
1-4-25
4.4.3 Grease replenishment procedure for Axis J6 cross roller bearing (NB4 / NB4L)

Type
Axis J6 grease
0
NB4 / NB4L 1ml each
180
(1) Remove a plug from the grease filling port of J6 axis (1 place).
(2) Mount a grease nipple (A-M6F) to the grease filling port. (To fix the nipple, tighten it by hand, and
turn it around about one-sixth.) Use a grease gun to fill grease. Grease to be used is Daphne
Multilex WR No.2. Position Axis J6 at the TP display angle as shown in Table 4.4.3.1, and inject the
amount specified in this Table. Before greasing, make sure that the manipulator is servo OFF.
(3) After that, remove the grease nipple and then attach the plug. In attaching the plugs, wrap a sealing
tape around the screw part. The tightening torque for each plug of Rc1/8 is specified to be 2.5
N*m. After greasing, shake down the Axis J6 after the application to have grease spread.
Fig.4.4.3.1 Location of grease inlet plug of Axis J6 cross roller bearing of NB4 / NB4L
damaged.
1-4-26
4.4.4 Grease replenishment procedure for Axis J6 cross roller bearing (NB15)

Amount of
TP display angle of
Type grease
Axis J6
No.1 No.2
0 1ml
each 1ml
NB15 120
each
240

(1) Remove a plug from the grease filling port of J6 axis (1 place).
(2) Mount a grease nipple (A-M6F) to the grease filling port. (To fix the nipple, tighten it by hand, and
turn it around about one-sixth.) Use a grease gun to fill grease. Grease to be used is Daphne
Multilex WR No.2. Position Axis J6 at the TP display angle as shown in Table 4.4.4.1, and inject the
amount specified in this Table. Before greasing, make sure that the manipulator is servo OFF.
(3) After that, remove the grease nipple and then attach the plug. In attaching the plugs, wrap a sealing
tape around the screw part. The tightening torque for each plug of Rc1/8 is specified to be 2.5
N*m. After greasing, shake down the Axis J6 after the application to have grease spread.
Fig.4.4.4.1 Location of grease inlet plug of Axis J6 cross roller bearing of NB15
damaged.
1-4-27
4.5 Battery
4.5 Battery
4.5.1 Function of Battery
A battery is provided to back up data of each absolute encoder used in the manipulators. This battery supplies
power to the absolute encoder for data backup purpose when the control power is OFF.
If the battery voltage excessively drops, it may fail to properly store the data. Timing of replacement depends on
the use condition, however, replace all of them at once periodically once in 3 years.
The life of the battery is about three years. If more than three years have passed, the
battery has to be replaced.
This is not a rechargeable battery. If you try to charge this battery, it may be
damaged. Be sure not to try charge this battery.
WARNING
The data backup period of the absolute encoder might become shorter depending
on the environmental conditions, operating conditions, and other factors.
4.5.2 Specification of Battery

Nominal voltage: 3.6V
* The above specification is applicable when absolute encoders and other loads are connected.
4.5.3 Replacing Battery

The replacing procedure described below.see Fig. 4.5.3.1
(1) Perform check go/back operation in accordance with the basic posture check program <such as P9999>
and make sure that the origin position is in alignment with the matchmark <> . If that is not the case, mark
that position.
(2) Remove the upper surface cover from the manipulator.
(3) While the control power is ON, cut off the tie band that fixes the batteries and take off the battery box.
(4) Replace the used batteries in the battery case with the new one. Replace with only DAIHEN Part
No.5096-434.Be sure to replace all of them at this time. At this time, be careful at the orientation in which
batteries are inserted. If placing a battery in a wrong position, the battery may be damaged.
Disconnecting the battery with the control power OFF results in the loss of absolute
encoder data. Be sure to turn on the control power when replacing the battery.
When the power is ON, never touch any parts of the robot controller other than the
battery since doing so may result in an electric shock hazard.
Because of the possible occurrence of a fire or an electric shock hazard, never

attempt to short circuit when replacing the battery with a new one or while conveying
and scrapping it.
WARNING This battery is lithium battery. Be sure to scrap it in accordance with law or the like.
Do not dispose of batteries in fire. If the batteries are put in fire, they may explode by
rapid heating.
The replacement of the batteries should be done in principle by a trained technician.
At disposal of the batteries, insulate the terminal parts with or the like.
1-4-28
4.5 Battery
(5) Connect three new battery connectors.
(6) Fix the battery box with a tie band. At this time, be careful at the orientation of the battery box. If the orientation
is wrong, the batteries may be damaged (see Fig. 4.5.3.1).
The tie band is to be prepared by a customer.
(7) Install a connector plate.
(8) Perform check go/back operation in accordance with the basic posture check program <P9999>, and make
sure that the origin position will not change from that obtained in (1) above.
(9) Perform encoder reset operation at the basic posture check program <P9999>. Refer to the instruction
manual SETUP. Also, see the aforementioned section to reset the encoder if the encoder data have been
lost.
Battery
Battery
Tie Band

Tie Band (Careful Position)
(Careful Position)

Battery Box
Battery Box
View A View A
A A
NB4/NV6 NB4L/NV6L/NB15/NV20/NV20A
Fig. 4.5.3.1 Battery
4.5.4 Notes on Battery Safekeeping
Store the battery in non-condensing, well ventilated locations, avoiding high temperatures and high humidity.
You are recommended to store them at room temperature(20+/-15) with minimal temperature variation and
relative humidity of 70% or below.
Note that the batteries are to be stored only for 6 months, and enforce First-in, first-out rigidly.

attempt to short circuit when replacing the battery with a new one or while
conveying and scrapping it.
WARNING
This battery is lithium battery. Be sure to scrap it in accordance with law or the like.
1-4-29
4.6 Replacing Internal Wires

Replace the internal wires of manipulator every 6 years or every 30,000 operating hours, though the use
condition may differ in each case.
Before replacing, contact to DAIHEN.

1-4-30
This chapter provides the instructions on the Parts List.

5.1 Parts List ..................................................................................................1-5-2
5.1.1 NB4 ....................................................................................................1-5-2
5.1.2 NB4L ..................................................................................................1-5-4
5.1.3 NB15 ..................................................................................................1-5-6
5.1.4 NV6 ....................................................................................................1-5-8
5.1.5 NV6L ................................................................................................1-5-10
5.1.6 NV20 ................................................................................................1-5-12
5.1.7 NV20A..............................................................................................1-5-14
5.2 Location and List of Warning Label ........................................................1-5-16
1-5-1
5.1 Parts List
5.1 Parts List
5.1.1 NB4
Location Ref. No. Parts Name DWG. No. & Model Qty DAIHEN Part No.
AC Servomotor W-L02662 1 W-L02662
Axis J1 RV Reduction Gear L11130X00 1 L11130X00
Grease VIGOGREASE RE0 250ml 100-0624*
Axis J2 RV Reduction Gear L11130Y00 1 L11130Y00
Axis J3 RV Reduction Gear L11130Z00 1 L11130Z00
Harmonic Reduction Gear W-L02034 1 W-L02034
Cross Roller Bearing W-L02551 1 W-L02551
Axis J4
Grease Multemp AC-N 5ml 2670-052*
Grease Albania EP-2 5ml 2670-017*
Grease Daphne Multilex WR No.2 4ml 100-1491*
Harmonic Reduction Gear L10725H 1 L10725H00
Axis J5 Timing Belt W-L02051 1 W-L02051
Pure Sealant Pure sealant clear 15ml 100-1516*
Axis J6 Pure Sealant Pure sealant clear 3ml 100-1516*
Grease Harmonic SK-2 2ml 2670-053*
Battery(Note) W-L02722 or W-L01399 3 5096-434
Cable Assembly (1)
L11130F00 1 L11130F00
frame rear to upper arm
Cable Assembly (2)
Internal (for Axis J5 and J6 of upper arm L10470F00 1 L10470F00
interior)
Wires
Cable Assembly (3)
(for Axis J5 and J6 of upper arm L10470G00 1 L10470G00
interior)
Cable Assembly (4)
L10470H00 1 L10470H00
(for Axis J6 of upper arm interior)
Axis J5 Unit
L10470C00 1 L10470C00
(Axis J5 Unit assembly)
Assembly Axis J6 Unit
(Axis J6 Unit assembly) L11140B00 1 L11140B00
Power Cable Assy1
L11130M00 1 L11130M00
Welding (inside of Axis J1)
cables Power Cable Assy2
(from Axis J2 to the upper arm) L11130P00 1 L11130P00
Note) On January 1, 2009, for revision of the UN Recommendations on the Transport of Dangerous Goods, Model
Regulations-15th edition, Transportation regulation of Lithium battery is partially revised.
When you transport the Lithium battery by air, transport it according to providing items of the newest ICAO-TI and
IMDG Code of IMO
IMPORTANT
1. Grease: Minimum quantity for a single order of VIGOGREASE RE0 is about 575 ml in a 500-g can.
2. Grease: Minimum quantity for a single order of Multemp AC-N is about 500 ml in a 500-g can.
3. Grease: Minimum quantity for a single order of Harmonic SK-2 is about 500ml in a 500-g can.
4. Grease: Minimum quantity for a single order of Albania EP-2 is 200ml.
5. Grease: Minimum quantity for a single order of Daphne Multilex WR No.2 is 400g.
6. The minimum quantity for a single order of pure sealant is 330 ml.
7. * mark is recommendatory spare parts.
1-5-2
5.1 Parts List
10 J4
8
7
J4
J5 7 9
14
13 12
10
1
6
3
J3
16 15
11 Pure Sealant Application Surface 15

17 J5
19 J6 18
12
3 J6
5 20
J2 4
J4
11
1
2
3
J1
Fig.5.1.1.1 NB4

1-5-3
5.1 Parts List
5.1.2 NB4L
Ref. DAIHEN Part

Location Parts Name DWG. No. & Model Qty
No. No.
Axis J1 Cyclo Reduction Gea W-L02116 1 W-L02116
Grease VIGOGREASE RE0 620ml 100-0624
Axis J2 Cyclo Reduction Gear W-L02117 1 W-L02117
Axis J3 RV Reduction G ar L10725F 1 L10725F00
AC Servomotor W-L02148 1 W-L021 8
Axis J4
Grease Alba ia EP-2 5ml 2670-017*
Harmonic Reduction Gear L10725H 1 L10725H00
rease Multemp AC-N 3ml 2670-052*
Harmonic Reduction Gear -L02036 1 W-L02036
Axis J6 Pure Sealant Pure sealant clear 3ml 100-1516*
Cable Assembly (1)
L10525C00 1 L10525C00
(frame rear to upper arm)
Cable Assembly (2)
Internal (for Axis J5 and J6 of upper arm L10525D00 1 L10525D00
interior)
Wires
Cable Assembly (3)
(for Axis J5 and J6 of upper arm L10525E00 1 L10525E00
interio )
Cable Assembly (4)
L10470H00 1 L10470H00
(for Axis J6 of upper arm interior)
Axis5 Unit
L10470C00 1 L10470C00
Assembly Axis6 Unit
(Axis J6 Unit assembly) L11140B00 1 L11140B00
Power Cable Assy1
(inside of Axis J1) L10485Q00 1 L10485Q00
Welding
cables Power Cable Assy2
(from Axis J2 to the upper arm) L10485S00 1 L10485S00
Note) On January 1, 2009, for revision of the UN Recommendations on the Transport of Dangerous Goods,
Model Regulations-15th edition, Transportation regulation of Lithium battery is partially revised.
When you transport the Lithium battery by air, transport it according to providing items of the newest
ICAO-TI and IMDG Code of IMO
IMPORTANT
2. Grease: Minimum quantity for a single order of Multemp AC-N is about 500 ml in a 500-g can.
5.Grease: Minimum quantity for a single order of Daphne Multilex WR No.2 is 400g.
1-5-4
5.1 Parts List
10 J4 J4 9
8
7 12
J5 7
14
13 1
10 6
3
J3
Pure Sealant Application Surface 15

16 15 18
11 12
17 J6
19 J6
3
5
J2 4 20
J4 11
1
2
3
J1
Fig.5.1.2.1 NB4L

1-5-5
5.1 Parts List
5.1.3 NB15
Ref. DAIHEN Part

Location Parts Name DWG. No. & Model Qty
No. No.
AC Servomotor W-L02152 W-L02152
Axis J3 RV Reduction Gear L10725F 1 L10725F00
AC Servomotor W-L02151 1 W-L021 1
Axis J4
AC Servomot W-L02404 W-L02404
5-Axis res. unit L10970S00 1 L10970S00
Grease Harmonic 4B No.2 3ml 100-1025
Timing Belt W-L02579 1 W-L02579
Cable Assembly (1)
L10974T00 1 L10974T00
(frame rear to upper arm)
Internal Cable Assembly (2)
Wires (for Axis J5 and J6 of upper arm L10974F00 1 L10974F00
interi r)
Cable Assembly (3)
interior)
Axis6 Unit
L10974B00 1 L10974B00
Assembly Drive Unit
(Axis J5 andJ6 motor and Gear L10974H00 1 L10974H00
assembly)
IMPORTANT
3. Grease: Minimum quantity for a single order of Harmonic 4B No.2 is about 568 ml in a 500-g can.
1-5-6
5.1 Parts List
J4
J6
J5
J3
J6 J5
J6
J2
J6
J6
J4
J1
Fig.5.1.3.1 NB15

1-5-7
5.1 Parts List
5.1.4 NV6
Axis J1 RV Reduction Gear L11130X00 1 L11130X00
Axis J2 RV Reduction Gear L11130Y00 1 L11130Y00
Axis J3 RV Reduction Gear L11130Z00 1 L11130Z00
Axis J4 Cross Roller Bearing W-L02555 1 W-L02555
Axis J5 Timing Belt J5 W-L01945 1 W-L01945
Cable Assembly (1)
Internal L11130F00 1 L111300F00
Wires Cable Assembly (2)
interior)
Axis J5 and J6 Unit
Assembly L10460B00 1 L10460B00
(Axis J5 and J6 Unit assembly)
IMPORTANT
2. Grease: Minimum quantity for a single order of Harmonic SK-2 is about 500 ml in a 500-g can.
1-5-8
5.1 Parts List
10 J4
8
7
J5 7
13
12
10
1
6
3
7 J3 4
16 Pure Sealant Application Surface
15 14
10 J6 J5,6
6
3
5 17 5
J2 4
9
11
J4
1
2
3
J1
Fig.5.1.4.1 NV6

1-5-9
5.1 Parts List
5.1.5 NV6L
Grease Daphne Multilex WR No.2 4ml 100-1491
Cable Assembly (1)
Internal L10525C00 1 L10525C00
interior)
Axis J5 and J6 Unit
IMPORTANT
1-5-10
5.1 Parts List
11 J4
9
8
J5 12
14
13 6
11 7
3
J3
12
16
15
11 J6
3 17
5
J2 4
10
18
J4
1
2
3
J1
Fig.5.1.5.1 NV6L

1-5-11
5.1 Parts List
5.1.6 NV20
Axis J5 Timing Belt(1) W-L02028 1 W-L02028
Cable Assembly (1)
Internal L10485F00 1 L10485F00
(for Axis J5 and J6 of upper L10485G00 1 L10485G00
arm interior)
Axis J5 and J6 Unit
IMPORTANT
1-5-12
5.1 Parts List
11 J4
9
8
J5 8
14
13
11
6
7
3
8 J3
16
15
11 J6
17
5
19
J2 4
10
18
J4
1
2
3
J1
Fig.5.1.6.1 NV20

1-5-13
5.1 Parts List
5.1.7 NV20A
Grease Multemp FZ No.00 860ml 100-0127
Axis J2 Cyclo Reduction Gear W-L02714 1 L W-L02714
Cable Assembly (1)
L11440E00 1 L11440E00
Cable Assembly (2)
(for Axis J5 and J6 of upper L10485G00 1 L10485G00
Internal arm interior)
Wires
Cable Assembly (4)
L11440R00 1 L11440R00
(for Axis J2 motor)
Cable Assembly (5)

L11440G00 1 L11440G00
(for Axis J2 motor encoder)
Axis J5 and J6 Unit
IMPORTANT
1. Grease: Minimum quantity for a single order of Multemp FZ No.00 is about 556 ml in a 500-g can.
1-5-14
5.1 Parts List
11 J4
9
8
J5 8
13
12
11
6
7
3
8 J3
15
14 16
11 J6
Pure Sealant Application Surface

3
5 18
J2 4
10
17
J4
1
2
3
J1
Fig.5.1.7.1 NV20A

1-5-15
5.2 Location and List of Warning Label
Every manipulator and robot controller of Almega series is provided with a warning labels (that states the
special cautions to be observed) to ensure the safe operation of the robot system.
If such warning labels have been peeled off or damaged, order them from our local distributor or our sales
office.
Table 5.2.0.1 Warning Label

Qty
Location Item Name Parts No
NB4/NB4L/NB15 NV6/NV6L/NV20/NV20A
Manipulator Waning Label NK7248 3 4
NB4 / NB4L / NB15 /
Waning Label NK7024 1 1
NV6 / NV6L / NV20 / NV20A
NK7248 NK7248
NK7024 NK7024
NB4 / NB4L NV6 / NV6L / NV20 / HA20
NK7248
NK7024
NB15
Fig. 5.2.0.1 Warning Label Location
1-5-16
This chapter provides the instructions on the Internal Wires.

6.1 Wiring Connection Figure ........................................................................1-6-2
6.1.1 Wiring Connection Figure for NB4 .....................................................1-6-2
6.1.2 Wiring Connection Figure for NB4L ...................................................1-6-4
6.1.3 Wiring Connection Figure for NB15 ...................................................1-6-6
6.1.4 Wiring Connection Figure for NV6 .....................................................1-6-8
6.1.5 Wiring Connection Figure for NV6L .................................................1-6-10
6.1.6 Wiring Connection Figure for NV20 .................................................1-6-12
6.1.7 Wiring Connection Figure for NV20A ...............................................1-6-14
1-6-1
6.1 Wiring Connection Figure
6.1.1 Wiring Connection Figure for NB4
Fig.6.1.1.1 Wiring Connection Figure for NB4
1-6-2
Fig. 6.1.1.2 Wiring Connection Figure for NB4

1-6-3
6.1.2 Wiring Connection Figure for NB4L
Fig.6.1.2.1 Wiring Connection Figure for NB4L
1-6-4
Fig.6.1.2.2 Wiring Connection Figure for NB4L

1-6-5
6.1.3 Wiring Connection Figure for NB15
1-6-6

1-6-7
6.1.4 Wiring Connection Figure for NV6
Fig.6.1.4.1 Wiring Connection Figure for NV6
1-6-8
Fig. 6.1.4.2 Wiring Connection Figure for NV6

1-6-9
6.1.5 Wiring Connection Figure for NV6L
Fig. 6.1.5.1 Wire Connection Figure for NV6L
1-6-10
Fig.6.1.5.2 Wiring Connection Figure for NV6L

1-6-11
6.1.6 Wiring Connection Figure for NV20
1-6-12

1-6-13
6.1.7 Wiring Connection Figure for NV20A
Fig.6.1.7.1 Wiring Connection Figure for NV20A
1-6-14
Fig.6.1.7.2 Wiring Connection Figure for NV20A

1-6-15
H-type Manipulator
Capter 1 Specifications of H-type Manipulator
Capter 2 Foundation Work and Installation
Capter 3 Periodic Inspection
Capter 4 Maintenance
Capter 5 Parts List
Capter 6 Internal Wires

Chapter 1 Specifications of H-type Manipulator
This chapter describes the specifications of H-type manipulator.

1.1 Manipulator model ....................................................................................2-1-2
1.2 Basic Specifications ..................................................................................2-1-3
1.3 Outside Dimensions and Working Range .................................................2-1-4
1.4 Description on Each Part of Manipulator ..................................................2-1-5
1.4.1 Allowable Load on Wrist Axis .............................................................2-1-5
1.4.2 Flange Dimensions of Wrist Axis ........................................................2-1-6
1.4.3 Mounting Equipment on Upper Arm ...................................................2-1-7
1.4.4 Restrictions of Working Range ...........................................................2-1-8
1.4.5 Instrument Connecting Cables and Air Piping ....................................2-1-9
1.4.6 Motion Warning Lamp (option) .........................................................2-1-12
1.4.7 Holding Brake ..................................................................................2-1-12
1.5 Reference Position of Moving Axis .........................................................2-1-13
1.5.1 Angular Reference Position of Each Joint in the Working Range.....2-1-13
1.5.2 Angular Reference Position of Each Joint in the Starting Area .........2-1-13
1.6 Motion Direction of Each Axis .................................................................2-1-14
1.6.1 Motion of Each Axis .........................................................................2-1-14
1.6.2 Motion in the Cartesian Coordinate..................................................2-1-14
1.7 Changing Working Range.......................................................................2-1-15
1.7.1 Changing Working Range of Axis J1 ................................................2-1-15
1.7.2 Changing Working Range of Axis J2 and J3 (with the option mounted)...2-1-16
1.8 Option .....................................................................................................2-1-17
2-1-1
The following section shows the nomenclature of manipulator model.
N No support Classification by overseas

U UL specifications standard support
F Floor-installed
C Ceiling-hung Classification by mount type
W Wall-hung
J Domestic specification
C Overseas specification(China) Classification by shipment
E Overseas specification(except China) destination
N Standard specification
H Handling specification Classification by design No.
A Handling specification (with Air Unit)
Manipulator series No.
Manipulator name
2-1-2

Item Specifications
Name NH5
Specification Arc welding Specification Handling Specification
Number of axes 6
Max. payload capacity 5 kg
Positional repeatability +/- 0.05 mm (Note 1)
Drive capacity 1440W
J1 (Revolving) +/- 170
Arm J2(Fore/Back) -125~ +90
Working range
J3 (Up/Down) -140~ +245

J4 (Swing) +/- 190
Wrist J5 (Bending) -30~ +210
J6 (Twist) +/- 360
J1 (Revolving) 3.49 rad/s {200/s} (2.79 rad/s {160/s})(Note 2)
Arm J2(Fore/Back) 3.49 rad/s {200/s}
Max. velocity
J3 (Up/Down) 4.54 rad/s {260/s}

J4 (Swing) 6.63 rad/s {380/s}
Wrist J5 (Bending) 6.63 rad/s {380/s}
J6 (Twist) 8.90 rad/s {510/s}
J4 (Swing) 11.9 N*m
Allowable
J5 (Bending) 11.9 N*m
Moment
Wrist load
J6 (Twist) 5.2 N*m

Allowable J4 (Swing) 0.303 kg *m2
moment of J5 (Bending) 0.303 kg *m2
inertia J6 (Twist) 0.061 kg *m2
Arm operation cross-sectional area 1.22 m2 x340
0 ~ 45C, 20 ~ 80 %RH
(No condensation)
Mass (weight) 58 kg 59kg
Upper arm payload capacity 1 kg
(J5J6) IP54 (J4~J6) IP65
IP Code
(J5J6) IP54 (J1~J3) IP64
Note) 1. The value of the positional repeatability is at the tool center point (TCP) compliant to ISO 9283.
The positional repeatability in X,Y,Z directions on the installation surface is 0.03mm.
2. The value in the parentheses indicates the wall-hung condition.
IMPORTANT
2-1-3
170
P-Point
214
P
224
142
R235
R269
66
R8
170
390
P-Point
70
P
766
95
370
330
145
608
597 269
866 666
Fig. 1.3.0.1 Outside Dimensions and Working Range (unit: mm)

As for the handling specification and the arc welding specification, a part of the upper arm shape is
different.
WARNING
2-1-4
1.4.1 Allowable Load on Wrist Axis

The payload of the manipulator must not exceed max. payload capacity (5kg) including a welding torch, or
chucking tools and a workpiece used for handling.
Mounting a standard welding torch does not cause any problems to the manipulator, but both the moment and the
moment of inertia must be within the allowance stated in the table below when the manipulator is used for
handling or any other similar purposes.
Also, when a load is imposed not in the form of mass but force, a wrist axis must not be used with these maximum
allowable values exceeded.
Table 1.4.1.1 Allowable Load on Wrist Axis

Axis NH5
Name Allowable Moment Allowable Moment of Inertia
2
J4 11.9 N*m 0.303 kg *m
2
J5 11.9 N*m 0.303 kg *m
2
J6 5.2 N*m 0.061 kg *m

Rotation Center
6(mm)
95
106
150 100 50
100
5(mm)
150
Rotation Center
W=5kg 200
242
250
300
Fig. 1.4.1.1 Allowable Load on Wrist Axis
Fig. 1.4.1.2 Wrist load conditions
2-1-5
1.4.2 Flange Dimensions of Wrist Axis

Fig. 1.4.2.1 shows the flange dimensions of wrist axis. Fit a tool using the flange spigot (25H7 or 50h7), and
Fig. 1.4.2.1 Flange Dimensions of Wrist Axis (unit : mm)
To avoid damaging to the motors or the reduction gears due to overload, be sure to keep
the allowable load on the wrist axis.
CAUTION
Use a specified tightening torque (Strength grade 12.9 : 11.8 N*m) for firmly tightening M6
bolts so that tools are prevented from falling off or forcibly flown off.
WARNING Note that M6 bolts must be fit into a tapping hole (8 mm deep) in the wrist axis flange.
2-1-6
1.4.3 Mounting Equipment on Upper Arm

The top of the upper arm is provided with the face to mount the equipment such as a cable hanger etc. To mount
the equipment, use them only for cable clamping or others that the large external force is not applied on.
(Payload Capacity: 1.0 kg)
120 17
4xM6 9 deep
9
30
131
70
Fig. 1.4.3.1 Equipment Mounting Position on Upper Arm (unit: mm)
To avoid damaging to the motors or the reduction gears due to overload, be sure to keep
the max. mountable mass on the upper arm.
CAUTION
WARNING
2-1-7
1.4.4 Restrictions of Working Range
Each axis of the manipulator has a limit in its working range for safety management and interference prevention.
The limit of working range set by the program in the robot controller is called Soft Limit.
In addition, the manipulator is usually equipped with an overrun limit switch and/or mechanical stoppers in case
that the manipulator moves beyond the Soft Limit.
NH5 manipulator has the working range restrictions as shown in the table 1.4.4.1 below.
Table 1.4.4.1 Restrictions of Working Range on Each Axis

NH5
Axis
Overrun Limit
Name Soft Limit Mechanical Stopper
Switch
J1
J2
J3
J4
J5
J6
: Standard equipment
: Optional equipment (Refer to the 1.8 Option)
: Unequipped
Fig. 1.4.4.1 Limit of Working Range
2-1-8
1.4.5 Instrument Connecting Cables and Air Piping

Inside the manipulator, the instrument connecting cables and a air hose (The maximum pressure: 0.5 MPa or
less) are built in for driving or signaling instruments such as an end-effector.
Instrument Connection Cable 2

1 Cable [0.4mm ] CM09-R25S
0.2mm 218pcs
2 NC (DDK)
0.4mm 21pc 2
3 Cable 0.2mm ]
2
Pins 4 Cable 0.2mm ] Prepare

5 Cable 0.2mm
2
] counter-connector
2
6 Cable 0.2mm ] CM09-P25P
2
7 Cable 0.2mm ] (DDK)
2
3
1 2
7
8 Cable 0.2mm ]
2
8 9 Cable 0.2mm ]
2
10 Cable 0.2mm ]
11 NC
12 NC
13 NC Air outlet
CM09-R25P Rc1/8(PT1/8)
14 Cable 0.2mm ]
2
15 Cable 0.2mm 2
]
16 Cable 0.2mm ]
2
17 Cable 0.2mm ]
2
18 Cable 0.2mm ]
2
2
19 Cable 0.2mm ]
2 Cable
20 Cable 0.2mm ] Instrument Connection Cable
Air Hose 1 [0.4mm ]
2
21 Cable 0.2mm ]
2
0.2mm 218pcs
22 Cable 0.2mm
2
] 2 NC
0.4mm 21pc 2
23 Cable 0.2mm
2
] 3 [0.2mm 2
]
24 NC Pins 4 [0.2mm 2
]
25 NC 5 [0.2mm 2
]
6 [0.2mm ]
<Allocation of CN5 Connector Pins> 2
7 [0.2mm 2
]
2 1
7 3 8 [0.2mm 2
]
8
Instrument Cable Connector(CN5) 9 [0.2mm 2
]
CM09-R25P(DDK) 10 [0.2mm ]
11 NC
Preare
12 NC
counter-connector
13 NC
CN09-P25S(DDK)
14 [0.2mm ]
2
CM09-R25S
15 [0.2mm ]
2
Air inlet 16 [0.2mm

2
]
Rc1/4(PT1/4) 17 [0.2mm
2
]
18 [0.2mm ]
2
Maximum Pressure: 0.5MPa)
2
19 [0.2mm ]
2
20 [0.2mm ]
2
21 [0.2mm ]
2
22 [0.2mm ]
2
23 [0.2mm ]
24 NC
25 NC
(a) Handling Specification(Standard)
Instrument Connection Cable 2

SOLV Signals and Condition Instrument Cable Connector(CN70)
1 24V [0.4mm ] CM09-R25S
0.2mm 210pcs Air Piping Joint SOLV Signals
2 NC (DDK)
3 NC Solenoid
Input Output SOLV
4 NC A B Prepare
Pins
5 SOL 1A [0.2mm 2
] 1A 1B ON OFF counter-connector
1
6 SOL 1B [0.2mm
2
] 1B 1A OFF ON CM09-P25P
AIR1
7 SOL 2A [0.2mm
2
] 2A 2B ON OFF (DDK)
2
1 2 8 SOL 2B [0.2mm
2
] 2B 2A OFF ON
3 7
9 SOL 3A [0.2mm
2
] 3A 3B ON OFF
8
3
10 SOL 3B [0.2mm
2
] 3B 3A OFF ON
AIR2
11 NC
12 NC SOLV:Solenoid Valve
Air outlet(M5) Air outlet
13 NC
CM09-R25P Rc1/8(PT1/8)
14 Cable 0.2mm ]
2
15 Cable 0.2mm 2
]
16 Cable 0.2mm
2
]
17 Cable 0.2mm ]
2
18 Cable 0.2mm ]
2
2
19 Cable 0.2mm ]
2 Cable
20 Cable 0.2mm ] Instrument Connection Cable
Air Hose 1 NC
21 Cable 0.2mm ]
2
0.2mm 210pcs
22 Cable 0.2mm
2
] 2 NC
23 Cable 0.2mm
2
] 3 NC
24 NC Pins
4 NC
25 NC 5 NC
6 NC
7 NC
7
2 1
3
8 NC
Instrument Cable Connector(CN5) 8 9 NC
CM09-R25P(DDK) 10 NC
11 NC
Preare
12 NC
counter-connector
13 NC
CN09-P25S(DDK)
14 Cable [0.2mm ]
2
CM09-R25S
15 Cable [0.2mm ]
2
Air inlet 16 Cable [0.2mm ]

2
Rc1/4(PT1/4) 17 Cable [0.2mm ]

2
Maximum Pressure: 0.5MPa) 18 Cable [0.2mm

2
]
2
19 Cable [0.2mm ]
2
20 Cable [0.2mm ]
2
21 Cable [0.2mm ]
2
22 Cable [0.2mm ]
2
23 Cable [0.2mm ]
24 NC
25 NC
(b) Handling Specification(Option)
Fig.1.4.5.1 Instrument Connecting Cables and Air Piping
2-1-9
Fig.1.4.5.2 shows the wiring diagram of the built-in cables of the manipulator for welding
application.
MOLEX 58691-0020
White
Black
(a) Arc welding Specification
CN5 CN70
Black 0.2
White 0.2
Red 0.2
Green 0.2
Yellow 0.2
Brown 0.2
Blue 0.2
Orange 0.2
Gray 0.2
CM09-P25S
CM09-R25P
CM09-R25S
Purple 0.2 CM09-P25P
Black 0.2
White 0.2
Red 0.2
Green 0.2
Yellow 0.2
Brown 0.2
Blue 0.2
Orange 0.2
Gray 0.2
Purple 0.2
(b) Handling Specification(Standard)
CN5 CN70
Black 0.2
Solenoid Valve
White 0.2
Red 0.2
Green 0.2
Yellow 0.2
Brown 0.2
Blue 0.2
Orange 0.2
Gray 0.2
CM09-P25S
CM09-R25P
CM09-R25S
CM09-P25P
Purple 0.2
Black 0.2
White 0.2
Red 0.2
Green 0.2
Yellow 0.2
Brown 0.2
Blue 0.2
Orange 0.2
Gray 0.2
Purple 0.2
(c) Handling Specification (Option)

Fig. 1.4.5.2 Cable Wiring Diagram
2-1-10
Table 1.4.5.1 Specifications of solenoid valve

Item Specifications
Type of actuation 2 position double
Fluid Air
Common exhaust for the pilot
Pilot exhaust method
and main valve
Lubrication Not required
Valve
Operating pressure range 0.15 to 0.7 MPa
Response time
15 ms or less
(at 0.5MPa)
Max. operating frequency 10Hz
Ambient and fluid temperature -10 to 50 (No freezing)
Coil rated voltage 24V10%
Solenoid Power consumption 0.35W
Surge voltage suppressor Not required
2-1-11
1.4.6 Motion Warning Lamp (option)

A manipulator is provided with a connector for the motion warning lamp. This warning lamp is optionally available
to indicate Servo ON, Automatic Operation and so on.
Refer to the 1.8 Option for more details.
Fig.1.4.6.1 Motion Warning Lamp
1.4.7 Holding Brake

All the motors of NH5 manipulator have built in holding brakes respectively.
A holding brake is intended to prevent the manipulator arm from falling when the control power is OFF or when
the servo power is OFF due to an emergency stop.
(Note: These brakes will be released only when the servo power is turned on.)
2-1-12
1.5.1 Angular Reference Position of Each Joint in the Working Range

Refer to V-type manipulator 1.5.1 Angular Reference Position of Each Joint in the Working Range.
1.5.2 Angular Reference Position of Each Joint in the Starting Area

Refer to V-type manipulator 1.5.2 Angular Reference Position of Each Joint in the Starting Area.
2-1-13
1.6.1 Motion of Each Axis

Refer to V-type manipulator1.6.1 Motion of Each Axis.
1.6.2 Motion in the Cartesian Coordinate

Refer to V-type manipulator1.6.2 Motion in the Cartesian Coordinate.
2-1-14
1.7.1 Changing Working Range of Axis J1

According to the conditions of the manipulators surrounding area, axis J1 can restrict its working range.
Furthermore, by mounting the limit switch (option) limitations can be provided, both electronically and
mechanically.
Axis J1 can be changed its working range according to the ambient condition, which is available by changing the
setting position of stopper bolt as shown in the figure below. Also modify the Soft Limit area at this time.
Stopper

1.Remove Stopper 2.Install Stopper

Fig. 1.7.1.1 Changing Working Range of Axis J1

In order to install stopper bolts, select two positions (+ and -) for the desired working range from the positions
shown in Fig.1.7.1.1. Note that it must be set within +170 ~-170 since the working range in excess of +/-170
cannot be set. In addition, the arm must face the front of the robot in the working range. Select the working range
from the + side and the - side in Fig.1.7.1.2. The stopper bolts are mounted at +/-170 at factory shipment.

Axis J1 Rotary -110 -80
Direction -50
J1 -140
- Stopper (Fixed Side)
-170
Arm Front

+170
Axis J1 Rotary Axis J1 Limit Switch(Option)
Direction J1
J1 +140
+ +110 +50
+80
Fig. 1.7.1.2 Stopper Setting Position
2-1-15
1.7.2 Changing Working Range of Axis J2 and J3 (with the option mounted)
For the axis J2 and J3, the working range can be changed by installing the optional Dog and Limit Switch.
At this time, modify the Soft Limit area as well. The installation position and the adjustment angle of Limit Switch
in each manipulator is shown in the figure below. When setting the dog, select a single position in each (+) and
(-) side in the desired working range.

Direction Direction
J2 J2
+ -
+90
Dog
+60
Dog
+30
-125
-95
-65 -35
Fig. 1.7.2.1 Dog Setting Position on Axis J2
Axis J3 Rotary Direction

J3
+ +200 +180
Dog +150

The angle contained by Axis J2 +120

90
0 Dog
+90

Axis J3 Rotary Direction -75
J3
- +60
-30 +30
Fig. 1.7.2.2 Dog Setting Position on Axis J3
2-1-16
1.8 Option
1.8 Option
(1) Part to restrict the working area of Axis J1
The following part can restrict the working area of Axis J1 electrically.
Limit switch parts for working restriction of
L10480Q00 Cable assembly LS1
Axis J1
(2) Part to restrict the working area of Axes J2 and J3
The following part can restrict the working area of Axis J2 and J3 electrically.
Limit switch parts for working restriction of Axes J2
L7520K00 Cable assembly LS
and J3.
L10480R00 Dog accessories Dog parts for working restriction of Axes J2 and J3
(3) Warning lamp
The warning lamp lights up while the robot is working (the servo power is ON).
L6600R00 Warning lamp ColorAmber
L6600S Warning lamp ColorRed

L10480T00 Lamp mounting ASSY For NH5
Every warning lamp needs the lamp mounting ASSY, regardless of their color.
(4) Jig to check the home position
The following jig is a necessary item to check the home position of each axis.
L10725M Mechanical origin checking parts For NH5
The option is not used for Mechanical adjustment(Performing encoder reset and encoder correction).
(5) Air Unit ( For Handling Specification )
The solenoid valves for application are built in the upper-arm.

The upper-arm is equipped with 3 solenoid
L10860V00 Air Unit valves for application ,air piping (M5:6 pcs,
Rc 1/8: 1 pcs) and 10 signal lines .
The maximum pressure is 0.5 MPa.
Note) The type of manipulator with Air Unit is NH51-A***.
(6) Manipulator stand
Model Name Specifications

L10965H00 Stand(7) For NH5 Stand height700mm
Reproducing block for mechanically defining the
L10965T00 Positioning block
positional relation between manipulator and stand.
This is to reproduce the positional relation in mounting the stand against manipulator.
Once the manipulator has been replaced, the block cannot guarantee the position.

2-1-17
This chapter provides the instructions for the foundation work and installation.
2.1 Safety Measures Relating to Installation ..................................................2-2-2

2.2 Installation Locations and Ambient Conditions.........................................2-2-5
2.3 Notes on Interference by Electromagnetic Noise .....................................2-2-6
2.4 Accessories..............................................................................................2-2-7
2.5 Transport Method.....................................................................................2-2-8
2.6 Installation of Manipulator ......................................................................2-2-10
2.6.1 Installation Method ...........................................................................2-2-10
2.6.2 Installing Manipulator and Jigs on Common Frame Base ................ 2-2-11
2.6.3 Maximum Manipulator Generative Force ......................................... 2-2-11
2.7 Note on Emergency stop of Manipulator................................................ 2-2-11
2-2-1
Measures to Ensure the Safety of Personnel Entering inside the Operating

Range of the Robot
While the robot is operating, there is a danger that the operators will come into contact
with the robot. For this reason, erect a guarding fence to ensure that the operators will
be kept at a distance from the robot. Accidents may occur if operators or other
DANGER individuals gain admittance inside the operating range of the robot by mistake.
Guarding fence
ISO 13857:2008 Safety of machinery - Safety distances to prevent hazard zone
being reached by the upper and lower limbs.
The guarding fence must be constructed in such a way that it cannot be easily climbed
over or easily moved. If the guarding fence is too low, individuals may climb over it and
enter inside the operating range of the robot, leading to accidents.
DANGER
Provide a door in the guarding fence to allow access in and out of the operating range.
Be absolutely sure to install a safety plug in the door, and construct the door in such a
way that it will not open unless the plug is removed. The entry of an individual inside the
CAUTION guarding fence can be detected by means of the signals from the safety plug.
Take steps to provide an interlock so that the servo power (motor power) of the robot
is turned off when the safety plug has been removed or ensure that the motor power
is turned off while the guarding fence is open. The robot can be stopped automatically
when an individual has made an attempt to enter inside the guarding fence. (The
CAUTION robot controller has a safety plug input.)
2-2-2
Provide the emergency stop button of the robot in a location where it can be pressed
immediately by the operator.
Accidents may occur since the emergency stop operation cannot be initiated
CAUTION immediately. (The robot controller has an external emergency stop input.)
If it is not possible to erect a guarding fence, install photoelectric switches, mat switches,
etc. in every location where individuals can enter inside the operating range of the robot
in place of the safety plug. The robot can be stopped automatically when an individual
DANGER has entered inside the operating range of the robot.
Color-code the floor so that the danger area (operating range of the robot) can be easily
identified visually.
CAUTION
Safety measures for positioning the robot and its peripheral devices
Do not position the operation and adjustment controls inside the operating range of the
robot. The robot may cramp the access to these controls.
Place the robot control panel, interlock panel and all other operation panels in positions
DANGER where they can be operated outside the guarding fence.
If an operation stand is to be provided, provide it with an emergency stop button as well.

Emergency stop can be initiated immediately even when fault occurs during operation
using the operation stand.
CAUTION
Do not route the wires and hoses between the robot body and the control panel,
inter-lock panel, etc. in such a way that the operators will trip over them or the forklift
trucks will run straight over them. Otherwise, operators may fall over, wires may break or
WARNING become disconnected, causing accidents.
Do not place the control panel, interlock panel, operation stand, etc. in positions where
the movements of the robot body are not visible.
If the robot movements cannot be seen, the operator will be slow to respond even when
fault has occurred, and this may lead to a serious accident. Accidents may also be
DANGER caused if the presence of the operators cannot be verified.
Place restrictions on the operating range of the robot if the necessary work range of the
robot is smaller than the range in which the robot can be operated. Restrictions can be
placed using limit switches and mechanical stoppers. Even if the robot has moved out of
CAUTION the normal work range due to a fault, for instance, it can be stopped ahead of time.
(Refer to 1.7 Changing Working Range.)
2-2-3
In the range where the movements of the robot body can be seen satisfactorily, install
light-shielding boards, covers, etc. in the directions where operators may be exposed to
spatter while welding is in progress. Operators may be injured by the light emitted during
CAUTION welding, by spatter, etc.
Ensure that the display of the automatic and manual modes indicating the operating
status of the robot is large and conspicuous enough to enable the modes to be easily
recognizable from a distance. The use of a buzzer, alarm or other warning to signal the
start of auto operation is also effective. This will enable the fact that auto operation is
WARNING underway to be easily verified from a distance.
Minimize the number of protruding parts on the devices around the robot.
If necessary, place covers over them. Protruding parts are dangerous when they are
touched by the operator even under normal circumstances, and they constitute a hazard
as well if the robot should suddenly move, surprising and possibly knocking over the
CAUTION operator in the process.
Avoid the kind of layout where operators need to put their hands inside the fenced
area to load and unload the work pieces. The robot may move to the place where an
operator has placed his or her hands inside the fenced area.
DANGER
Safety Precautions for Installation Work
In installing the robot, it is important to position the robot where the operator will not be
cramped. While tools are still installed on the robot, the robot must not be operated in its
maximum operating range so that it touches its peripheral devices.
WARNING
The designated method for installing the robot must be followed without fail. Following a
method which is not designated may cause the robot to move or topple over during
operation which is extremely dangerous.
WARNING
Before proceeding to connect the wires between the robot and the robot controller or
peripheral devices, ensure that the connection methods are thoroughly understood.
Faults may be caused in the operation of the robot by taking the wrong steps.
WARNING
Ensure that the grounding work is done properly. If there are any welders or other
devices that generate significant levels of noise, proceed with the designated grounding
work for them.
WARNING
When moving the robot into position and installing it, be very careful not to damage the
wiring. Furthermore, after having positioned the units, take protective measures such as
providing protective covers to ensure that the wiring will not be damaged by the
WARNING operators and other individuals or by the forklift truck.
2-2-4
(1) The ambient temperature must be in the 0 to 45 degrees Celsius range.

(2) The ambient relative humidity must be in the 20 to 80%RH range, and there must be no condensation.
(3) The amounts of dust, dirt, oily vapors, water, etc. must be minimal.
(4) There must be no flammable or corrosive liquids or gases present.
(5) There must be no major sources of impact or vibration.
(6) No major sources of electrical noise must be in the vicinity of the robot.
2
(7) The vibration level must be less than 0.5G (4.9m/s ).
(8) Avoid direct sunlight.
2-2-5

A high-frequency arc starting unit, an inverter-type welding power supply and other units that generate
electromagnetic noises may cause an adverse effect on the robot system, such as malfunction.
To prevent this effect, select a proper installation location and install them in a most appropriate manner.
2-2-6
2.4 Accessories
2.4 Accessories
NH5 manipulator is provided with the following standard accessories.
Table. 2.4.0.1 Standard accessories (L10480U)

Hexagon Socket Head For fixing the main body
M12x40 4
Cap Screw (Strength grade: 10.9)
Spring Washer M12 4 For fixing the main body
Washer M12 4 For fixing the main body
Grease Nipple A-M6F 1 For refilling the Axis J4 grease
NH5 manipulator can be provided with the following parts as optional accessories.
Table. 2.4.0.2 Optional accessories

Allen Wrench Set L7096B 1 Tool
Point Mark Assembly L7096C 1 For origin confirmation
Arrow Indicator Plate NB10107A 1set 12 pcs / set
2-2-7
Use a crane or a pallet to transport the manipulator for unpacking or installing. The manipulator must be
transported at the factory-configured posture as shown in Fig. 2.5.0.1, secure the manipulator onto a pallet in
order to prevent it from overturning. Since the weight of a single manipulator for arc welding specification is 58
kg (handling specification:59kg) , use a pallet strong enough to withstand that load.
When transporting the manipulator with a crane, hook a rope on the M8 eyebolts (2 pcs.) of manipulator using
shackles and lift it up as shown in Fig. 2.5.0.2 by a transport posture with the angle specified in the Table 2.5.0.1.
Many precision parts are used in the manipulator. Therefore, be sure to avoid
transporting the manipulator with excessive external force imposed on its arm or its
motor sections as those sections may be damaged.
WARNING
Center of
Gravity
Please keep away over
200mm from the connector
when the motion warning
40
lamp (option) is mounted.

15

200mm

(261)
200
(11) (28)
Posture at transpotation

Note) Center of Gravity position is reference.

Fixing Rope

Protector

Cart

Fig. 2.5.0.1 Transport Method (by pallet)
Table. 2.5.0.1 NH5 Axis angle in the transport posture by installation type
Ceiling type 0 180 -75 0 -40 180
2-2-8
Wire Rope Shackles

Model :SC-8
Withstand Load : min.0.35t (770 lb) Withstand Load: 0.35t (770lb)
0.35t ISO 2415
Length : min. 1m (40 in.) SC-8
1m 0.35t
JIS B2801
Eyebolts (M8)


Note) Center of Gravity position is reference.
Fig. 2.5.0.2 Transport Method (by crane)
Ensure that the manipulator is moved into position by individuals who have acquired the
permits or licenses needed for carrying out slinging work, operating cranes, driving
forklift trucks, etc. The weights of the robot and controller are given in the Operation
Manual and Maintenance Manual. After checking the weights, adopt handling
WARNING procedures which are commensurate with these weights.
When hoisting the manipulator and/or the controller, follow the method set forth in this
manual or in the Maintenance Manual. Moving the robot into position using a method not
specified by the manufacturer may cause the robot to topple over or fall, which may lead
WARNING to accidents.
Take more than enough care to ensure that the wiring is not damaged during the moving
and installation processes. After having positioned the units, take protective measures
such as providing protective covers to ensure that the wiring will not be damaged by the
WARNING operators, other individuals or the forklift trucks.
2-2-9
2.6.1 Installation Method

Large reaction force will be applied to the revolving base from all directions when the manipulator works at an
adjustable speed. Considering this mentioned above, the base needs to tolerate not only the static load but also
the reaction force at adjustable speed. Install the manipulator with its revolving base stable.
When installing the manipulator on the floor, repair the roughness and crack on the floor first and perform the
installation with 4 pieces of the attached hexagon socket head cap screws (M12), spring washers and washers
with a tightening torque (88 N*m).
190
160
190
1180.1
RP
1180.1 245
RP
A
(20)
RP :Reference Plane
A
Fig. 2.6.1.1 Manipulator Installation Dimensionsunit : mm
2-2-10
2.6.2 Installing Manipulator and Jigs on Common Frame Base

Movements of the manipulator cause a large force of inertia, requiring the installation floor to be strong and rigid.
Therefore, when the manipulator and jigs are to be mounted together on the same common frame base, the frame
base must be at least 20 mm in thickness and the manipulator must be firmly fixed using four pieces of hexagon
socket head cap screws (M12), spring washers and washers with a tightening torque (88 N*m).
For the mounting method of the manipulator on the base, see Fig.2.6.2.1.
Hexagon Socket Head

Cap Screw(M12)
(M12)
Spring Washer Washer

Robot-side Base

Common Frame Base

Fig. 2.6.2.1 Installing the Manipulator Directly on Common Frame Base
2.6.3 Maximum Manipulator Generative Force

Movements of the manipulator may cause a large force as shown in Table 2.6.3.1.
Please design the common frame base that has an enough safety factor to the force shown below.
Table. 2.6.3.1 Maximum manipulator generative force
Maximum vertical Maximum horizontal Maximum vertical Maximum horizontal
Name
generative force FV generative force FH generative moment MV generative moment MH
NH5 2200N 1500N 1300Nm 1100Nm
Fig. 2.6.3.1 Maximum manipulator generative forceNote on Emergency stop of Manipulator
2-2-11
Table 2.7.0.1 shows the length of time from Emergency stop SW pressed to the robot stopped and the
angles of each axis to move. For designing a work cell etc., these values shall be considered.
Table 2.7.0.1 Emergency stop of Manipulator

Stop Time Stop Angle
Model Axis No.
ms deg
Axis J1 480 39.1
Axis J2 510 42.5
Axis J3 570 53.9
NH5
Axis J4 510 44.2
Axis J5 390 45.0
Axis J6 460 52.4
2-2-12
This chapter provides the instructions on the periodic inspection.

3.1 Periodic Inspection .................................................................................. 2-3-2
3.1.1 Safety Measures for Inspection, Maintenance,Adjustments and Repairs of the Manipulator... 2-3-2
3.1.2 Periodic Inspection Schedule ............................................................ 2-3-4
3.1.3 Notes on Periodic Inspection ............................................................. 2-3-4
3.1.4 Deadline for Supplying/ Repairing the Robot Maintenance Parts ...... 2-3-4
3.2 List of Maintenance Items........................................................................ 2-3-5
2-3-1
3.1.1 Safety Measures for Inspection, Maintenance, Adjustments and Repairs of the Manipulator
To perform inspection, maintenance, adjustments, repairs or other similar work on the manipulator, access to the
necessary. In any case, be sure to observe the following precautions for inspection, maintenance, adjustments
and repairs.

WARNING
Never touch any charged parts. Touching any charged part may result in a fatal electric
shock hazard or burn.
WARNING
Putting your hand, finger, hair or clothes close to the wire feed roll of the wire feed
unit may cause you to get caught, resulting in a serious injury.
Similarly, putting your hand, finger, hair or clothes close to the rotating section of a
WARNING cooling fan may cause you to get caught and hurt.
(1) Prior to carrying out robot inspection, maintenance, adjustments, repairs, etc., be sure to wear a helmet,
(2) Prior to initiating work, press the EMERGENCY Stop button or the Stop button to check if the robot system
stops instantly. Furthermore, if a safety plug, a dead man switch or other protective devices are added to the
robot system, they must be checked for proper operation. Should any fault be detected, stop the inspection
work, turn off the primary power immediately, check for causes and take necessary countermeasures
accordingly.
(4) Prior to starting work, put up a sign Under Inspection

at a visible place to let people around the robot system
know that inspection is now being carried out. Under Inspection
(5) Do not use any equipment that may generate electromagnetic noises, in and around the place where
inspection is being performed.
(6) At least two workers should be involved in the inspection or maintenance work, one performing actual work
and the other serving as a watcher.
(7) Personnel to be involved in robot inspection, maintenance, adjustment and/or repairs should receive
instructions and training on robot functions, operation and maintenance. In addition, if special equipment or
facilities are provided in the robot system, then their entire mechanism must also be fully understood.
(8) Robot inspection, maintenance, adjustment and repairs must be performed by only those who are qualified by
receiving special training. Furthermore, even if they have received such special training, they are not allowed
to perform inspection, maintenance, adjustment or repairs of other machinery that they are not fully familiar
with.
2-3-2
(10) The watcher must observe the following. He shall:
(A) Stand at a place that commands a view of the entire robot working range, and devote himself to the duty
of watching the work.
(B) Always hold the EMERGENCY Stop button, and press it immediately whenever any abnormality occurs.
(C) Make sure that people other than those who are involved in inspection, etc. do not come close to the
robot working range.
(11) The workers to be involved in inspection or other work must observe the following.
(A) If work can be carried out outside the robot working range, specify the work details prior to starting the
work. In any case, be sure that work is done outside the robot working range.
(B) In principle, perform inspection, etc., with the robot stopped. However, if such inspection or other work is
inevitably required during robot operation, then be sure to report this to the responsible safety manager,
and with permission obtained, perform the work outside the robot working range.
(C) If the robot is required to be in an operable condition when performing inspection work or the like, specify
the work procedure details beforehand so that safe work can be efficiently proceeded with. Furthermore,
if work is not particularly required to be performed in the robot operable condition, carry out the work with
the robot controller, the welding power supply and/or other input-side power supplies all turned off. If no
special safety procedure is required, be sure to turn off such input-side power supplies for jigs and
peripheral equipment or to make them inactive.
(D) When working in the robot working range, be sure you are always in a ready-to-act posture so that you
can immediately press the EMERGENCY Stop button just in case of robot malfunction.
(E) Carefully check your footing before starting work. Be sure to avoid an unstable scaffold or a scaffold
(G) To replace PCBs provided in the robot controller or the teach pendant, take anti-static electricity
countermeasures including anti static electricity sheets.
(12) If any abnormal condition has occurred during work, carefully perform the following procedure.
(A) If any malfunction is observed on the robot system, immediately press the EMERGENCY Stop button.
(B) Immediately report this to the watcher, turn off the control power
of the robot controller, then put up a sign Do not switch on.
Do not Switch ON
(C) Be sure to check that all the related machines are stopped.
(D) When necessity arises to go inside the guarding fence, be sure that the person who is going to enter pulls
out the safety plug himself, carries it with him and proceeds with the work concerned.
(E) Even when the robot has automatically stopped due to a fault in supply voltage to the robot system,
hydraulic pressure or air pressure of related equipment, make sure that it is at a complete stop, then
investigate causes to take necessary countermeasures.
(F) If the EMERGENCY Stop switch or other safety devices should have failed to operate, immediately turn
off the primary power, investigate causes and take necessary countermeasures.
(G) To restart the robot after stopping it by pressing the EMERGENCY Stop button, investigate causes, take
necessary countermeasures, replace the safety plug, and then restart it from outside the guarding fence.
(13) To end the work, carefully check that the necessary connectors, covers, panels, etc. have been all correctly
mounted and wired.
2-3-3
3.1.2 Periodic Inspection Schedule

The periodic inspection is indispensable in order to continue operating Almega series in a safe and an efficient
manner. Perform the periodic inspection in accordance with the following schedule.
Be sure to overhaul in either a period of whole 6 years or 30,000 cumulative operating hours after delivery,
The inspection and maintenance period is estimated, supposing the manipulator only for Arc welding use. For
more frequent use such as handling operation, that period may be shorter.
Contact to our engineers for details.
3yrs
Maintenance
1yr 1yr 1yr
Inspection Inspection Inspection
3mths 3mths 3mths 3mths 3mths 3mths 3mths 3mths 3mths 3mths 3mths 3mths
Inspection Inspection Inspection Inspection Inspection Inspection Inspection Inspection Inspection Inspection Inspection Inspection
Daily Inspection
0 3mths 6mths 9mths 1yr 15mths 18mths 21mths 2yrs 27mths 30mths 33mths 3yrs
3.1.3 Notes on Periodic Inspection
(1) Periodic inspection must be performed by those who have received the special training program by the
Government or DAIHEN Corporation and maintenance instructions offered by DAIHEN Corporation, or at
their presence.
(2) Prior to performing inspection or maintenance, be sure to turn off the external breaker.
Note that, with turning off only the non-fuse breaker of the robot controller, the primary side of the non-fuse
breaker is still being applied with voltage.
In order to show that inspection or maintenance is underway, hang a noticeable sign on the switch of
the external breaker.
WARNING
ELECTRIC SHOCK
can kill.

Never touch the charged parts.

parts.
WARNING



enclosure.
NK3637
3.1.4 Deadline for Supplying/ Repairing the Robot Maintenance Parts
Deadline for supplying the robot maintenance parts is guaranteed for 7 years from the discontinuation date of the
product, and that for repairing is for 10 years.
For the detailed information about discontinuation date of the product, please see the guidance on the
maintenance parts in our homepage: http://www.daihen.co.jp/ .
Repair of the maintenance parts is provided for the above period of time in principle, however, we will support
our customers as long as the stock is available.
We will make our every effort to secure the required maintenance parts. However, please note that it may be
occasionally unavailable due to the external factors such as the market situation even during the guaranteed
period.
2-3-4

Mainten
Inspection
-ance
3 1 3 6
Daily
mths yr yrs yrs
3 Visual check
Check with torch
Cracks, chipping and
4 Torch mount positioning gauge
bending
Replacing the parts
Deviation
checking program.
Confirm that there is no
5 Torch aiming point noticeable play by checking
Backlash and play around 6th axis output flange by
hand (back/forth, right/left,
up/down).
Looseness at cable Retightening
connection
6 Welding torch
Attached spatter on torch Cleaning
mounted section
Worm feed roll replacing if needed.
7 Wire feed unit
Attached oil or dust on Cleaning
cable replacing if needed.
Worn or bent coil liner
Gas hose
8 Welding power Damaged hose, gas Check with soapy water
cable leakage applied and replacing
Conduit cable Looseness at cable
Retightening
connection
9 Base bolts Looseness Retightening
Connector housing
Base portion
No noise and vibration by
Brake
11 Brake operating servo ON. No falling of the
arm with the servo OFF.
Damaged cable
Check visually and
Loose connectors
12 Internal wires retighten if necessary.
Bolt for mounting
Reduction gear
13 Abnormality in the Chapter 4.2).Replacing the
(Axis J1, J2, J3)
reduction gear reduction gear if it is abnormal
Reduction gear
(Axis J4, J5, J6)
reduction gear reduction gear is abnormal
(Axis J3, J4, J5, J6) Abnormality in the belt
tension belt is abnormal
Grease replenishment (See
Cross roller bearing Grease replenishment
Chapter 4.3). Replacing the
16 (In reduction gear Abnormality in the
reduction gear if the cross
of Axis J4) Cross roller bearing
roller bearing is abnormal
Replacement
See Chapter 4.4
18 Overhaul
Inspection Replacement
2-3-5
2 16
11 1
13 8
15
4
15 14
6 2 7
11 9
13
5
14
15
11
17 10
14 15 11 12
13
Fig. 3.2.0.1 Check Points
WARNING
ELECTRIC SHOCK
can kill.


parts.
WARNING



enclosure.
NK3637
Fig. 3.2.0.2 Names of the robot components
2-3-6

4.1 Tension Adjustments of Timing Belts ..................................................... 2-4-4
4.1.1 Tension Adjustment of Timing Belt for Axis J3 ..........................................2-4-4
4.1.2 Tension Adjustment of Timing Belt for Axis J4 ..........................................2-4-5
4.1.3 Tension Adjustments of Timing Belts for Axis J5 and J6 ...........................2-4-6
4.2 Replacement and Replenishment of Grease for Reduction Gears .................... 2-4-7
4.2.1 Grease Replacement Procedure for Axis J1, J2 and J3 Reduction Gears2-4-7
4.2.2 Grease Replenishment Procedure for Axis J4, J5 and J6 Reduction Gears2-4-11
4.3 Grease Replenishment for Cross Roller Bearing ................................. 2-4-12
4.3.1 Grease replenishment procedure for Axis J4 cross roller bearing ..........2-4-12
4.4 Battery ................................................................................................. 2-4-13
4.4.1 Function of Battery .................................................................................2-4-13
4.4.2 Specification of Battery ..........................................................................2-4-13
4.4.3 Replacing Battery...................................................................................2-4-13
4.4.4 Notes on Battery Safekeeping ...............................................................2-4-14
4.5 Replacing Internal Wires...................................................................... 2-4-15
2-4-1
To perform inspection, maintenance, adjustment, repairs or other similar works on the robot system, access to
the robot working range may be required, or work with the primary-side power or the servo power turned on
may be necessary. In any case, be sure to observe the following precautions for inspection, maintenance,
adjustments and repairs.

WARNING
Never touch any live electrical parts. Touching any live electrical parts may result in a
fatal electric shock hazard or a burn.
WARNING
Bringing hands, fingers, hair or clothes close to the wire feed roll of the wire feed unit
may cause an injury by being caught by it.
Bringing hands, fingers, hair or clothes close to the rotating section of a cooling fan may
WARNING cause an injury by being caught by it.
(1) Before carrying out robot inspection, maintenance, adjustments, repairs, etc., be sure to wear a helmet,
(2) Before initiating work, press the EMERGENCY Stop button or the Stop button to check if the robot system
stops instantly. Furthermore, if a safety plug, a Deadman switch and/or other protective devices are added
to the robot system, they must be checked for their proper operation. Should any fault be detected, stop the
inspection work, turn off the primary power immediately, check for causes and take necessary measures
accordingly.
(4) Before starting work, put up a sign Under Inspection Under Inspection
at a visible place to notify people around the robot system
that the inspection is now underway.
(5) Do not use any devices that may generate electromagnetic noises in and around the place where the
inspection is being conducted.
(6) At least two workers should be involved in the inspection or maintenance work, one performing the actual
work and the other serving as a watchman.
(7) Personnel who are going to conduct the robot inspection, maintenance, adjustment and/or repairs should
receive instructions and training on robot functions, operation and maintenance. In addition, if special
devices or facilities are provided in the robot system, their entire mechanism must also be fully understood.
(8) Robot inspection, maintenance, adjustment and repairs must be performed only by qualified personnel who
have received special training. Furthermore, even if they have received such special training, they are not
allowed to perform inspection, maintenance, adjustment or repairs of machinery other than those they are
fully familiar with.
(9) Any sign that may be given to workers, watchmen and/or operators of related machines must be in
conformity with the Customers safety management standards.
2-4-2
(10) The watchman has to observe the following.
(A) Stand at a place that commands a view of the entire robot work envelope and concentrate on the duty of
watching the work.
(B) Always hold the EMERGENCY STOP button and press it immediately whenever any abnormality occurs.
(C) Keep personnel except the teaching operator away from the robot work envelope.
(11) The workers to be involved in the inspection or other works must observe the following.
(A) If work can be carried out outside the robot working range, specify the work details before starting the work
and make sure to carry out the work outside the robot working range.
(B) In principle, perform inspection, etc., with the robot stopped. However, if the inspection or other work is
inevitably required while the robot is operating, be sure to report this to the responsible safety manager, and,
with permission obtained, perform the work outside the robot working range.
(C) If the robot is required to be in an operable condition when the inspection work or the like is carried out,
specify the work procedure in detail beforehand so that work can be carried out safely and efficiently.
Furthermore, if work is not particularly required to be performed in the robot operable condition, carry out the
work while the robot controller, the welding power supply and/or other input-side power supplies are all
turned off.
If no special safety procedure is required, be sure to turn off such input-side power supplies for jigs and
peripheral equipment or make them inactive.
(D) When working in the robot working range, be sure that you are always in a ready-to-act posture to be
promptly able to press the EMERGENCY Stop button in case of robot malfunction.
(E) Check your footing carefully before initiating work. Be sure to avoid an unstable scaffold or a scaffold
(G) When replacing PCBs provided in the robot controller or the teach pendant, take countermeasures against
static electricity, for instance by using anti-static electricity sheets.
(12) If any abnormal condition occurs during the work, follow the procedure below carefully.
(A) If any malfunction is observed in the robot system, press the EMERGENCY Stop button immediately.
(B) Report this immediately to the watchman, turn off the control
power of the robot controller, and then put up a sign
Do Not Switch On. Do Not Switch ON
(C) Make sure that all the related machines are stopped.
(D) When necessity arises to go inside the guarding fence, be sure that the person who is going to enter pulls out
the safety plug himself, carries it with him while proceeding with the work concerned.
(E) Even when the robot has automatically stopped due to a fault in supply voltage to the robot system, hydraulic
pressure or air pressure of related equipment, make sure that the robot is at a complete stop. Then,
investigate causes and take necessary countermeasures.
(F) If the EMERGENCY Stop switch or other safety devices should have failed to operate, turn off the primary
power immediately, investigate causes and take necessary countermeasures.
(G) In order to restart the robot after stopping it by pressing the EMERGENCY Stop button, investigate causes,
take necessary countermeasures, replace the safety plug, and then restart it from outside the guarding fence.
(13) To end the work, check carefully that the necessary connectors, covers, panels, etc. have been all correctly
mounted and wired.
2-4-3

To make the timing belts tension adjustments, every years or every 3,000 operating hours, whichever is shorter
period.
To drive Axis from J3 to J6, timing belts are used between the motor unit and the reduction gear. Attaining
smooth transmission by the timing belts requires appropriate belt tension. For the adjusting method of timing belt
tension of each axis, read the following instructions.
4.1.1 Tension Adjustment of Timing Belt for Axis J3

(1) By removing the cover on the left side of lower arm and shoulder looking the robot from a front view, you will
find a timing belt as shown in Fig. 4.1.1.1.
(2) To make its tension adjustment, loosen four pieces of motor fixing bolts (M5x15) and the lock nut of motor
unit and adjust the tension of Axis J3 by tightening or loosening the tension adjusting bolt (M4) until the
deflection thus obtained will be the specified value.
To adjust the tension, move the timing belt to and fro with seen and loosen/tighten the adjusting bolt so that
the measurement value by the tension meter becomes as given in Table 4.1.1.1.For how to set up the tension
meter, refer to the instruction manual of the product in use.
(3) When the specified value is obtained, lock the adjusting bolt with the lock nut, retighten the motor fixing bolts
with a tightening torque of 7.3 N*m, and then apply LOCKTITE to these bolts in order to prevent them from
loosening.
(4) Install the cover removed in (1).
When it is Handling specification, apply an appropriate amount of sealing agent (Liquid gaskets #1184D) to
the entire circumference of the cover-mounting surface.
Table 4.1.1.1 Belt Tension Values for Tension Adjustment of Timing Belt
Axis Name Belt Span Unit Mass of Belt Belt Tension Belt Width
J3 205 mm 0.034 kg/m 85.3 ~ 93.0 N 10mm
Shoulder

Timing Belt

Adjusting Bolt

Lock Nut

Lower-arm
Motor Fixing Bolt(4pcs)

(4
Fig 4.1.1.1 Tension Adjustment of Timing Belt for Axis J3

WARNING
2-4-4
4.1.2 Tension Adjustment of Timing Belt for Axis J4

(1) Removing the front cover on the lower shoulder, the timing belt will come out as shown in Fig. 4.1.2.1.
(2) To make its tension adjustment, loosen four pieces of motor fixing bolts (M4x16) and the lock nut of each
motor unit and adjust the tension of Axis J4 by tightening or loosening the tension adjusting bolt (M4) until the
deflection thus obtained will be the specified value.
the measurement value by the tension meter becomes as given in Table 4.1.2.1. For how to set up the
tension meter, refer to the instruction manual of the product in use.
(3) When the specified value is obtained, lock the adjusting bolt with the lock nut, retighten the motor fixing bolts
with a tightening torque of 3.5 N*m, and then apply LOCKTITE to these bolts in order to prevent them from
loosening.
(4) Install the cover removed in (1).
When it is Handling specification, apply an appropriate amount of sealing agent (Liquid gaskets #1184D) to
the entire circumference of the cover-mounting surface.
Table 4.1.2.1 Belt Tension Values for Tension Adjustment of Timing Belt
J4 157.5 mm 0.034 kg/m 47.6 ~ 52.0 N 6mm
Shoulder

Timing Belt

Adjusting Bolt

Lock Nut

Motor Fixing Bolt(3pcs)

(3
Lower-arm

Fig 4.1.2.1 Tension Adjustment of Timing Belt for Axis J4

WARNING
2-4-5
4.1.3 Tension Adjustments of Timing Belts for Axis J5 and J6

(1) Removing covers from side of Axis J5 and J6 Unit will reveal the timing belts of the respective axes as
shown in Fig 4.1.3.1.
(2) To make their tension adjustments, loosen three pieces of motor fixing bolts (M4x12) and the lock nut of
each motor unit and adjust the tension of Axis J5 or Axis J6 by tightening or loosening the tension adjusting
bolt (M4) until the deflection thus obtained will be the specified value.
the measurement value by the tension meter becomes as given in Table 4.1.3.1.For how to set up the
tension meter, refer to the instruction manual of the product in use.
(Another way of adjustments: Press the timing belt of Axis J5 or Axis J6 at the center with a force shown in
Table 4.1.3.2 and adjust the tension by tightening or loosening the adjusting bolt until the deflection
obtained becomes the specified value shown below.)
(3) When the specified value is obtained, lock the adjusting bolt with the lock nut, retighten the motor fixing
bolts with a tightening torque of 3.5 N*m, and then apply LOCKTITE to these bolts in order to prevent them
from loosening.
Table 4.1.3.1 Belt Tension Values for Tension Adjustments of Timing Belts
J5, J6 105 mm 0.034 kg/m 50.4 ~ 55.0 N 7mm
Axis Name Pressing Force Deflection
J5, J6 4.0N 1.7mm
Motor Fixing Bolt

(3pcs) Lock Nut Timing Belt Adjusting Bolt
Timing Belt
mm

L=1.7

(3 4.0N
4.0N
N.P.
m
L=1.7m
N.P.
52.5
52.5 Motor Fixing Bolt(3pcs)
Adjusting Bolt
52.5 Lock Nut (3
52.5

Fig. 4.1.3.3 Tension Adjustments of Timing Belts for Axis J5 and J6
(4) When all the above adjustments have been successfully completed, apply an appropriate amount of sealing
agent (Liquid gaskets #1184D) to the entire circumference of the cover-mounting surface.
Be sure not to let the sealing agent enter the hole

Liquid Gaskets Application Surface(Shaded Area)

Fig. 4.1.3.4 Application Surface of Sealing Agent (Liquid gaskets)

WARNING
2-4-6

Carry out periodical replacement and replenishment of grease for the reduction gear, referring to Table 4.2.0.1.
Table 4.2.0.1 Period of Replacement and Replenishment Grease
Axis Name Period for Replacement and Replenishment of Grease

Every three years or every 3,000 operating hours,
J1, J2, J3 Replacement
Every one year or every 3,000 operating hours,
J4, J5, J6 Replenishment
If you request us for replacement or replenishment work, you will be charged for the work.
4.2.1 Grease Replacement Procedure for Axis J1, J2 and J3 Reduction Gears
For the location of inlet and outlet, see Fig 4.2.1.4.
Use the grease gun with the filling amount check counter function.
If it is not possible to prepare the tool to check the grease filling amount, users are able to measure the difference in
the grease amount before and after the greasing work to see the amount actually injected. Injecting of grease more
than necessary may cause a grease leakage or abnormal robot operation.
When the internal pressure is at the high level such as soon after the manipulator has stopped, it is very dangerous
because the grease may spatter at the moment of removing the plug of grease inlet port and outlet port. Therefore,
take enough care in performing soon after the manipulator has stopped.
(1) Set the posture of manipulator suitable for the work.

Table 4.2.1.1 Posture at the grease replacement
Any 90 0
TP display angle of Axis J2 and J3 is the one of the Axis J4 displayed when the axis
monitor is started with the teach pendant.
(2) Remove a plug from each outlet (Axis J1 and J2) and a grease nipple (Axis J3).
(3) Replace the grease nipple on Axis J3 (or A-PT 1/8 type) with a plug on each axis inlet.
(4) Make sure that neither grease inlet port nor outlet port has a choke. Inject the grease for some 50mm from the
tip of the outlet hose [85, Max. length 100mm].Attach the air equipment fitting [Rc1/8,8] and the outlet
hose to the outlet port.
As the outlet port for the J1 axis is located inside the frame, attach the hose to the outlet port and lay it outside
the frame.
Fig.4.2.1.1 Air equipment fitting and outlet hose for choke checking
2-4-7
(5) Prepare the grease catch container under the outlet part. Use the grease gun to inject the grease of 1.4ml
from the grease inlet port at the rate of 1.6ml/sec. or lower. And make sure that the grease comes out from the
tip of outlet hose. If not, eliminate a choke from the hole of inlet and outlet port.
Fig.4.2.1.2 Grease catch container
(6) Use the grease gun to inject the given amount of grease at the rate of 1.6ml/sec. or lower. At this time, make
sure that the color of grease come out is gradually going to change. In addition, be sure to observe the
injecting rate. If not, it may cause a abnormal robot operation.
Grease to use is VIGOGREASE RE0, and the filling amount is as follows.
Table.4.2.1.1 Amount of Grease

NH5 158ml 128ml 60ml
The density of VIGOGREASE RE0 is 0.9g/ml.
(7) Check the amount of grease injected and discharged when the actual injecting amount reaches the given
filling amount. As for the actual injecting amount, check the grease gun counter or the difference in the amount
before and after the greasing work. For the discharged amount on the other hand, check the grease catch
container to see the difference in the amount before and after the greasing work. When the amount of injected
and discharged becomes equal, it is considered that the grease replacement has been completed. Then, go to
the procedure (12).
(8) If the discharged amount is less than the injected amount, the difference indicates the surplus. In that case,
discharge the surplus by applying push-out air into the outlet port so that the injected and discharged amount
becomes equal.
(9) Remove the grease nipple from the inlet port, and attach the air equipment fitting [Rc1/8,8] and the outlet
hose [85, Max. length 100mm] to the inlet port.
(10) Prepare the grease catch container as shown in Fig.4.2.1.2.
(11) Make the pressure of push-out air lower than the maximum of 0.025MPa using the regulator.
If the grease does not come out but only air even if applying push-out air, operate the target axis at the low
speed with the posture shown in Table.4.2.1.3 and within the working range shown in Fig.4.2.1.3, applying
push-out air at the same time, to discharge the surplus. When the amount of injected and discharged
becomes equal, it is considered that the grease replacement has been completed. Then, go to the procedure
(12).
2-4-8
Table.4.2.1.3 Recommended posture
Recommended Recommended Recommended

posture with posture with posture with
Axis
J1 axis at J2 axis at J3 axis at
motion motion motion
Axis J1 Any Any Any
Axis J2 Any 90 90
Axis J3 Any Any 0
(a) Low speed working range of J1 axis
(b) Low speed working range of J2 axis
(c) Low speed working range of J3 axis
Fig.4.2.1.3 Low speed working range in applying push-out air
2-4-9
(12) Wipe off grease adhered to the body, and attach the plug. To attach it, wrap the seal tape around the screw
part.
Refer to Table 4.2.1.4, and attach the plug correctly according to the setup posture.
On completion of replacement, be sure to attach the plug to the grease inlet port of every axis and fit the
removed grease nipple to the outlet port of J3 axis.
Table 4.2.1.4 Installation posture and plug type
Installation type
Axis name Plug location Floor-installed / Wall-hung Ceiling-hung

Side of Frame Orifice plugOutlet Plug (Inlet)
J1
Downside of Base PlugInlet Orifice plugOutlet
Upside of Flange Grease nippleOutlet Plug
J2 Downside of Flange Plug Grease nippleOutlet
Downside of Lower-arm PlugInlet PlugInlet
Reduction Gear PlugOutlet PlugInlet
J3
Upside of Lower-arm PlugInlet PlugOutlet
Note) 1. The grease inlet and outlet of Axis J1, J2 and J3 all differ depending on the installation posture of
manipulator as well as the plug type. Mounting a wrong plug may cause grease leakage, therefore,
comply with the prescription shown in Table 4.2.1.4.
2. Also when modifying the installation posture of manipulator after delivery, be sure to see Table 4.2.1.4
and check the plug type.
3. The initial installation posture of manipulator at shipment is the floor-installation type.
4. When operating after grease replenishment, a small amount of grease may leak from the outlet. This
is just remains from the outlet, not an abnormal thing.
*
5. The Rc1/8 grease nipple, orifice plug and plug are tightened by torques of 8 N m.
6. When it is handling specification, after grease replenishment of Axis J3, apply an appropriate amount
of sealing agent (Liquid gaskets #1184D) to the entire circumference of the cover-mounting surface.
Fig 4.2.1.4 Location of grease inlet and outlet in Axis J1, J2 and J3 reduction gears
WARNING be damaged.
2-4-10

NH5 Axis J4 Axis J5 Axis J6
Amount 5ml 3ml 3ml
(3) After replenishment, remount all the plugs.
Fig. 4.2.2.1 Location of plug in Axis J4, J5 and J6 reduction gears
WARNING be damaged.
2-4-11
4.3 Grease Replenishment for Cross Roller Bearing
4.3 Grease Replenishment for Cross Roller Bearing

Replenish the cross roller bearing with grease according to the cycle shown in Table 4.3.0.1.
Table 4.3.0.1 Grease replenishment cycle
Axis name Cycle of replenishment

J4 Every one year or every 3,000 operating hours, whichever is shorter.
4.3.1 Grease replenishment procedure for Axis J4 cross roller bearing

Type
Axis J4 grease
-90
0
NH5 1ml each
90
180
(1) Remove a plug to take out a rubber stopper inside.

(2) Then, replace it with a grease nipple (A-M6F).
(3) Apply grease using a grease gun. Grease to be used is Harmonic 4B No.2.
table.
(4) After filling grease, take out a grease nipple and put a rubber stopper once removed in (1) back on a filler port of
the cross roller bearing. Then, attach a plug.
Grease filler port

Lable

damaged.
2-4-12
4.4 Battery
4.4 Battery
4.4.1 Function of Battery
A battery is provided to back up data of each absolute encoder used in the manipulators. This battery supplies
power to the absolute encoder for data backup purpose when the control power is OFF.
If the battery voltage excessively drops, it may fail to properly store the data. Timing of replacement depends on
the use condition; however, replace all of them at once periodically once in 3 years.
The life of the battery is about three years. If more than three years have passed, the
battery has to be replaced.
This is not a rechargeable battery. If you try to charge this battery, it may be
WARNING damaged. Be sure not to try charge this battery.
The data backup period of the absolute encoder might become shorter depending
on the environmental conditions, operating conditions, and other factors.
4.4.2 Specification of Battery

Nominal voltage: 3.6V
* The above specification is applicable when absolute encoders and other loads are connected.
4.4.3 Replacing Battery

The replacing procedure described below.see Fig.4.4.3.1
(1) Perform check go/back operation in accordance with the basic posture check program <such as P9999>
and make sure that the origin position is in alignment with the matchmark <> . If that is not the case, mark
that position.
(2) Remove the base surface cover from the manipulator.
(3) While the control power is ON, cut off the tie band that fixes the batteries and take off the battery box.
(4) Replace the used batteries in the battery case with the new one. Replace with only DAIHEN Part
No.5096-434.Be sure to replace all of them at this time. At this time, be careful at the orientation in which
batteries are inserted. If placing a battery in a wrong position, the battery may be damaged.
Disconnecting the battery with the control power OFF results in the loss of absolute
encoder data. Be sure to turn on the control power when replacing the battery.
When the power is ON, never touch any parts of the robot controller other than the
battery since doing so may result in an electric shock hazard.

and scrapping it.
WARNING This battery is lithium battery. Be sure to scrap it in accordance with law or the like.
Do not dispose of batteries in fire. If the batteries are put in fire, they may explode by
rapid heating.
The replacement of the batteries should be done in principle by a trained technician.
At disposal of the batteries, insulate the terminal parts with or the like.
2-4-13
4.4 Battery
(5) Connect three new battery connectors.
(6) Fix the battery box with a tie band. At this time, be careful at the orientation of the battery box. If the orientation
is wrong, the batteries may be damaged (see
(7) Fig. 4.4.3.1).
The tie band is to be prepared by a customer.
(8) Install the base surface cover.

When it is Handling specification, after replacing, apply an appropriate amount of sealing agent (Liquid
gaskets #1184D) to the entire circumference of the cover-mounting surface.
(9) Perform check go/back operation in accordance with the basic posture check program < such as P9999>,
and make sure that the origin position will not change from that obtained in (1) above.
(10) Perform encoder reset operation at the basic posture check program < such as P9999>. Refer to the
instruction manual SETUP. Also, see the aforementioned section to reset the encoder if the encoder data
have been lost.
Battery

Tie Band

CN.2
Battery Box

CN.1
Fig. 4.4.3.1 Battery
4.4.4 Notes on Battery Safekeeping
Store the battery in non-condensing, well ventilated locations, avoiding high temperatures and high humidity.
You are recommended to store them at room temperature(20+/-15) with minimal temperature variation and
relative humidity of 70% or below.
Note that the batteries are to be stored only for 6 months, and enforce First-in, first-out rigidly.

and scrapping it.
WARNING
This battery is lithium battery. Be sure to scrap it in accordance with law or the like.
2-4-14

Replace the internal wires of manipulator every 6 years or every 30,000 operating hours, though the use
condition may differ in each case.
Before replacing, contact to DAIHEN.

2-4-15
This chapter provides the instructions on the Parts List.

5.1 Parts List ..................................................................................................2-5-2
5.1.1 NH5 ....................................................................................................2-5-2
5.2 Location and List of Warning Label ..........................................................2-5-6
2-5-1
5.1 Parts List
5.1 Parts List
5.1.1 NH5
Arc welding specification
RV Reduction Gear W-L02357 1 W-L02357
Axis J1
Grease 158
VIGOGREASE RE0 100-0624*
ml
Axis J2
128
Grease VIGOGREASE RE0 100-0624*
ml
60m
Grease VIGOGREASE RE0 100-0624*
l
Harmonic Reduction Gear L10725N00 1 L10725N00
Axis J4

Grease Harmonic 4B No.2 100-1025
ml
Axis J5

Liquid gaskets #1184D
10m
100-0942*
l
Axis J6

Liquid gaskets #1184D
10m
100-0942*
l
Cable Assembly (1)
L10480G00 1 L10480G00
frame rear to frame
Cable Assembly (2)
Internal L10480H00 1 L10480H00
frame to lower arm
Wires
Cable Assembly (3)
L10480J00 1 L10480J00
lower arm to upper arm
Cable Assembly (4)
L10480K00 1 L10480K00
(shoulder to upper arm)
Axis 5 & 6 Unit
(Axis 5 & 6 Unit assembly)
IMPORTANT
4. The minimum quantity for a single order of liquid gaskets is 100g (about 80 ml ) .
2-5-2
5.1 Parts List
4 3
5
1
11
12 10 6
3 2 1
13
9
10
7
15
14
10 12 6
1 2 3
Fig. 5.1.1.1 NH5 Arc specification

2-5-3
5.1 Parts List
Handling specification
Axis J1
Liquid gaskets #1184D 10ml 100-0942*
Axis J2
Harmonic Reduction Gear W-L10725N 1 L10725N00
Axis J4
Grease Harmonic 4B No.2 ml 100-1025
Cable Assembly (1)
L10860G00 1 L10860G00
frame rear to frame
Cable Assembly (2)
Internal L10860H00 1 L10860H00
frame to lower arm
Wires
Cable Assembly (3)
L10860J00 1 L10860J00
lower arm to upper arm
Cable Assembly (4)
L10860K00 1 L10860K00
(shoulder to upper arm)
Axis 5 & 6 Unit
(Axis 5 & 6 Unit assembly)
IMPORTANT
4. The minimum quantity for a single order of liquid gaskets is 100g (about 80 ml ) .
2-5-4
5.1 Parts List
4 3 13
5
13
1
11 13
12 10 6
13
3 2 1
13 13
10
7
8 13
6
13
13
15
14
10 12 6
1 2 3
Fig. 5.1.1.2 NH5 Handling specification

2-5-5

Every manipulator and robot controller of Almega series is provided with warning labels (that states the special
cautions to be observed) to ensure the safe operation of the robot system.
If such warning labels have been peeled off or damaged, order them from our local distributor or our sales
office.
Table 2.0.1 Warning Label
Location Item Name Parts No. Qty

Manipulator Warning Label NK7248 4
NH5 Caution Label NK7024 1
NK7248
NK7024
Fig. 5.2.0.1 Warning Label Location
2-5-6
This chapter provides the instructions on the Internal Wires.

6.1 Wiring Connection Figure ........................................................................2-6-2
6.1.1 Wiring Connection Figure(Arc welding Specification).........................2-6-2
6.1.2 Wiring Connection Figure(Handling Specification) .............................2-6-4
2-6-1
6.1.1 Wiring Connection Figure(Arc welding Specification)
Fig. 6.1.1.1 Wiring Connection Figure (Arc welding Specification)
2-6-2
Fig.6.1.1.2 Wiring Connection Figure (Arc welding Specification)

2-6-3
6.1.2 Wiring Connection Figure (Handling Specification)
Fig.6.1.2.1 Wiring Connection Figure (Handling Specification)
2-6-4
Fig.6.1.2.2 Wiring Connection Figure (Handling Specification)
2-6-5
Fig. 6.1.2.3 CN5 Wiring Connection Figure (Handling Specification)
Fig. 6.1.2.4 CN5 Wiring Connection Figure (Handling Specification with option)

2-6-6
Almega FD series INSTRUCTION MANUAL (MANIPULATOR)
No. 1L11130A-E-10 Sep 2014 10th Edition

Robot Manipulator

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Robot Manipulator

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Give this manual to the operator.

For help, call your distributor.

Cases in which death or serious injury can be expected if handled incorrectly.

Cases in which injury or physical damage can be expected if handled incorrectly.

The following symbols are also used for important checkpoints:

A particularly important checkpoint is shown.

Injury which does not require either hospitalization or long-term treatment as an

Direct and indirect damage in connection with damage of property and

Chapter 1 Specifications of B-type / V-type Manipulator

1.1 Manipulator model .................................................................................................................. 1-1-2

1.2 Basic Specifications ................................................................................................................ 1-1-4

1.4 Description on Each Part of Manipulator .............................................................................. 1-1-17

Chapter 2 Foundation Work and Installation

2.1 Safety Measures Relating to Installation ................................................................................. 1-2-2

2.2 Installation Locations and Ambient Conditions ....................................................................... 1-2-5

2.3 Notes on Interference by Electromagnetic Noise.................................................................... 1-2-6

2.4 Accessories ............................................................................................................................. 1-2-7

2.5 Transport Method .................................................................................................................... 1-2-8

2.6 Installation of Manipulator ..................................................................................................... 1-2-16

Chapter 3 Periodic Inspection

3.1 Periodic Inspection .................................................................................................................. 1-3-2

4.1 Tension Adjustments of Timing Belts ...................................................................................... 1-4-4

4.4 Grease Replenishment for Roller Bearing ............................................................................ 1-4-24

Chapter 5 Parts List

5.1 Parts List ................................................................................................................................. 1-5-2

5.2 Location and List of Warning Label....................................................................................... 1-5-16

Chapter 6 Internal Wires

6.1 Wiring Connection Figure ....................................................................................................... 1-6-2

Chapter 1 Specifications of H-type Manipulator

1.1 Manipulator model .................................................................................................................. 2-1-2

1.2 Basic Specifications ................................................................................................................ 2-1-3

1.3 Outside Dimensions and Working Range ............................................................................... 2-1-4

1.4 Description on Each Part of Manipulator ................................................................................ 2-1-5

Chapter 2 Foundation Work and Installation

2.1 Safety Measures Relating to Installation ................................................................................. 2-2-2

2.2 Installation Locations and Ambient Conditions ....................................................................... 2-2-5

2.3 Notes on Interference by Electromagnetic Noise.................................................................... 2-2-6

2.4 Accessories ............................................................................................................................. 2-2-7

2.5 Transport Method .................................................................................................................... 2-2-8

2.6 Installation of Manipulator ..................................................................................................... 2-2-10

Chapter 3 Periodic Inspection

3.1 Periodic Inspection .................................................................................................................. 2-3-2

4.1 Tension Adjustments of Timing Belts ...................................................................................... 2-4-4

Chapter 5 Parts List

5.1 Parts List ................................................................................................................................. 2-5-2

Chapter 6 Internal Wires

6.1 Wiring Connection Figure ....................................................................................................... 2-6-2

Capter 1 Specifications of B-type/

Capter 2 Foundation Work and Installation

Capter 3 Periodic Inspection

Capter 5 Parts List

Capter 6 Internal Wires

This chapter describes the specifications of B-type / V-type manipulator.

1.2 Basic Specifications .................................................................................1-1-4

1.4 Description on Each Part of Manipulator ...............................................1-1-17

1.1 Manipulator model

The following section shows the nomenclature of manipulator model.

1.2 Basic Specifications

1.2.1 Basic Specifications of NB4/NB4L/NB15 Manipulator

J4 (Swing) +/- 155 +/- 155 +/- 155

Wrist J5 (Bending) -45~ +225(Note 4) -45~ +225(Note 4) -37~ +217(Note 4)

J6 (Twist) 2.94 N*m 2.94 N*m 7.36 N*m

J6 (Twist) 2.94 Nm 2.94 Nm 7.36 N*m

J6 (Twist) 5.9 Nm 5.9 Nm

J6 (Twist) 19.6Nm 19.6Nm