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FANUC Robot LR Mate 200iD

FANUC Robot ARC Mate 50iD

MECHANICAL UNIT

MAINTENANCE MANUAL
MARMT200D09131E REV. A
©2013 FANUC America Corporation
All Rights Reserved.

This publication contains proprietary information


of FANUC America Corporation furnished for
customer use only. No other uses are authorized
without the express written permission of
FANUC America Corporation.

FANUC America Corporation


3900 W. Hamlin Road
Rochester Hills, Michigan 48309–3253

B-83495EN/01
Copyrights and Trademarks
This new publication contains proprietary information of FANUC America
Corporation furnished for customer use only. No other uses are authorized
without the express written permission of FANUC America Corporation.

The descriptions and specifications contained in this manual were in effect at the
time this manual was approved for printing. FANUC America Corporation,
hereinafter referred to as FANUC, reserves the right to discontinue models at
any time or to change specifications or design without notice and without
incurring obligations.

FANUC manuals present descriptions, specifications, drawings, schematics,


bills of material, parts, connections and/or procedures for installing,
disassembling, connecting, operating and programming FANUC products and/or
systems. Such systems consist of robots, extended axes, robot controllers,
application software, the KAREL® programming language, INSIGHT® vision
equipment, and special tools.

FANUC recommends that only persons who have been trained in one or more
approved FANUC Training Course(s) be permitted to install, operate, use,
perform procedures on, repair, and/or maintain FANUC products and/or systems
and their respective components. Approved training necessitates that the
courses selected be relevant to the type of system installed and application
performed at the customer site.

WARNING
This equipment generates, uses, and can radiate
radiofrequency energy and if not installed and used in
accordance with the instruction manual, may cause
interference to radio communications. As temporarily
permitted by regulation, it has not been tested for
compliance with the limits for Class A computing devices
pursuant to subpart J of Part 15 of FCC Rules, which are
designed to provide reasonable protection against such
interference. Operation of the equipment in a residential
area is likely to cause interference, in which case the user,
at his own expense, will be required to take whatever
measure may be required to correct the interference.
FANUC conducts courses on its systems and products on a regularly scheduled
basis at the company's world headquarters in Rochester Hills, Michigan. For
additional information contact
FANUC America Corporation
Training Department
3900 W. Hamlin Road
Rochester Hills, Michigan 48309-3253
www.fanucrobotics.com

For customer assistance, including Technical Support, Service, Parts & Part
Repair, and Marketing Requests, contact the Customer Resource Center, 24
hours a day, at 1-800-47-ROBOT (1-800-477-6268). International customers
should call 011-1-248-377-7159.

Send your comments and suggestions about this manual to:


product.documentation@fanucrobotics.com

Copyright © 2013 by FANUC America Corporation


All Rights Reserved

The information illustrated or contained herein is not to be


reproduced, copied, downloaded, translated into another language, published in
any physical or electronic format, including internet, or transmitted in whole or
in part in any way without the prior written consent of FANUC America
Corporation.

AccuStat®, ArcTool®, iRVision®, KAREL®, PaintTool®, PalletTool®,


SOCKETS®, SpotTool®, SpotWorks®, and TorchMate® are Registered
Trademarks of FANUC.

FANUC reserves all proprietary rights, including but not


limited to trademark and trade name rights, in the following names:

AccuAir™, AccuCal™, AccuChop™, AccuFlow™, AccuPath™,


AccuSeal™, ARC Mate™, ARC Mate Sr.™, ARC Mate System 1™,
ARC Mate System 2™, ARC Mate System 3™, ARC Mate System 4™,
ARC Mate System 5™, ARCWorks Pro™, AssistTool™, AutoNormal™,
AutoTCP™, BellTool™, BODYWorks™, Cal Mate™, Cell Finder™,
Center Finder™, Clean Wall™, DualARM™, LR Tool™,
MIG Eye™, MotionParts™, MultiARM™, NoBots™, Paint
Stick™, PaintPro™, PaintTool 100™, PAINTWorks™, PAINTWorks
II™, PAINTWorks III™, PalletMate™, PalletMate PC™,
PalletTool PC™, PayloadID™, RecipTool™, RemovalTool™,
Robo Chop™, Robo Spray™, S-420i™, S-430i™, ShapeGen™,
SoftFloat™, SOFT PARTS™, SpotTool+™, SR Mate™, SR
ShotTool™, SureWeld™, SYSTEM R-J2 Controller™, SYSTEM R-J3
Controller™, SYSTEM R-J3iB Controller™, SYSTEM R-J3iC Controller™,
SYSTEM R-30iA Controller™, SYSTEM R-30iA Mate Controller™, SYSTEM
R-30iB Controller™, SYSTEM R-30iB Mate Controller™, TCP Mate™,
TorchMate™, TripleARM™, TurboMove™, visLOC™, visPRO-3D™,
visTRAC™, WebServer™, WebTP™, and YagTool™.

©FANUC CORPORATION 2013


 No part of this manual may be reproduced in any form.
 All specifications and designs are subject to change without notice.
Patents

One or more of the following U.S. patents might be related to the FANUC
products described in this manual.

FANUC America Corporation Patent List


4,630,567 4,639,878 4,707,647 4,708,175 4,708,580 4,942,539 4,984,745
5,238,029 5,239,739 5,272,805 5,293,107 5,293,911 5,331,264 5,367,944
5,373,221 5,421,218 5,434,489 5,644,898 5,670,202 5,696,687 5,737,218
5,823,389 5,853,027 5,887,800 5,941,679 5,959,425 5,987,726 6,059,092
6,064,168 6,070,109 6,086,294 6,122,062 6,147,323 6,204,620 6,243,621
6,253,799 6,285,920 6,313,595 6,325,302 6,345,818 6,356,807 6,360,143
6,378,190 6,385,508 6,425,177 6,477,913 6,490,369 6,518,980 6,540,104
6,541,757 6,560,513 6,569,258 6,612,449 6,703,079 6,705,361 6,726,773
6,768,078 6,845,295 6,945,483 7,149,606 7,149,606 7,211,978 7,266,422
7,399,363

FANUC CORPORATION Patent List


4,571,694 4,626,756 4,700,118 4,706,001 4,728,872 4,732,526 4,742,207
4,835,362 4,894,596 4,899,095 4,920,248 4,931,617 4,934,504 4,956,594
4,967,125 4,969,109 4,970,370 4,970,448 4,979,127 5,004,968 5,006,035
5,008,834 5,063,281 5,066,847 5,066,902 5,093,552 5,107,716 5,111,019
5,130,515 5,136,223 5,151,608 5,170,109 5,189,351 5,267,483 5,274,360
5,292,066 5,300,868 5,304,906 5,313,563 5,319,443 5,325,467 5,327,057
5,329,469 5,333,242 5,337,148 5,371,452 5,375,480 5,418,441 5,432,316
5,440,213 5,442,155 5,444,612 5,449,875 5,451,850 5,461,478 5,463,297
5,467,003 5,471,312 5,479,078 5,485,389 5,485,552 5,486,679 5,489,758
5,493,192 5,504,766 5,511,007 5,520,062 5,528,013 5,532,924 5,548,194
5,552,687 5,558,196 5,561,742 5,570,187 5,570,190 5,572,103 5,581,167
5,582,750 5,587,635 5,600,759 5,608,299 5,608,618 5,624,588 5,630,955
5,637,969 5,639,204 5,641,415 5,650,078 5,658,121 5,668,628 5,687,295
5,691,615 5,698,121 5,708,342 5,715,375 5,719,479 5,727,132 5,742,138
5,742,144 5,748,854 5,749,058 5,760,560 5,773,950 5,783,922 5,799,135
5,812,408 5,841,257 5,845,053 5,872,894 5,887,122 5,911,892 5,912,540
5,920,678 5,937,143 5,980,082 5,983,744 5,987,591 5,988,850 6,023,044
6,032,086 6,040,554 6,059,169 6,088,628 6,097,169 6,114,824 6,124,693
6,140,788 6,141,863 6,157,155 6,160,324 6,163,124 6,177,650 6,180,898
6,181,096 6,188,194 6,208,105 6,212,444 6,219,583 6,226,181 6,236,011
6,236,896 6,250,174 6,278,902 6,279,413 6,285,921 6,298,283 6,321,139
6,324,443 6,328,523 6,330,493 6,340,875 6,356,671 6,377,869 6,382,012
6,384,371 6,396,030 6,414,711 6,424,883 6,431,018 6,434,448 6,445,979
6,459,958 6,463,358 6,484,067 6,486,629 6,507,165 6,654,666 6,665,588
6,680,461 6,696,810 6,728,417 6,763,284 6,772,493 6,845,296 6,853,881
6,888,089 6,898,486 6,917,837 6,928,337 6,965,091 6,970,802 7,038,165
7,069,808 7,084,900 7,092,791 7,133,747 7,143,100 7,149,602 7,131,848
7,161,321 7,171,041 7,174,234 7,173,213 7,177,722 7,177,439 7,181,294
7,181,313 7,280,687 7,283,661 7,291,806 7,299,713 7,315,650 7,324,873
7,328,083 7,330,777 7,333,879 7,355,725 7,359,817 7,373,220 7,376,488
7,386,367 7,464,623 7,447,615 7,445,260 7,474,939 7,486,816 7,495,192
7,501,778 7,502,504 7,508,155 7,512,459 7,525,273 7,526,121
Conventions

WARNING
Information appearing under the "WARNING" caption concerns the protection of
personnel. It is boxed and bolded to set it apart from the surrounding text.

CAUTION
Information appearing under the "CAUTION" caption concerns the protection of
equipment, software, and data. It is boxed and bolded to set it apart from the
surrounding text.

Note Information appearing next to NOTE concerns related information or useful hints.
• Original Instructions

Before using the Robot, be sure to read the "FANUC Robot Safety Manual (B-80687EN)" and understand
the content.

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


• All specifications and designs are subject to change without notice.

The products in this manual are controlled based on Japan’s “Foreign Exchange and
Foreign Trade Law”. The export from Japan may be subject to an export license by the
government of Japan.
Further, re-export to another country may be subject to the license of the government of
the country from where the product is re-exported. Furthermore, the product may also be
controlled by re-export regulations of the United States government.
Should you wish to export or re-export these products, please contact FANUC for advice.

In this manual we have tried as much as possible to describe all the various matters.
However, we cannot describe all the matters which must not be done, or which cannot be
done, because there are so many possibilities.
Therefore, matters which are not especially described as possible in this manual should be
regarded as ”impossible”.
Safety
FANUC America Corporation is not and does not represent itself as an expert in safety
systems, safety equipment, or the specific safety aspects of your company and/or its work
force. It is the responsibility of the owner, employer, or user to take all necessary steps to
guarantee the safety of all personnel in the workplace.

The appropriate level of safety for your application and installation can be best
determined by safety system professionals. FANUC America Corporation therefore,
recommends that each customer consult with such professionals in order to provide a
workplace that allows for the safe application, use, and operation of FANUC America
Corporation systems.

According to the industry standard ANSI/RIA R15-06, the owner or user is advised to
consult the standards to ensure compliance with its requests for Robotics System design,
usability, operation, maintenance, and service. Additionally, as the owner, employer, or
user of a robotic system, it is your responsibility to arrange for the training of the operator
of a robot system to recognize and respond to known hazards associated with your
robotic system and to be aware of the recommended operating procedures for your
particular application and robot installation.

Ensure that the robot being used is appropriate for the application. Robots used in
classified (hazardous) locations must be certified for this use.

FANUC America Corporation therefore, recommends that all personnel who intend to
operate, program, repair, or otherwise use the robotics system be trained in an approved
FANUC America Corporation training course and become familiar with the proper
operation of the system. Persons responsible for programming the system–including the
design, implementation, and debugging of application programs–must be familiar with
the recommended programming procedures for your application and robot installation.

The following guidelines are provided to emphasize the importance of safety in the
workplace.

CONSIDERING SAFETY FOR YOUR ROBOT INSTALLATION


Safety is essential whenever robots are used. Keep in mind the following factors with
regard to safety:
 The safety of people and equipment
 Use of safety enhancing devices
 Techniques for safe teaching and manual operation of the robot(s)
 Techniques for safe automatic operation of the robot(s)
 Regular scheduled inspection of the robot and workcell
 Proper maintenance of the robot

i
Safety

Keeping People Safe

The safety of people is always of primary importance in any situation. When applying
safety measures to your robotic system, consider the following:
 External devices
 Robot(s)
 Tooling
 Workpiece

Using Safety Enhancing Devices

Always give appropriate attention to the work area that surrounds the robot. The safety
of the work area can be enhanced by the installation of some or all of the following
devices:
 Safety fences, barriers, or chains
 Light curtains
 Interlocks
 Pressure mats
 Floor markings
 Warning lights
 Mechanical stops
 EMERGENCY STOP buttons
 DEADMAN switches

Setting Up a Safe Workcell

A safe workcell is essential to protect people and equipment. Observe the following
guidelines to ensure that the workcell is set up safely. These suggestions are intended to
supplement and not replace existing federal, state, and local laws, regulations, and
guidelines that pertain to safety.

 Sponsor your personnel for training in approved FANUC America Corporation


training course(s) related to your application. Never permit untrained personnel to
operate the robots.
 Install a lockout device that uses an access code to prevent unauthorized persons
from operating the robot.
 Use anti–tie–down logic to prevent the operator from bypassing safety measures.
 Arrange the workcell so the operator faces the workcell and can see what is going on
inside the cell.
 Clearly identify the work envelope of each robot in the system with floor markings,
signs, and special barriers. The work envelope is the area defined by the maximum
motion range of the robot, including any tooling attached to the wrist flange that
extend this range.

ii
Safety

 Position all controllers outside the robot work envelope.


 Never rely on software or firmware based controllers as the primary safety element
unless they comply with applicable current robot safety standards.
 Mount an adequate number of EMERGENCY STOP buttons or switches within easy
reach of the operator and at critical points inside and around the outside of the
workcell.
 Install flashing lights and/or audible warning devices that activate whenever the robot
is operating, that is, whenever power is applied to the servo drive system. Audible
warning devices shall exceed the ambient noise level at the end–use application.
 Wherever possible, install safety fences to protect against unauthorized entry by
personnel into the work envelope.
 Install special guarding that prevents the operator from reaching into restricted areas
of the work envelope.
 Use interlocks.
 Use presence or proximity sensing devices such as light curtains, mats, and
capacitance and vision systems to enhance safety.
 Periodically check the safety joints or safety clutches that can be optionally installed
between the robot wrist flange and tooling. If the tooling strikes an object, these
devices dislodge, remove power from the system, and help to minimize damage to
the tooling and robot.
 Make sure all external devices are properly filtered, grounded, shielded, and
suppressed to prevent hazardous motion due to the effects of electro–magnetic
interference (EMI), radio frequency interference (RFI), and electro–static discharge
(ESD).
 Make provisions for power lockout/tagout at the controller.
 Eliminate pinch points. Pinch points are areas where personnel could get trapped
between a moving robot and other equipment.
 Provide enough room inside the workcell to permit personnel to teach the robot and
perform maintenance safely.
 Program the robot to load and unload material safely.
 If high voltage electrostatics are present, be sure to provide appropriate interlocks,
warning, and beacons.
 If materials are being applied at dangerously high pressure, provide electrical
interlocks for lockout of material flow and pressure.

Staying Safe While Teaching or Manually Operating the Robot

Advise all personnel who must teach the robot or otherwise manually operate the robot to
observe the following rules:

 Never wear watches, rings, neckties, scarves, or loose clothing that could get caught
in moving machinery.
 Know whether or not you are using an intrinsically safe teach pendant if you are
working in a hazardous environment.

iii
Safety

 Before teaching, visually inspect the robot and work envelope to make sure that no
potentially hazardous conditions exist. The work envelope is the area defined by the
maximum motion range of the robot. These include tooling attached to the wrist
flange that extends this range.
 The area near the robot must be clean and free of oil, water, or debris. Immediately
report unsafe working conditions to the supervisor or safety department.
 FANUC America Corporation recommends that no one enter the work envelope of a
robot that is on, except for robot teaching operations. However, if you must enter the
work envelope, be sure all safeguards are in place, check the teach pendant
DEADMAN switch for proper operation, and place the robot in teach mode. Take
the teach pendant with you, turn it on, and be prepared to release the DEADMAN
switch. Only the person with the teach pendant should be in the work envelope.

WARNING
Never bypass, strap, or otherwise deactivate a safety device, such as a limit switch,
for any operational convenience. Deactivating a safety device is known to have
resulted in serious injury and death.

 Know the path that can be used to escape from a moving robot; make sure the escape
path is never blocked.
 Isolate the robot from all remote control signals that can cause motion while data is
being taught.
 Test any program being run for the first time in the following manner:

WARNING
Stay outside the robot work envelope whenever a program is being run. Failure to do
so can result in injury.

- Using a low motion speed, single step the program for at least one full cycle.
- Using a low motion speed, test run the program continuously for at least one
full cycle.
- Using the programmed speed, test run the program continuously for at least
one full cycle.
 Make sure all personnel are outside the work envelope before running production.

Staying Safe During Automatic Operation

Advise all personnel who operate the robot during production to observe the following
rules:
 Make sure all safety provisions are present and active.

iv
Safety

 Know the entire workcell area. The workcell includes the robot and its work
envelope, plus the area occupied by all external devices and other equipment with
which the robot interacts.
 Understand the complete task the robot is programmed to perform before initiating
automatic operation.
 Make sure all personnel are outside the work envelope before operating the robot.
 Never enter or allow others to enter the work envelope during automatic operation of
the robot.
 Know the location and status of all switches, sensors, and control signals that could
cause the robot to move.
 Know where the EMERGENCY STOP buttons are located on both the robot control
and external control devices. Be prepared to press these buttons in an emergency.
 Never assume that a program is complete if the robot is not moving. The robot could
be waiting for an input signal that will permit it to continue its activity.
 If the robot is running in a pattern, do not assume it will continue to run in the same
pattern.
 Never try to stop the robot, or break its motion, with your body. The only way to
stop robot motion immediately is to press an EMERGENCY STOP button located on
the controller panel, teach pendant, or emergency stop stations around the workcell.

Staying Safe During Inspection

When inspecting the robot, be sure to


 Turn off power at the controller.
 Lock out and tag out the power source at the controller according to the policies of
your plant.
 Turn off the compressed air source and relieve the air pressure.
 If robot motion is not needed for inspecting the electrical circuits, press the
EMERGENCY STOP button on the operator panel.
 Never wear watches, rings, neckties, scarves, or loose clothing that could get caught
in moving machinery.
 If power is needed to check the robot motion or electrical circuits, be prepared to
press the EMERGENCY STOP button, in an emergency.
 Be aware that when you remove a servomotor or brake, the associated robot arm will
fall if it is not supported or resting on a hard stop. Support the arm on a solid support
before you release the brake.

Staying Safe During Maintenance

When performing maintenance on your robot system, observe the following rules:
 Never enter the work envelope while the robot or a program is in operation.
 Before entering the work envelope, visually inspect the workcell to make sure no
potentially hazardous conditions exist.

v
Safety

 Never wear watches, rings, neckties, scarves, or loose clothing that could get caught
in moving machinery.
 Consider all or any overlapping work envelopes of adjoining robots when standing in
a work envelope.
 Test the teach pendant for proper operation before entering the work envelope.
 If it is necessary for you to enter the robot work envelope while power is turned on,
you must be sure that you are in control of the robot. Be sure to take the teach
pendant with you, press the DEADMAN switch, and turn the teach pendant on. Be
prepared to release the DEADMAN switch to turn off servo power to the robot
immediately.
 Whenever possible, perform maintenance with the power turned off. Before you
open the controller front panel or enter the work envelope, turn off and lock out the
3–phase power source at the controller.
 Be aware that when you remove a servomotor or brake, the associated robot arm will
fall if it is not supported or resting on a hard stop. Support the arm on a solid support
before you release the brake.

WARNING
Lethal voltage is present in the controller WHENEVER IT IS CONNECTED to a
power source. Be extremely careful to avoid electrical shock. HIGH VOLTAGE IS
PRESENT at the input side whenever the controller is connected to a power
source. Turning the disconnect or circuit breaker to the OFF position removes
power from the output side of the device only.

 Release or block all stored energy. Before working on the pneumatic system, shut
off the system air supply and purge the air lines.
 Isolate the robot from all remote control signals. If maintenance must be done when
the power is on, make sure the person inside the work envelope has sole control of
the robot. The teach pendant must be held by this person.
 Make sure personnel cannot get trapped between the moving robot and other
equipment. Know the path that can be used to escape from a moving robot. Make
sure the escape route is never blocked.
 Use blocks, mechanical stops, and pins to prevent hazardous movement by the robot.
Make sure that such devices do not create pinch points that could trap personnel.

WARNING
Do not try to remove any mechanical component from the robot before thoroughly
reading and understanding the procedures in the appropriate manual. Doing so can
result in serious personal injury and component destruction.

vi
Safety

 Be aware that when you remove a servomotor or brake, the associated robot arm will
fall if it is not supported or resting on a hard stop. Support the arm on a solid support
before you release the brake.
 When replacing or installing components, make sure dirt and debris do not enter the
system.
 Use only specified parts for replacement. To avoid fires and damage to parts in the
controller, never use nonspecified fuses.
 Before restarting a robot, make sure no one is inside the work envelope; be sure that
the robot and all external devices are operating normally.

KEEPING MACHINE TOOLS AND EXTERNAL DEVICES SAFE


Certain programming and mechanical measures are useful in keeping the machine tools
and other external devices safe. Some of these measures are outlined below. Make sure
you know all associated measures for safe use of such devices.

Programming Safety Precautions

Implement the following programming safety measures to prevent damage to machine


tools and other external devices.
 Back–check limit switches in the workcell to make sure they do not fail.
 Implement ‘‘failure routines” in programs that will provide appropriate robot actions
if an external device or another robot in the workcell fails.
 Use handshaking protocol to synchronize robot and external device operations.
 Program the robot to check the condition of all external devices during an operating
cycle.

Mechanical Safety Precautions

Implement the following mechanical safety measures to prevent damage to machine tools
and other external devices.
 Make sure the workcell is clean and free of oil, water, and debris.
 Use DCS (Dual Check Safety), software limits, limit switches, and mechanical
hardstops to prevent undesired movement of the robot into the work area of machine
tools and external devices.

vii
Safety

KEEPING THE ROBOT SAFE


Observe the following operating and programming guidelines to prevent damage to the
robot.

Operating Safety Precautions

The following measures are designed to prevent damage to the robot during operation.
 Use a low override speed to increase your control over the robot when jogging the
robot.
 Visualize the movement the robot will make before you press the jog keys on the
teach pendant.
 Make sure the work envelope is clean and free of oil, water, or debris.
 Use circuit breakers to guard against electrical overload.

Programming Safety Precautions

The following safety measures are designed to prevent damage to the robot during
programming:
 Establish interference zones to prevent collisions when two or more robots share a
work area.
 Make sure that the program ends with the robot near or at the home position.
 Be aware of signals or other operations that could trigger operation of tooling
resulting in personal injury or equipment damage.
 In dispensing applications, be aware of all safety guidelines with respect to the
dispensing materials.

NOTE: Any deviation from the methods and safety practices described in this manual
must conform to the approved standards of your company. If you have questions, see
your supervisor.

ADDITIONAL SAFETY CONSIDERATIONS FOR PAINT ROBOT


INSTALLATIONS
Process technicians are sometimes required to enter the paint booth, for example, during
daily or routine calibration or while teaching new paths to a robot. Maintenance
personnel also must work inside the paint booth periodically.

Whenever personnel are working inside the paint booth, ventilation equipment must be
used. Instruction on the proper use of ventilating equipment usually is provided by the
paint shop supervisor.

viii
Safety

Although paint booth hazards have been minimized, potential dangers still exist.
Therefore, today’s highly automated paint booth requires that process and maintenance
personnel have full awareness of the system and its capabilities. They must understand
the interaction that occurs between the vehicle moving along the conveyor and the
robot(s), hood/deck and door opening devices, and high–voltage electrostatic tools.

CAUTION
Ensure that all ground cables remain connected. Never operate the paint robot with
ground provisions disconnected. Otherwise, you could injure personnel or damage
equipment.

Paint robots are operated in three modes:


 Teach or manual mode
 Automatic mode, including automatic and exercise operation
 Diagnostic mode

During both teach and automatic modes, the robots in the paint booth will follow a
predetermined pattern of movements. In teach mode, the process technician teaches
(programs) paint paths using the teach pendant.

In automatic mode, robot operation is initiated at the System Operator Console (SOC) or
Manual Control Panel (MCP), if available, and can be monitored from outside the paint
booth. All personnel must remain outside of the booth or in a designated safe area within
the booth whenever automatic mode is initiated at the SOC or MCP.

In automatic mode, the robots will execute the path movements they were taught during
teach mode, but generally at production speeds.

When process and maintenance personnel run diagnostic routines that require them to
remain in the paint booth, they must stay in a designated safe area.

Paint System Safety Features

Process technicians and maintenance personnel must become totally familiar with the
equipment and its capabilities. To minimize the risk of injury when working near robots
and related equipment, personnel must comply strictly with the procedures in the
manuals.

This section provides information about the safety features that are included in the paint
system and also explains the way the robot interacts with other equipment in the system.

The paint system includes the following safety features:


 Most paint booths have red warning beacons that illuminate when the robots are
armed and ready to paint. Your booth might have other kinds of indicators. Learn
what these are.

ix
Safety

 Some paint booths have a blue beacon that, when illuminated, indicates that the
electrostatic devices are enabled. Your booth might have other kinds of indicators.
Learn what these are.
 EMERGENCY STOP buttons are located on the robot controller and teach pendant.
Become familiar with the locations of all E–STOP buttons.
 An intrinsically safe teach pendant is used when teaching in hazardous paint
atmospheres.
 A DEADMAN switch is located on each teach pendant. When this switch is held in,
and the teach pendant is on, power is applied to the robot servo system. If the
engaged DEADMAN switch is released or pressed harder during robot operation,
power is removed from the servo system, all axis brakes are applied, and the robot
comes to an EMERGENCY STOP. Safety interlocks within the system might also
E–STOP other robots.

WARNING
An EMERGENCY STOP will occur if the DEADMAN switch is released on a bypassed
robot.

 Overtravel by robot axes is prevented by software limits. All of the major and minor
axes are governed by software limits. DCS (Dual Check Safety), limit switches and
hardstops also limit travel by the major axes.
 EMERGENCY STOP limit switches and photoelectric eyes might be part of your
system. Limit switches, located on the entrance/exit doors of each booth, will
EMERGENCY STOP all equipment in the booth if a door is opened while the system
is operating in automatic or manual mode. For some systems, signals to these
switches are inactive when the switch on the SOC is in teach mode.
 When present, photoelectric eyes are sometimes used to monitor unauthorized
intrusion through the entrance/exit silhouette openings.
 System status is monitored by computer. Severe conditions result in automatic
system shutdown.

Staying Safe While Operating the Paint Robot

When you work in or near the paint booth, observe the following rules, in addition to all
rules for safe operation that apply to all robot systems.

WARNING
Observe all safety rules and guidelines to avoid injury.

x
Safety

WARNING
Never bypass, strap, or otherwise deactivate a safety device, such as a limit switch,
for any operational convenience. Deactivating a safety device is known to have
resulted in serious injury and death.

WARNING
Enclosures shall not be opened unless the area is known to be nonhazardous or
all power has been removed from devices within the enclosure. Power shall not be
restored after the enclosure has been opened until all combustible dusts have
been removed from the interior of the enclosure and the enclosure purged. Refer
to the Purge chapter for the required purge time.

 Know the work area of the entire paint station (workcell).


 Know the work envelope of the robot and hood/deck and door opening devices.
 Be aware of overlapping work envelopes of adjacent robots.
 Know where all red, mushroom–shaped EMERGENCY STOP buttons are located.
 Know the location and status of all switches, sensors, and/or control signals that
might cause the robot, conveyor, and opening devices to move.
 Make sure that the work area near the robot is clean and free of water, oil, and debris.
Report unsafe conditions to your supervisor.
 Become familiar with the complete task the robot will perform BEFORE starting
automatic mode.
 Make sure all personnel are outside the paint booth before you turn on power to the
robot servo system.
 Never enter the work envelope or paint booth before you turn off power to the robot
servo system.
 Never enter the work envelope during automatic operation unless a safe area has been
designated.
 Never wear watches, rings, neckties, scarves, or loose clothing that could get caught
in moving machinery.
 Remove all metallic objects, such as rings, watches, and belts, before entering a
booth when the electrostatic devices are enabled.
 Stay out of areas where you might get trapped between a moving robot, conveyor, or
opening device and another object.
 Be aware of signals and/or operations that could result in the triggering of guns or
bells.
 Be aware of all safety precautions when dispensing of paint is required.
 Follow the procedures described in this manual.

xi
Safety

Special Precautions for Combustible Dusts (Powder Paint)


When the robot is used in a location where combustible dusts are found, such as the
application of powder paint, the following special precautions are required to insure that
there are no combustible dusts inside the robot.
 Purge maintenance air should be maintained at all times, even when the robot power
is off. This will insure that dust can not enter the robot.
 A purge cycle will not remove accumulated dusts. Therefore, if the robot is exposed
to dust when maintenance air is not present, it will be necessary to remove the covers
and clean out any accumulated dust. Do not energize the robot until you have
performed the following steps.
1. Before covers are removed, the exterior of the robot should be cleaned to remove
accumulated dust.
2. When cleaning and removing accumulated dust, either on the outside or inside of the
robot, be sure to use methods appropriate for the type of dust that exists. Usually lint
free rags dampened with water are acceptable. Do not use a vacuum cleaner to
remove dust as it can generate static electricity and cause an explosion unless special
precautions are taken.
3. Thoroughly clean the interior of the robot with a lint free rag to remove any
accumulated dust.
4. When the dust has been removed, the covers must be replaced immediately.
5. Immediately after the covers are replaced, run a complete purge cycle. The robot can
now be energized.

Staying Safe While Operating Paint Application Equipment


When you work with paint application equipment, observe the following rules, in
addition to all rules for safe operation that apply to all robot systems.

WARNING
When working with electrostatic paint equipment, follow all national and local codes
as well as all safety guidelines within your organization. Also reference the
following standards: NFPA 33 Standards for Spray Application Using Flammable or
Combustible Materials, and NFPA 70 National Electrical Code.
 Grounding: All electrically conductive objects in the spray area must be grounded.
This includes the spray booth, robots, conveyors, workstations, part carriers, hooks,
paint pressure pots, as well as solvent containers. Grounding is defined as the object
or objects shall be electrically connected to ground with a resistance of not more than
1 megohms.
 High Voltage: High voltage should only be on during actual spray operations.
Voltage should be off when the painting process is completed. Never leave high
voltage on during a cap cleaning process.
 Avoid any accumulation of combustible vapors or coating matter.
 Follow all manufacturer recommended cleaning procedures.
 Make sure all interlocks are operational.

xii
Safety

 No smoking.
 Post all warning signs regarding the electrostatic equipment and operation of
electrostatic equipment according to NFPA 33 Standard for Spray Application Using
Flammable or Combustible Material.
 Disable all air and paint pressure to bell.
 Verify that the lines are not under pressure.

Staying Safe During Maintenance

When you perform maintenance on the painter system, observe the following rules, and
all other maintenance safety rules that apply to all robot installations. Only qualified,
trained service or maintenance personnel should perform repair work on a robot.
 Paint robots operate in a potentially explosive environment. Use caution when
working with electric tools.
 When a maintenance technician is repairing or adjusting a robot, the work area is
under the control of that technician. All personnel not participating in the
maintenance must stay out of the area.
 For some maintenance procedures, station a second person at the control panel within
reach of the EMERGENCY STOP button. This person must understand the robot
and associated potential hazards.
 Be sure all covers and inspection plates are in good repair and in place.
 Always return the robot to the ‘‘home’’ position before you disarm it.
 Never use machine power to aid in removing any component from the robot.
 During robot operations, be aware of the robot’s movements. Excess vibration,
unusual sounds, and so forth, can alert you to potential problems.
 Whenever possible, turn off the main electrical disconnect before you clean the robot.
 When using vinyl resin observe the following:
- Wear eye protection and protective gloves during application and removal.
- Adequate ventilation is required. Overexposure could cause drowsiness or
skin and eye irritation.
- If there is contact with the skin, wash with water.
- Follow the Original Equipment Manufacturer’s Material Safety Data Sheets.
 When using paint remover observe the following:
- Eye protection, protective rubber gloves, boots, and apron are required
during booth cleaning.
- Adequate ventilation is required. Overexposure could cause drowsiness.
- If there is contact with the skin or eyes, rinse with water for at least 15
minutes. Then seek medical attention as soon as possible.
- Follow the Original Equipment Manufacturer’s Material Safety Data Sheets.

xiii
B-83495EN/01 SAFETY PRECAUTIONS

SAFETY PRECAUTIONS
Thank you for purchasing FANUC Robot.
This chapter describes the precautions which must be observed to ensure the safe use of the robot.
Before attempting to use the robot, be sure to read this chapter thoroughly.

Before using the functions related to robot operation, read the relevant operator's manual to become
familiar with those functions.

If any description in this chapter differs from that in the other part of this manual, the description given in
this chapter shall take precedence.

For the safety of the operator and the system, follow all safety precautions when operating a robot and its
peripheral devices installed in a work cell.
In addition, refer to the “FANUC Robot SAFETY HANDBOOK (B-80687EN)”.

1 WORKING PERSON
The personnel can be classified as follows.

Operator:
• Turns robot controller power ON/OFF
• Starts robot program from operator’s panel

Programmer or teaching operator:


• Operates the robot
• Teaches robot inside the safety fence

Maintenance engineer:
• Operates the robot
• Teaches robot inside the safety fence
• Maintenance (adjustment, replacement)

- An operator cannot work inside the safety fence.


- A programmer, teaching operator, and maintenance engineer can work inside the safety fence. The
working activities inside the safety fence include lifting, setting, teaching, adjusting, maintenance,
etc.
- To work inside the fence, the person must be trained on proper robot operation.

During the operation, programming, and maintenance of your robotic system, the programmer, teaching
operator, and maintenance engineer should take additional care of their safety by using the following
safety precautions.

- Use adequate clothing or uniforms during system operation


- Wear safety shoes
- Use helmet

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SAFETY PRECAUTIONS B-83495EN/01

2 DEFINITION OF WARNING, CAUTION AND


NOTE
To ensure the safety of user and prevent damage to the machine, this manual indicates each precaution on
safety with "Warning" or "Caution" according to its severity. Supplementary information is indicated by
"Note". Read the contents of each "Warning", "Caution" and "Note" before attempting to use the
robots.

WARNING
Applied when there is a danger of the user being injured or when there is a
danger of both the user being injured and the equipment being damaged if the
approved procedure is not observed.

CAUTION
Applied when there is a danger of the equipment being damaged, if the
approved procedure is not observed.

NOTE
Notes are used to indicate supplementary information other than Warnings and
Cautions.

• Read this manual carefully, and store it in a sales place.

3 WORKING PERSON SAFETY


Working person safety is the primary safety consideration. Because it is very dangerous to enter the
operating space of the robot during automatic operation, adequate safety precautions must be observed.
The following lists the general safety precautions. Careful consideration must be made to ensure
working person safety.

(1) Have the robot system working persons attend the training courses held by FANUC.

FANUC provides various training courses. Contact our sales office for details.

(2) Even when the robot is stationary, it is possible that the robot is still in a ready to move state, and is
waiting for a signal. In this state, the robot is regarded as still in motion. To ensure working
person safety, provide the system with an alarm to indicate visually or aurally that the robot is in
motion.
(3) Install a safety fence with a gate so that no working person can enter the work area without passing
through the gate. Install an interlocking device, a safety plug, and so forth in the safety gate so that
the robot is stopped as the safety gate is opened.

The controller is designed to receive this interlocking signal of the door switch. When the gate
is opened and this signal received, the controller stops the robot (Please refer to "STOP
TYPE OF ROBOT" in SAFETY PRECAUTIONS for detail of stop type). For connection, see
Fig.3 (a) and Fig.3 (b).

(4) Provide the peripheral devices with appropriate grounding (Class A, Class B, Class C, and Class D).
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B-83495EN/01 SAFETY PRECAUTIONS

(5) Try to install the peripheral devices outside the work area.
(6) Draw an outline on the floor, clearly indicating the range of the robot motion, including the tools
such as a hand.
(7) Install a mat switch or photoelectric switch on the floor with an interlock to a visual or aural alarm
that stops the robot when a working person enters the work area.
(8) If necessary, install a safety lock so that no one except the working person in charge can turn on the
power of the robot.

The circuit breaker installed in the controller is designed to disable anyone from turning it on
when it is locked with a padlock.

(9) When adjusting each peripheral device independently, be sure to turn off the power of the robot
(10) Operators should be ungloved while manipulating the operator’s panel or teach pendant. Operation
with gloved fingers could cause an operation error.
(11) Programs, system variables, and other information can be saved on memory card or USB memories.
Be sure to save the data periodically in case the data is lost in an accident.
(12) The robot should be transported and installed by accurately following the procedures recommended
by FANUC. Wrong transportation or installation may cause the robot to fall, resulting in severe
injury to workers.
(13) In the first operation of the robot after installation, the operation should be restricted to low speeds.
Then, the speed should be gradually increased to check the operation of the robot.
(14) Before the robot is started, it should be checked that no one is in the area of the safety fence. At the
same time, a check must be made to ensure that there is no risk of hazardous situations. If detected,
such a situation should be eliminated before the operation.
(15) When the robot is used, the following precautions should be taken. Otherwise, the robot and
peripheral equipment can be adversely affected, or workers can be severely injured.
- Avoid using the robot in a flammable environment.
- Avoid using the robot in an explosive environment.
- Avoid using the robot in an environment full of radiation.
- Avoid using the robot under water or at high humidity.
- Avoid using the robot to carry a person or animal.
- Avoid using the robot as a stepladder. (Never climb up on or hang from the robot.)
(16) When connecting the peripheral devices related to stop(safety fence etc.) and each signal (external
emergency , fence etc.) of robot. be sure to confirm the stop movement and do not take the wrong
connection.
(17) When preparing trestle, please consider security for installation and maintenance work in high place
according to Fig.3 (c). Please consider footstep and safety bolt mounting position.

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SAFETY PRECAUTIONS B-83495EN/01

RP1
Pulsecoder
RI/RO,XHBK,XROT
RM1
Motor power/brake

EARTH

Safety fence

Interlocking device and safety plug that are activated if the


gate is opened.

Fig. 3 (a) Safety fence and safety gate

Dual chain Emergency stop board


(Note)
orPanel
Panelboard
board (Note)

EAS1 In case
In caseofofR-30iB,
R-30iAR-30iB Mate
TerminalsEAS1,EAS11,EAS2,EAS21
Terminals EAS1,EAS11,EAS2,EAS21 areorprovided
FENCE1,FENCE2
on the
EAS11 are provided
emergency onboard.
stop the operation box or on the terminal block
of the printed circuit boar d.
EAS2
Refer
In casetoof R-30iA
the ELECTRICAL
Mate CONNCETIONS Chapter of
EAS21 CONNECTION of
Terminals EAS1,EAS11,EAS2,EAS21 are provided
R-30iB controller maintenance
on the emergency stop board manual (B-83195EN)
or connector panel. or
(in caseMate
R-30iB of Open air type)
controller maintenance manual (B-83525EN)
or R-30iB Mate controller (Open Air) maintenance manual
Termianls FENCE1,FENCE2
(B-83525EN) for details. ar e provided
on the emergency stop board.
Single chain
Panel board
Refer to controller maintenance manual for details.
FENCE1

FENCE2

Fig. 3 (b) Limit switch circuit diagram of the safety fence

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B-83495EN/01 SAFETY PRECAUTIONS

Hook for safety belt

Fence

Steps

Trestle

Footstep
for maintenance

Fig.3 (c) Footstep for maintenance

3.1 OPERATOR SAFETY


The operator is a person who operates the robot system. In this sense, a worker who operates the teach
pendant is also an operator. However, this section does not apply to teach pendant operators.

(1) If you do not have to operate the robot, turn off the power of the robot controller or press the
EMERGENCY STOP button, and then proceed with necessary work.
(2) Operate the robot system at a location outside of the safety fence
(3) Install a safety fence with a safety gate to prevent any worker other than the operator from entering
the work area unexpectedly and to prevent the worker from entering a dangerous area.
(4) Install an EMERGENCY STOP button within the operator’s reach.

The robot controller is designed to be connected to an external EMERGENCY STOP button.


With this connection, the controller stops the robot operation (Please refer to "STOP TYPE
OF ROBOT" in SAFETY PRECAUTIONS for detail of stop type), when the external
EMERGENCY STOP button is pressed. See the diagram below for connection.

Dual chain (Note)


External stop button Connect EES1 and EES11, EES2 and EES21
Emergency stop boa rd
Panel board
o r Pane l boa rd In case R-30iB, R-30iB Mate
EES1 EES1,EES11,EES2,EES21 are on the emergenc y stop board
(Note)
EES11 Connect EES1and EES11,EES2 and EES21or EMGIN1and EMGIN2.
Refer to the ELECTRICAL CONNCETIONS Chapter of
EES2 In case of R-30iA
CONNECTION of
EES1,EES11,EES2,EES21 or EMGIN1,EMGIN2 are on the panel board.
EES21 R-30iB controller maintenance manual (B-83195EN) or
In case of
R-30iB R-30iA
Mate Mate maintenance manual (B-83525EN)
controller
EES1,EES11,EES2,EES21 are on the emergency stop board
or R-30iB Mate
or connector controller
panel (in (Open
case of Open Air) maintenance manual
air type).
Single chain EMGIN1,EMGIN2 are
(B-83525EN) on the emergency stop board.
for details.
External stop button Refer to the maintenance manual of the controller for details.
Panel board
EMGIN1
EMGIN2

Fig.3.1 Connection diagram for external emergency stop button

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SAFETY PRECAUTIONS B-83495EN/01

3.2 SAFETY OF THE PROGRAMMER


While teaching the robot, the operator must enter the work area of the robot. The operator must ensure
the safety of the teach pendant operator especially.

(1) Unless it is specifically necessary to enter the robot work area, carry out all tasks outside the area.
(2) Before teaching the robot, check that the robot and its peripheral devices are all in the normal
operating condition.
(3) If it is inevitable to enter the robot work area to teach the robot, check the locations, settings, and
other conditions of the safety devices (such as the EMERGENCY STOP button, the DEADMAN
switch on the teach pendant) before entering the area.
(4) The programmer must be extremely careful not to let anyone else enter the robot work area.
(5) Programming should be done outside the area of the safety fence as far as possible. If programming
needs to be done in the area of the safety fence, the programmer should take the following
precautions:
- Before entering the area of the safety fence, ensure that there is no risk of dangerous situations
in the area.
- Be prepared to press the emergency stop button whenever necessary.
- Robot motions should be made at low speeds.
- Before starting programming, check the entire system status to ensure that no remote instruction
to the peripheral equipment or motion would be dangerous to the user.

Our operator panel is provided with an emergency stop button and a key switch (mode switch) for selecting the
automatic operation mode (AUTO) and the teach modes (T1 and T2). Before entering the inside of the safety
fence for the purpose of teaching, set the switch to a teach mode, remove the key from the mode switch to prevent
other people from changing the operation mode carelessly, then open the safety gate. If the safety gate is opened
with the automatic operation mode set, the robot stops (Please refer to "STOP TYPE OF ROBOT" in SAFETY
PRECAUTIONS for detail of stop type). After the switch is set to a teach mode, the safety gate is disabled. The
programmer should understand that the safety gate is disabled and is responsible for keeping other people from
entering the inside of the safety fence. (In case of R-30iA Mate Controller standard specification, there is no mode
switch. The automatic operation mode and the teach mode is selected by teach pendant enable switch.)

Our teach pendant is provided with a DEADMAN switch as well as an emergency stop button. These button and
switch function as follows:
(1) Emergency stop button: Causes an emergency stop (Please refer to "STOP TYPE OF ROBOT" in SAFETY
PRECAUTIONS for detail of stop type) when pressed.
(2) DEADMAN switch: Functions differently depending on the teach pendant enable/disable switch setting
status.
(a) Disable: The DEADMAN switch is disabled.
(b) Enable: Servo power is turned off when the operator releases the DEADMAN switch or when the
operator presses the switch strongly.
Note) The DEADMAN switch is provided to stop the robot when the operator releases the teach pendant or
presses the pendant strongly in case of emergency. The R-30iB/R-30iB Mate employs a 3-position
DEADMAN switch, which allows the robot to operate when the 3-position DEADMAN switch is pressed
to its intermediate point. When the operator releases the DEADMAN switch or presses the switch
strongly, the robot stops immediately.

The operator’s intention of starting teaching is determined by the controller through the dual operation of setting the
teach pendant enable/disable switch to the enable position and pressing the DEADMAN switch. The operator
should make sure that the robot could operate in such conditions and be responsible in carrying out tasks safely.

Based on the risk assessment by FANUC, number of operation of DEADMAN SW should not exceed about 10000
times per year.

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B-83495EN/01 SAFETY PRECAUTIONS

The teach pendant, operator panel, and peripheral device interface send each robot start signal. However the
validity of each signal changes as follows depending on the mode switch and the DEADMAN switch of the operator
panel, the teach pendant enable switch and the remote condition on the software.

Software
Teach pendant
Mode remote Teach pendant Operator panel Peripheral device
enable switch
condition
Local Not allowed Not allowed Not allowed
On
AUTO Remote Not allowed Not allowed Not allowed
mode Local Not allowed Allowed to start Not allowed
Off
Remote Not allowed Not allowed Allowed to start
Local Allowed to start Not allowed Not allowed
On
T1, T2 Remote Allowed to start Not allowed Not allowed
mode Local Not allowed Not allowed Not allowed
Off
Remote Not allowed Not allowed Not allowed
T1,T2 mode: DEADMAN switch is effective.

(6) To start the system using the operator’s panel, make certain that nobody is the robot work area and
that there are no abnormal conditions in the robot work area.
(7) When a program is completed, be sure to carry out a test operation according to the procedure
below.
(a) Run the program for at least one operation cycle in the single step mode at low speed.
(b) Run the program for at least one operation cycle in the continuous operation mode at low
speed.
(c) Run the program for one operation cycle in the continuous operation mode at the intermediate
speed and check that no abnormalities occur due to a delay in timing.
(d) Run the program for one operation cycle in the continuous operation mode at the normal
operating speed and check that the system operates automatically without trouble.
(e) After checking the completeness of the program through the test operation above, execute it in
the automatic operation mode.
(8) While operating the system in the automatic operation mode, the teach pendant operator should
leave the robot work area.

3.3 SAFETY OF THE MAINTENANCE ENGINEER


For the safety of maintenance engineer personnel, pay utmost attention to the following.

(1) During operation, never enter the robot work area.


(2) A hazardous situation may arise when the robot or the system, are kept with their power-on during
maintenance operations. Therefore, for any maintenance operation, the robot and the system should
be put into the power-off state. If necessary, a lock should be in place in order to prevent any other
person from turning on the robot and/or the system. In case maintenance needs to be executed in the
power-on state, the emergency stop button must be pressed.
(3) If it becomes necessary to enter the robot operation range while the power is on, press the
emergency stop button on the operator panel, or the teach pendant before entering the range. The
maintenance personnel must indicate that maintenance work is in progress and be careful not to
allow other people to operate the robot carelessly.
(4) When entering the area enclosed by the safety fence, the maintenance worker must check the entire
system in order to make sure no dangerous situations exist. In case the worker needs to enter the
safety area whilst a dangerous situation exists, extreme care must be taken, and entire system status
must be carefully monitored.
(5) Before the maintenance of the pneumatic system is started, the supply pressure should be shut off
and the pressure in the piping should be reduced to zero.

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SAFETY PRECAUTIONS B-83495EN/01

(6) Before the start of teaching, check that the robot and its peripheral devices are all in the normal
operating condition.
(7) Do not operate the robot in the automatic mode while anybody is in the robot work area.
(8) When you maintain the robot alongside a wall or instrument, or when multiple workers are working
nearby, make certain that their escape path is not obstructed.
(9) When a tool is mounted on the robot, or when any moving device other than the robot is installed,
such as belt conveyor, pay careful attention to its motion.
(10) If necessary, have a worker who is familiar with the robot system stand beside the operator panel
and observe the work being performed. If any danger arises, the worker should be ready to press
the EMERGENCY STOP button at any time.
(11) When replacing a part, please contact FANUC service center. If a wrong procedure is followed, an
accident may occur, causing damage to the robot and injury to the worker.
(12) When replacing or reinstalling components, take care to prevent foreign matter from entering the
system.
(13) When handling each unit or printed circuit board in the controller during inspection, turn off the
circuit breaker to protect against electric shock.
If there are two cabinets, turn off the both circuit breaker.
(14) A part should be replaced with a part recommended by FANUC. If other parts are used, malfunction
or damage would occur. Especially, a fuse that is not recommended by FANUC should not be used.
Such a fuse may cause a fire.
(15) When restarting the robot system after completing maintenance work, make sure in advance that
there is no person in the work area and that the robot and the peripheral devices are not abnormal.
(16) When a motor or brake is removed, the robot arm should be supported with a crane or other
equipment beforehand so that the arm would not fall during the removal.
(17) Whenever grease is spilled on the floor, it should be removed as quickly as possible to prevent
dangerous falls.
(18) The following parts are heated. If a maintenance worker needs to touch such a part in the heated
state, the worker should wear heat-resistant gloves or use other protective tools.
- Servo motor
- Inside the controller
- Reducer
- Gearbox
- Wrist unit
(19) Maintenance should be done under suitable light. Care must be taken that the light would not cause
any danger.
(20) When a motor, reducer, or other heavy load is handled, a crane or other equipment should be used to
protect maintenance workers from excessive load. Otherwise, the maintenance workers would be
severely injured.
(21) The robot should not be stepped on or climbed up during maintenance. If it is attempted, the robot
would be adversely affected. In addition, a misstep can cause injury to the worker.
(22) When performing maintenance work in high place, secure a footstep and wear safety belt.
(23) After the maintenance is completed, spilled oil or water and metal chips should be removed from the
floor around the robot and within the safety fence.
(24) When a part is replaced, all bolts and other related components should put back into their original
places. A careful check must be given to ensure that no components are missing or left not mounted.
(25) In case robot motion is required during maintenance, the following precautions should be taken :
- Foresee an escape route. And during the maintenance motion itself, monitor continuously the
whole system so that your escape route will not become blocked by the robot, or by peripheral
equipment.
- Always pay attention to potentially dangerous situations, and be prepared to press the emergency
stop button whenever necessary.
(26) The robot should be periodically inspected. (Refer to the robot mechanical manual and controller
maintenance manual.) A failure to do the periodical inspection can adversely affect the performance
or service life of the robot and may cause an accident
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B-83495EN/01 SAFETY PRECAUTIONS

(27) After a part is replaced, a test operation should be given for the robot according to a predetermined
method. (See TESTING section of “Controller operator’s manual”.) During the test execution, the
maintenance staff should work outside the safety fence.

4 SAFETY OF THE TOOLS AND


PERIPHERAL DEVICES
4.1 PRECAUTIONS IN PROGRAMMING
(1) Use a limit switch or other sensor to detect a dangerous condition and, if necessary, design the
program to stop the robot when the sensor signal is received.
(2) Design the program to stop the robot when an abnormal condition occurs in any other robots or
peripheral devices, even though the robot itself is normal.
(3) For a system in which the robot and its peripheral devices are in synchronous motion, particular care
must be taken in programming so that they do not interfere with each other.
(4) Provide a suitable interface between the robot and its peripheral devices so that the robot can detect
the states of all devices in the system and can be stopped according to the states.

4.2 PRECAUTIONS FOR MECHANISM


(1) Keep the component cells of the robot system clean, and operate the robot in an environment free of
grease, water, and dust.
(2) Don’t use unconfirmed liquid for cutting fluid and cleaning fluid.
(3) Observe the following precautions about the mechanical unit cables. Failure to follow precautions
may cause mechanical troubles.
(4) Observe the following precautions about the mechanical unit cables. When theses attentions are not
kept, unexpected troubles might occur.
• Use mechanical unit cable that have required user interface.
• Don’t add user cable or hose to inside of mechanical unit.
• Please do not obstruct the movement of the mechanical unit cable when cables are added to
outside of mechanical unit.
• In the case of the model that a cable is exposed, Please do not perform remodeling (Adding a
protective cover and fix an outside cable more) obstructing the behavior of the outcrop of the
cable.
• When installing user peripheral equipment on the robot mechanical unit, please pay attention
that equipment does not interfere with the robot itself.”
(5) The frequent power-off stop for the robot during operation causes the trouble of the robot. Please
avoid the system construction that power-off stop would be operated routinely. (Refer to bad case
example.) Please execute power-off stop after reducing the speed of the robot and stopping it by
hold stop or cycle stop when it is not urgent. (Please refer to "STOP TYPE OF ROBOT" in
SAFETY PRECAUTIONS for detail of stop type.)
(Bad case example)
• Whenever poor product is generated, a line stops by emergency stop.
• When alteration was necessary, safety switch is operated by opening safety fence and
power-off stop is executed for the robot during operation.
• An operator pushes the emergency stop button frequently, and a line stops.
• An area sensor or a mat switch connected to safety signal operate routinely and power-off stop
is executed for the robot.

s-9
SAFETY PRECAUTIONS B-83495EN/01

(6) Robot stops urgently when collision detection alarm (SRVO-050) etc. occurs. Please try to avoid
unnecessary power-off stops. It may cause the trouble of the robot, too. So remove the causes of the
alarm.

5 SAFETY OF THE ROBOT MECHANISM


5.1 PRECAUTIONS IN OPERATION
(1) When operating the robot in the jog mode, set it at an appropriate speed so that the operator can
manage the robot in any eventuality.
(2) Before pressing the jog key, be sure you know in advance what motion the robot will perform in the
jog mode.

5.2 PRECAUTIONS IN PROGRAMMING


(1) When the work areas of robots overlap, make certain that the motions of the robots do not interfere
with each other.
(2) Be sure to specify the predetermined work origin in a motion program for the robot and program the
motion so that it starts from the origin and terminates at the origin.
Make it possible for the operator to easily distinguish at a glance that the robot motion has
terminated.

5.3 PRECAUTIONS FOR MECHANISMS


(1) Keep the work areas of the robot clean, and operate the robot in an environment free of grease, water,
and dust.

5.4 PROCEDURE TO MOVE ARM WITHOUT DRIVE POWER


IN EMERGENCY OR ABNORMAL SITUATIONS
(1) For emergency or abnormal situations (e.g. persons is sandwiched or trapped by the robot), turn off
the robot controller immediately, change robot posture by directly pressing robot arm and release the
worker.

6 SAFETY OF THE END EFFECTOR


6.1 PRECAUTIONS IN PROGRAMMING
(1) To control the pneumatic, hydraulic and electric actuators, carefully consider the necessary time
delay after issuing each control command up to actual motion and ensure safe control.
(2) Provide the end effector with a limit switch, and control the robot system by monitoring the state of
the end effector.

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B-83495EN/01 SAFETY PRECAUTIONS

7 STOP TYPE OF ROBOT


The following three robot stop types exist:

Power-Off Stop (Category 0 following IEC 60204-1)


Servo power is turned off and the robot stops immediately. Servo power is turned off when the robot is
moving, and the motion path of the deceleration is uncontrolled.
The following processing is performed at Power-Off stop.
- An alarm is generated and servo power is turned off.
- The robot operation is stopped immediately. Execution of the program is paused.

Controlled stop (Category 1 following IEC 60204-1)


The robot is decelerated until it stops, and servo power is turned off.
The following processing is performed at Controlled stop.
- The alarm "SRVO-199 Controlled stop" occurs along with a decelerated stop. Execution of the
program is paused.
- An alarm is generated and servo power is turned off.

Hold (Category 2 following IEC 60204-1)


The robot is decelerated until it stops, and servo power remains on.
The following processing is performed at Hold.
- The robot operation is decelerated until it stops. Execution of the program is paused.

WARNING
The stopping distance and stopping time of Controlled stop are longer than the
stopping distance and stopping time of Power-Off stop. A risk assessment for
the whole robot system, which takes into consideration the increased stopping
distance and stopping time, is necessary when Controlled stop is used.

When the emergency stop button is pressed or the FENCE is open, the stop type of robot is Power-Off
stop or Controlled stop. The configuration of stop type for each situation is called stop pattern. The stop
pattern is different according to the controller type or option configuration.

There are the following 3 Stop patterns.


Emergency External
Stop Servo
Mode stop Emergency FENCE open SVOFF input
pattern disconnect
button stop
AUTO P-Stop P-Stop C-Stop C-Stop P-Stop
A T1 P-Stop P-Stop - C-Stop P-Stop
T2 P-Stop P-Stop - C-Stop P-Stop
AUTO P-Stop P-Stop P-Stop P-Stop P-Stop
B T1 P-Stop P-Stop - P-Stop P-Stop
T2 P-Stop P-Stop - P-Stop P-Stop
AUTO C-Stop C-Stop C-Stop C-Stop C-Stop
C T1 P-Stop P-Stop - C-Stop P-Stop
T2 P-Stop P-Stop - C-Stop P-Stop
P-Stop: Power-Off stop
C-Stop: Controlled stop
-: Disable

s-11
SAFETY PRECAUTIONS B-83495EN/01

The following table indicates the Stop pattern according to the controller type or option configuration.
Option R-30iB/ R-30iB Mate
Standard A (*)
Controlled stop by E-Stop (A05B-2600-J570) C (*)
(*) R-30iB / R-30iB Mate does not have servo disconnect. / R-30iB Mate does not have SVOFF input.

The stop pattern of the controller is displayed in "Stop pattern" line in software version screen. Please
refer to "Software version" in operator's manual of controller for the detail of software version screen.

"Controlled stop by E-Stop" option


When "Controlled stop by E-Stop" (A05B-2600-J570) option (In case of R-30iA/R-30iA Mate, it is Stop
type set (Stop pattern C) (A05B-2500-J570)) is specified, the stop type of the following alarms becomes
Controlled stop but only in AUTO mode. In T1 or T2 mode, the stop type is Power-Off stop which is
the normal operation of the system.

Alarm Condition
SRVO-001 Operator panel E-stop Operator panel emergency stop is pressed.
SRVO-002 Teach pendant E-stop Teach pendant emergency stop is pressed.
SRVO-007 External emergency stops External emergency stop input (EES1-EES11, EES2-EES21) is
open.
SRVO-408 DCS SSO Ext Emergency Stop In DCS Safe I/O connect function, SSO[3] is OFF.
SRVO-409 DCS SSO Servo Disconnect In DCS Safe I/O connect function, SSO[4] is OFF.

Controlled stop is different from Power-Off stop as follows:


- In Controlled stop, the robot is stopped on the program path. This function is effective for a system
where the robot can interfere with other devices if it deviates from the program path.
- In Controlled stop, physical impact is less than Power-Off stop. This function is effective for
systems where the physical impact to the mechanical unit or EOAT (End Of Arm Tool) should be
minimized.
- The stopping distance and stopping time of Controlled stop is longer than the stopping distance and
stopping time of Power-Off stop, depending on the robot model and axis. Please refer to the
operator's manual of a particular robot model for the data of stopping distance and stopping time.

In case of R-30iA or R-30iA Mate, this function is available only in CE or RIA type hardware.

When this option is loaded, this function cannot be disabled.

The stop type of DCS Position and Speed Check functions is not affected by the loading of this option.

WARNING
The stopping distance and stopping time of Controlled stop are longer than the
stopping distance and stopping time of Power-Off stop. A risk assessment for
the whole robot system, which takes into consideration the increased stopping
distance and stopping time, is necessary when this option is loaded.

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B-83495EN/01 SAFETY PRECAUTIONS

8 WARNING LABEL
(1) Transportation label

Fig. 8 (a) Transportation label


Description
When transporting the robot, observe the instructions indicated on this label.

1) Use a crane with a load capacity of 500 kg or greater.


2) Use four slings with each load capacity of 980N (100 kgf) or greater.
3) Use four shackles with each load capacity of 784 N (80 kgf) or greater.

(2) Greasing label (if greasing kit A05B-1142-K021,A05B-1139-K022 is specified)

在将润滑脂装入注射器之前,
请揉搓软管使里面的润滑脂变软。
每向前推动柱塞2.5mm,
就会有1cc的润滑脂被推出来。
轴 量

供脂时

Fig. 8 (b) Greasing label

s-13
SAFETY PRECAUTIONS B-83495EN/01

Description
When using a grease kit, observe the instructions indicated on this label.

1) Before filling the cylinder with grease from tube, squeeze the tube to make the grease in it soft.
2) Pushing in the plunger by 2.5 mm causes a grease of 1 cc to be pushed out.

(3) Motion range and payload label


The following label is added if the CE specification is requested.

Fig 8 (c) Motion range and payload label

s-14
B-83495EN/01 PREFACE

PREFACE
This manual explains maintenance procedures for the mechanical units of the following robots:

Mechanical unit Maximum


Model name Remarks
specification No. load
FANUC Robot LR Mate 200iD A05B-1142-B201
FANUC Robot ARC Mate 50iD A05B-1142-B251
7kg
FANUC Robot LR Mate 200iD/7L A05B-1142-B301
FANUC Robot ARC Mate 50iD/7L A05B-1142-B351

NOTE
The following abbreviations are used herein.
STANDARD : LR Mate 200iD, ARC Mate 50iD
7L : LR Mate 200iD/7L, ARC Mate 50iD/7L

The label stating the mechanical unit specification number is affixed in the position shown below. Before
reading this manual, determine the specification number of the mechanical unit.

(1)

TYPE (2)
NO. (3) WEIGHT
DATE (4) (5) kg

Position of label indicating mechanical unit specification number


TABLE 1)
(1) (2) (3) (4) (5)
WEIGHT kg
CONTENTS - TYPE No. DATE
(Without controller)
FANUC Robot
A05B-1142-B201 25
LR Mate 200iD
FANUC Robot ARC PRODUCTION
A05B-1142-B251 SERIAL 25
Mate 50iD YEAR AND
LETTERS NO. IS
FANUC Robot MONTH ARE
A05B-1142-B301 PRINTED 27
LR Mate 200iD/7L PRINTED
FANUC Robot ARC
A05B-1142-B351 27
Mate 50iD/7L
Position of label indicating mechanical unit specification number

p-1
PREFACE B-83495EN/01

RELATED MANUALS
For the FANUC Robot series, the following manuals are available:

Safety handbook B-80687EN Intended readers :


All persons who use the FANUC Robot and All persons who use FANUC Robot, system designer
system designer must read and understand Topics :
thoroughly this handbook Safety items for robot system design, operation, maintenance
R-30iB Mate OPERATOR’S MANUAL Intended readers :
controller Basic Operation Operator, programmer, maintenance person, system designer
B-83284EN Topics :
Alarm Code List Robot functions, operations, programming, setup, interfaces, alarms
B-83284EN-1 Use :
Optional Function Robot operation, teaching, system design
B-83284EN-2

MAINTENANCE MANUAL Intended readers :


Standard : B-83525EN Maintenance person, system designer
Open Air : B-83555EN Topics :
Installation, connection to peripheral equipment, maintenance
Use :
Installation, start-up, connection, maintenance
Mechanical Operator’s manual Intended readers:
unit FANUC Robot System designer, Maintenance person
LR Mate 200iD Topics:
ARC Mate 50iD Installation, connection to controller, maintenance
Use:
B-83494EN Installation, start-up, connection, maintenance

p-2
B-83495EN/01 TABLE OF CONTENTS

TABLE OF CONTENTS
SAFETY PRECAUTIONS............................................................................s-1
PREFACE ....................................................................................................p-1
1 CHECKS AND MAINTENANCE ............................................................. 1
1.1 DAILY CHECKS ............................................................................................ 1
1.2 FIRST 1-MONTH (320 HOURS) CHECK ...................................................... 3
1.3 FIRST 3-MONTH (960 HOURS) CHECKS .................................................... 3
1.4 3-MONTH (960 HOURS) CHECKS ............................................................... 6
1.5 1-YEAR (3840 HOURS) CHECKS................................................................. 6
1.6 1.5-YEAR (5760 HOURS) CHECKS.............................................................. 6
1.7 4-YEAR (15360 HOURS) CHECKS............................................................... 6
1.8 MAINTENANCE............................................................................................. 7
2 PERIODIC MAINTENANCE .................................................................... 9
2.1 REPLACING THE BATTERIES
(1-YEAR PERIODIC INSPECTION IF BUILT-IN BATTERIES ARE
SPECIFIED)
(1.5-YEAR PERIODIC INSPECTION IF EXTERNAL BATTERIES ARE
SPECIFIED)................................................................................................... 9
2.2 REPLENISH THE GREASE OF THE DRIVE MECHANISM
(4 YEARS (15360 HOURS) CHECKS) ........................................................ 11
3 TROUBLESHOOTING .......................................................................... 13
3.1 OVERVIEW ................................................................................................. 13
3.2 FAILURES, CAUSES AND MEASURES ..................................................... 13
3.3 BACKLASH MEASUREMENT..................................................................... 19
4 REPLACING PARTS ............................................................................ 23
4.1 FIGURE OF DRIVE MECHANISM .............................................................. 24
4.2 REPLACING J1-AXIS MOTOR.................................................................... 26
4.3 REPLACING J1-AXIS REDUCER ............................................................... 28
4.4 REPLACING J2-AXIS MOTOR.................................................................... 32
4.5 REPLACING J2-AXIS REDUCER ............................................................... 35
4.6 REPLACING J3-AXIS MOTOR.................................................................... 38
4.7 REPLACING J3-AXIS REDUCER ............................................................... 40
4.8 REPLACING J4-AXIS MOTOR.................................................................... 45
4.9 REPLACING J4-AXIS REDUCER ............................................................... 47
4.10 REPLACING J5-AXIS MOTOR.................................................................... 51
4.11 REPLACING J5-AXIS REDUCER (Standard) ............................................. 52
4.12 REPLACING J5-AXIS REDUCER (7L) ........................................................ 56
4.13 REPLACING J6-AXIS MOTOR.................................................................... 61
4.14 REPLACING WRIST UNIT (Standard) ........................................................ 63
4.15 REPLACING WRIST UNIT (7L)................................................................... 65
4.16 REPLACING J6-AXIS REDUCER ............................................................... 67

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TABLE OF CONTENTS B-83495EN/01

4.17 REPLACING J3 BELT ................................................................................. 68


4.18 REPLACING J5/J6 BELT ............................................................................ 69
4.19 REPLACING SOLENOID VALVE ................................................................ 70
4.20 SEALANT APPLICATION............................................................................ 71
5 REPLACING CABLES .......................................................................... 73
5.1 CABLE WIRING........................................................................................... 74
5.2 CABLE FORMING ....................................................................................... 75
5.3 CABLE AND AIR TUBE REPLACEMENT ................................................... 76
5.3.1 Replacing Cable K101 and Air Tube (Connector panel to J2 base).......................76
5.3.2 Replacing Cable K106, K107, K108,K109 and Air Tube (J2 base to J3 housing) 81
5.3.3 Replacing Cable K102, K103, K104, K105, K109, K110, K111, K112, K113.....85
5.3.4 Replacing Cable K118............................................................................................85
5.3.5 Replacing Air Tube ................................................................................................87

6 ADJUSTMENTS.................................................................................... 92
6.1 ADJUSTING TENSION OF BELT................................................................ 92

APPENDIX
A SPARE PARTS LIST ............................................................................ 97
B CIRCUIT DIAGRAM, AIR PRESSURE DIAGRAM ............................. 101
C PERIODIC MAINTENANCE TABLE ................................................... 109
D MOUNTING BOLT TORQUE LIST ..................................................... 112
E OPTIONAL CONNECTOR WIRING PROCEDURE ............................ 113

c- 2
B-83495EN/01 1.CHECKS AND MAINTENANCE

1 CHECKS AND MAINTENANCE


Optimum performance of the robot can be maintained by performing the periodic maintenance procedures
presented in this chapter.
(See the APPENDIX A PERIODIC MAINTENANCE TABLE.)

NOTE
The periodic maintenance procedures described in this chapter assume that the
FANUC robot is used for up to 3840 hours a year. In case however the use of
the robot exceeds these 3840 hours/year, please adjust the given maintenance
frequencies accordingly. The ratio of actual operation time/year vs. the 3840
hours/year should be used for calculating the new (higher) frequencies. For
example, when using the robot 7680 hours a year, the maintenance frequency
should be doubled – i.e. the time interval should be divided by 2.

1.1 DAILY CHECKS


Clean each part, and visually check component parts for damage before daily system operation. Check the
following items as the occasion demands.

(1) Before turning on power


Item Check items Check points
1 Oil leak Check if there is any oil leak on sealed part of each joint parts.
If there is oil leak, clean it (Note 1)

NOTE
1 Oil leak may be attached (Slightly a loot oil stick) to outside of lip depend on the
movement condition or environment of the circumference. If this oil contents
change to a state of dew, it may fail depend on the movement.
You can prevent oil spot from falling down by wiping the oil contents which is
accumulated to under part of oil seal before operation.
2 Also, motors may become the high temperature and the internal pressure of
grease bath may rise by frequent repetition movement and use in the high
temperature environment.
In these cases, you can return internal pressure by releasing grease inlet just
after operation of robot. (When opening grease inlet, pay attention grease is not
scattered.)

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1.CHECKS AND MAINTENANCE B-83495EN/01

Fig. 1.1 (a) Check parts of oil leak

Item Check items Check points


1 When air control Air pressure Check air pressure using the pressure gauge on the air regulator as
set is provided. shown in Fig.1.1 (b). If it does not meet the specified pressure of
0.49MPa (5 kg/cm2), adjust it using the regulator pressure setting
handle.

2 Leakage from Check the joints, tubes, etc. for leaks.


hose Repair leaks, or replace parts, as required.
3 Drain Check drain and release it. When quantity of the drain is remarkable,
examine the setting of the air dryer to the air supply side.
4 When air purge kit Supply Check the supply pressure using the air purge kit shown in Fig.1.1 (c).
is provided. pressure If it does not meet the specified pressure of 10 KPa (0.1 kgf/cm2),
adjust it using the regulator pressure setting handle.
5 Dryer Check whether the color of the dew point checker is blue. When it is not
blue, identify the cause and replace the dryer. Maintenance for air
purge kit, refer to the operator’s manual attached kit.
6 Drain Check drain. When quantity of the drain is remarkable, examine the
setting of the air dryer to the air supply side.

Pressure
Adjusting Knob 2-6.5×16.5
Length round hole

Rc1/4
AIR OUTLET

Pressure gauge

Rc1/4
AIR SUPPLY

Fig. 1.1 (b) Air control set

-2-
B-83495EN/01 1.CHECKS AND MAINTENANCE

Dew point checker

2-7x11
Length round hole
Air outlet
(O6 Air tube)

Pressure gauge
Pneumatic
air outlet

Air inlet
(O10 air tube)
Pressure adjustment knob
O O
S S

Dryer unit

Fig.1.1 (c) Air purge kit (option)

(2) After automatic operation


Item Check items Check points
1 Vibration, abnormal noises, and Check whether the robot moves along and about the axes smoothly
motor heating without unusual vibration or sounds. Also check whether the
temperature of the motors are excessively high.
2 Changing repeatability Check to see that the stop positions of the robot have not deviated
from the previous stop positions.
3 Peripheral devices for proper Check whether the peripheral devices operate properly according to
operation commands
from the robot.
4 Brakes for each axis Check that the end effector drops within 2 mm when the power is cut.

1.2 FIRST 1-MONTH (320 HOURS) CHECK


Check the following items at the first month(320 hours ) inspection, then every 3 months (960 hours)
thereafter. (See Section 1.4.)

First 1-month check


Item Check items Check points
1 Ventilation portion of controller If the ventilation portion of the controller is dusty, turn off power and
clean the unit.

1.3 FIRST 3-MONTH (960 HOURS) CHECKS


Check the following items at the first quarterly inspection, then every year (3840 hours) thereafter. (See
Section 1.5.)

Item Check items Check points


1 Connector used in mechanical unit Check the looseness of connector of connector panel. (NOTE 1)
Retightening external main bolts Retighten the end-effecter mounting bolts and external main
2
bolts.(NOTE 2)

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1.CHECKS AND MAINTENANCE B-83495EN/01

Item Check items Check points


Check the mechanical stopper Check the spring ping of J1/J3-axis mechanical stopper is not
3
transformed, if it is transformed, replace it to new one. (NOTE 3)
Cleaning and checking each part Clean each part (remove chips, etc.) and check component parts for
4
cracks and flaws. (NOTE 4)
Check the end effector (hand)
5 cable and external battery cable Confirm whether there is any damage to the cable.
(option)
Check the robot cable, teach
Check whether the cable connected to the teach pendant and robot is
6 pendant cable and robot
unevenly twisted.
connecting cable

(NOTE 1) Inspection points of the connectors

• Robot connection cables, earth terminal and user cables

Check items
• Circular connector: Check the connector for looseness by turning it manually.
• Square connector: Check the connector for disengagement of its lever.
• Earth terminal: Check the terminal for looseness by turning.

Fig. 1.3 (a) Check items of connector

(NOTE 2) Points to be retightened


- The end effecter mounting bolts, robot installation bolts, and bolts to be removed for inspection need
to be retightened.
- The bolts exposed to the outside of the robot need to be retightened.
For the tightening torque, see the recommended bolt tightening torque shown in the Appendix.
A loose prevention agent (adhesive) is applied to some bolts. If the bolts are tightened with greater
than the recommended torque, the loose prevention agent may be removed. So, follow the
recommended tightening torque when retightening them.

(NOTE 3) Check of mechanical stopper and adjustable mechanical stopper.


- Check the spring pin of J1/J3-axis mechanical stopper is not transformed, if it is transformed, replace
it to new one.

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B-83495EN/01 1.CHECKS AND MAINTENANCE

J1-axis mechanical stopper


Spec.:
spring pin:A6-PS-8X20S

J3-axis mechanical stopper


Spec.:
J3 stopper:A290-7142-X427
spring pin:A6-PS-8X20S Section A-A
Note: When assembling J3 stopper to
spring pin, apply cemedine super X
(clear).

A A

Fig. 1.3 (b) Check of mechanical stopper


(NOTE 4) Cleaning

- Necessary cleaning points, dust on the flat part, spatter depositions


Clean sediments periodically.
In particular, clean the following points carefully.

Vicinity of the wrist axis and oil seal


→If chippings or spatters are attached to the oil seal, an oil leak may be caused.
- Check if the vicinity of the necessary inspection points, wrist part, and J3 arm significantly wears
due to rubbing against the welding cable or hand cable.
- Check if there is a trace of a collision around the hand.
- Check the reducer or grease bath for an oil leak.
→ If oil can be found a day after wiping oil, an oil leak may be caused.

Fig. 1.3 (c) Cleaning part

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1.CHECKS AND MAINTENANCE B-83495EN/01

1.4 3-MONTH (960 HOURS) CHECKS


Check the following items in the cycle that is shorter between every three months and 960 hours of
operating. Additional inspection areas and times should be added to the table according to the robot's
working conditions, environment, etc.

Item Check items Check points


1 Ventilation portion of controller If the ventilation portion of the controller is dusty, tum off
power and clean the unit.

1.5 1-YEAR (3840 HOURS) CHECKS


Check the following items in the cycle that is shorter between every year and 3840 hours of operating.

Item Check itmes Check points


1 Connector used in mechanical unit (See Section 1.3)
2 Retightening external main bolts (See Section 1.3)
3 Check the mechanical stopper (See Section 1.3)
4 Cleaning and checking each part (See Section 1.3)
5 Check the end effector (hand) cable and (See Section 1.3)
external battery cable (option)
6 Replacing battery Replace battery in the mechanical unit. (See Section 2.1)
7 Check the robot cable, teach pendant cable (See Section 1.3)
and robot connecting cable

1.6 1.5-YEAR (5760 HOURS) CHECKS


Check the following items in the cycle that is shorter between every 1.5 years and 5760 hours of
operating.

Item Check items Check points


1 Replacing battery Replace the batteries in the mechanical unit.
(if external batteries are specified) (See Section 2.1.)

1.7 4-YEAR (15360 HOURS) CHECKS


Check the following items about once in the cycle that is shorter between every four years an 15360
hours.
Item Check itmes Check points
1 Greasing of reducers of each-axis Supply grease with each axis reducer (See Section 2.2)

2 Replace the mechanical unit cable Please refer to Chapter 5 about replacing method.

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B-83495EN/01 1.CHECKS AND MAINTENANCE

1.8 MAINTENANCE
The following tools and instruments are required for the maintenance procedures contained in this
manual.

(a) Measuring instruments

Instrument Specifications Vendor Manufacturer model No. Application


DOCTOR TENSION Adjustment of belt
Tension meter A97L-0218-0700 Mitsuboshi Belting Ltd.
TYPE-Ⅲ tension

Instruments Accuracy/Tolerance Applications


Dial gauge accuracy 1/100 mm Measurement of positioning and backlash
Slide calipers 150 mm

(b) Tools

・Torque wrench
・Cross tip (+) screwdrivers Large, medium, and small sizes
・Flat tip (–) screwdrivers Large, medium, and small sizes
・Nut driver Width across flats 7 (for grease nipple)
・Hexagon wrench set Width across flats 2.5, 3, 4 (for replacing parts)
・Monkey wrench Middle, little
・Pincers
・Needle nose pliers
・Nippers
・Gear puller
・Separator
・Offset wrench
・Pliers for C–retaining ring
・LOCTITE 243,263,518,638
・Grease applying kit
A05B-1142-K021
(It is options that grease (80g) for the grease greasing
with the injection syringe and the tube makes a set.)
・ grease in tube (80g)
A05B-1139-K022

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1.CHECKS AND MAINTENANCE B-83495EN/01

O5

Fig 1.8 example of cylinder

-8-
B-83495EN/01 2.PERIODIC MAINTENANCE

2 PERIODIC MAINTENANCE
2.1 REPLACING THE BATTERIES
(1-YEAR PERIODIC INSPECTION IF BUILT-IN BATTERIES
ARE SPECIFIED)
(1.5-YEAR PERIODIC INSPECTION IF EXTERNAL
BATTERIES ARE SPECIFIED)
The position data of each axis is preserved by the backup batteries. If built-in batteries are in use,
replace them every year. If external batteries are in use, replace them every year and a half. Also use
the following procedure to replace when the backup battery voltage drop alarm occurs.

Procedure of replacing the battery (if built-in batteries are specified)


1 Keep the power on. Press the EMERGENCY STOP button to prohibit the robot motion.

CAUTION
Be sure to keep the power supply turned on. Replacing the batteries with the
power supply turned off causes all current position data to be lost. Therefore,
mastering will be required again.

2 Remove the battery case cap.( Fig.2.1 (a)) If it cannot be removed, tap it to side direction with a
plastic hammer.
3 Loosen the plate screw and take out the lid of the battery box and replace battery. Battery can be
taken out by pulling the stick which is center of the battery box.
4 Assemble them in the reversed sequence. Pay attention to the direction of batteries.
It is necessary to exchange gasket.

C battery (4 pcs)
FANUC spec.:A98L-0031-0027

The battery can be taken out


by pulling this stick
Plate screw M4X12(2 pcs)
Lid of battery box
Gasket
A290-7139-X253

Bolt with plate processing


hex-head hole 
M4X20(4 pcs)

Battery box cover

Fig. 2.1 (a) Replacing the battery (if built-in batteries are specified)

-9-
2.PERIODIC MAINTENANCE B-83495EN/01

Procedure of replacing the battery (if external batteries are specified)


1 During battery replacement, hold down the emergency stop button for the sake of safety.

CAUTION
Be sure to keep the power supply turned on. Replacing the batteries with the
power supply turned off causes all current position data to be lost. Therefore,
mastering will be required again.

2 Uncap the battery case (Fig. 2.1 (b)).


3 Take out the old batteries from the battery case.
4 Insert new batteries into the battery case while observing their correct orientation.
5 Cap the battery case.

External battery box

Battery cable
Diameter About O5mm
(Max O5.5mm)

Case cap
Battery case Spec. of battery :A98L-0031-0005
(D battery alkali 4pcs)

Fig. 2.1 (b) Replacing the battery (if external batteries are specified)

Fig .2.1 (c) shows the external size of external battery box.
When the battery box needs to be built into the controller or other internal units, refer to the outer
dimensions shown in Fig.2.1 (c)
The battery box can be fixed by using M4 flat–head screws. (The bolts do not come with the system.)
A maximum of six terminals can be attached to the backplane of the battery box.

- 10 -
B-83495EN/01 2.PERIODIC MAINTENANCE

Fig. 2.1 (c) Outer dimensions of the battery box

2.2 REPLENISH THE GREASE OF THE DRIVE MECHANISM


(4 YEARS (15360 HOURS) CHECKS)
Supply the grease of the reducers every four years or 15360 hours by using the following procedures.
For the grease name and quantity, see the table 2.2 (a).

Table 2.2 (a) Grease for 4-year (15360 hours) periodical greasing
Greasing points Greasing amount Specified grease
J1-axis reducer 2.7g(3ml)
J2-axis reducer 2.7g(3ml)
J3-axis reducer 1.8g(2ml) Harmonic grease 4BNo.2
J4-axis reducer 1.8g(2ml) Spec: A98L-0040-0230
J5-axis reducer 1.8g(2ml)
J6-axis reducer 1.8g(2ml)

For grease replacement, use the arbitrary postures.

CAUTION
The following maintenance kits are prepared for the grease greasing.
-Greasing kit: A05B-1142-K021
(This a set of greasing syringe and grease in tube. (80g))
-Grease in tube: A05B-1139-K022 (grease in tube. (80g))

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2.PERIODIC MAINTENANCE B-83495EN/01

NOTE
Failure to correct greasing, the internal pressure of the grease bath may
suddenly increase, may cause damage to the seal performance, which would in
turn lead to grease leakage and abnormal operation. When performing greasing,
therefore, observe the following cautions.
1 Use grease only of the specified type. Grease of a type other than that specified
may damage the reducer or lead to other problems. Do no use Harmonic grease
SK-3
2 To prevent accidents caused by slipping, completely remove any excess grease
from the floor or robot.
3 Please fill a necessary amount to the injection syringe after softening grease in
the tube massaging it by the hand when you use the grease greasing kit. Please
install the nozzle in the point of the injection syringe. Please remove the nozzle
and do the cap when you do not use the injection syringe.

1 Turn off the controller power.


2 Remove the seal bolts of the grease inlet .
3 Supply a regulated amount of grease by using the injection syringe. Please note that grease might
come out immediately after the grease has been supplied, or during the greasing. Even in this case,
please do not supply grease beyond the regulated amount specified.
4 Replace seal bolts by new one. When reusing the seal bolt, be sure to seal it with seal tape.

J6-axis reducer grease inlet


Seal bolt M4X6
J5-axis reducer grease inlet
Seal bolt M4X6

J4-axis reducer grease inlet


Seal bolt M4X6

J3-axis reducer grease inlet


Seal bolt M4X6

J2-axis reducer grease inlet J1-axis reducer grease inlet


Seal bolt M4X6 Seal bolt M8X10

Fig.2.2 Applying grease of the reducer

Table 2.2 (b) Spec. of seal bolts


Parts name Specifications Remarks
Seal bolt A97L-0318-0405#040606EN J2 - J6-axis grease inlet 5 pcs/1 robot
Seal bolt A97L-0318-0406#081010EN J1-axis grease inlet

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B-83495EN/01 3.TROUBLESHOOTING

3 TROUBLESHOOTING
3.1 OVERVIEW
The cause of a failure in the mechanical unit may be difficult to localize, because failures can arise from
many interrelated factors. If you fail to take the correct measures, the failure may be aggravated. So, it is
necessary to analyze the symptoms of the failure precisely so that the true cause can be found.

3.2 FAILURES, CAUSES AND MEASURES


Table 3.2 lists the major failures, causes and measures that may occur in the mechanical unit and their
probable causes. If you cannot pinpoint a failure cause or which measures to apply, contact your local
FANUC representative.

Table 3.2 Failures, causes and measures


Symptom Description Cause Measure
Vibration -The J1 base lifts off the floor [J1 base fastening] -If a bolt is loose, apply
Noise plate as the robot operates. -It is likely that the robot J1 base is LOCTITE and tighten it to the
-There is a gap bfetween the not securely fastened to the floor appropriate torque.
J1 base and floor plate. plate. -Adjust the floor plate surface
-A J1 base retaining bolt is -Probable causes are a loose bolt, flatness to within the specified
loose. an insuffcient degree of surface tolenrance.
flatness, or foreign material caught -If there is any foreign
between the floor plate and floor material between the J1 base
plate. and floor plate, remove it.
-If the robot is not securely fastened
to the floor plate, the J1 base lifts
the floor plate as the robot operates,
allowing the base and floor plates to
strike each other wihich, in turn,
leads to vibration.
-Apply epoxy to the floor [Rack or floor] -Reinforce the rack or floor to
surface and re-install the -It is likely that the rack or floor is not make it more rigid.
plate. suffciently rigid. -If it is impossible to reinforce
-If the rack or floor is not sufficiently the rack or floor, modify the
rigid, reaction from the robot robot control program; doing
deforms the rack or floor, leading to so might reduce the amount
vibration. of vibration.
-Vibration becomes more [Overload] -Check the maximum load
serious when the robot -It is likely that the load on the robot that the robot can handle
adopts a specific posture. is greater than the maximum rating. once more. If the robot is
-If the operating speed of the -It is likely that the robot control found to be overloaded,
robot is reduced, vibration program is too demanding for the reduce the load, or modify the
stops. robot hardware. robot control program.
-Vibration is most noticeable -It is likely that the ACCELERATION -Vibration in a specific portion
when the robot is value is excessive. can be reduced by modifying
accelerating. the robot control program
-Vibration occurs when two while slowig the robot and
or more axes operate at the reducing its acceleration (to
same time. minimize the influenece on
the entire cycle time).

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3.TROUBLESHOOTING B-83495EN/01

Symptom Description Cause Measure


Vibration -Vibration was first noticed [Broken gear, bearing, or reducer] -Operate one axis at a time to
Noise after the robot collided with - It is likely that collision or overload determine which axis is
(Continued) an object or the robot was applied an excessive force on the vibrating.
overloaded for a long period. drive mechanism, thus damaging -Remove the motor, and
-The grease of the vibrating the geartooth surface or rolling replace the gear , the bearing,
axis has not been surface of a bearing, or reducer. and the reducer. For the
replenished for a long - It is likely that prolonged use of the spec. of parts and the method
period. robot while overloaded caused of replacement, contact
fretting of the gear tooth surface or FANUC.
rolling surface of a bearing, or -Using the robot within its
reducer due to resulting metal maximum rating prevents
fatigue. problems with the drive
- It is likely that foreign material mechanism.
caught in a gear, bearing, or within a -Regularly greasing with a
reducer caused damage on the gear specified type can help
tooth surface or rolling surface of the prevent problems.
bearing, or reducer.
- It is likely that, because the grease
has not been replenished for a long
period, fretting occurred on the gear
tooth surface or rolling surface of a
bearing, or reducer due to metal
fatigue.

These factors all generate cyclic


vibration and noise.

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B-83495EN/01 3.TROUBLESHOOTING

Symptom Description Cause Measure


Vibration -The cause of problem [Controller, cable, and motor] -Refer to the Controller
Noise cannot be identified from -If a failure occurs in a controller Maintenance Manual for
(Continued) examination of the floor, circuit, preventing control commands troubleshooting related to the
rack, or mechanical section. from being supplied to the motor controller and amplifier.
normally, or preventing motor -Replace the Pulsecoder for
information from being sent to the the motor of the axis that is
controller normally, vibration might vibrating, and check whether
occur. the vibration still occurs.
-If the Pulsecoder develops a fault, -Also, replace the motor of
vibration might occur because the axis that is vibrating, and
information about the motor position check whether vibration still
cannot be transferred to the occurs. For the method of
controller accurately. replacement, contact FANUC.
-If the motor becomes defective, -Check that the robot is
vibration might occur because the supplied with the rated
motor cannot deliver its rated voltage.
performance. -Check whether the sheath of
-If a power line in a movable cable of the power cord is damaged. If
the mechanical section has an so, replace the power cord,
intermittent break, vibration might and check whether vibration
occur because the motor cannot still occurs.
accurately respond to commands. -Check whether the sheath of
-If a Pulsecoder wire in a movable the cable connecting the
part of the mechanical section has mechanical section
an intermittent break, vibration might and controller is damaged. If
occur because commands cannot so, replace the connection
be sent to the motor accurately. cable, and check whether
-If a connection cable between them vibration still occurs.
has an intermittent break, vibration -If vibration occurs only when
might occur. the robot assumes a specific
-If the power cable between them posture, it is likely that a cable
has an intermittent break, vibration in the mechanical unit is
might occur. broken.
-If the power source voltage drops -Shake the movable part
below the rating, vibration might cable while the robot is at
occur. rest, and check whether an
-If a robot control parameter is set to alarm occurs. If an alarm or
an invalid value, vibration might any other abnormal condition
occur. occurs, replace the
mechanical unit cable.
-Check that the robot control
parameter is set to a valid
value. If it is set to an invalid
value, correct it. Contact
FANUC for further information
if necessary.

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3.TROUBLESHOOTING B-83495EN/01

Symptom Description Cause Measure


Vibration -There is some relationship [Noise from a nearby machine] -Connect the grounding wire
Noise between the vibration of the -If the robot is not grounded firmly to ensure a reliable
(Continued) robot and the operation of a properly, electrical noise is induced ground potential and prevent
machine near the robot. on the grounding wire, preventing extraneous electrical noise.
commands from being transferred
accurately, thus leading to vibration.
-If the robot is grounded at an
unsuitable point, its grounding
potential becomes unstable, and
noise is likely to be induced on the
grounding line, thus leading to
vibration.
Rattling -While the robot is not [Mechanical section coupling bolt] -Check that the following bolts
supplied with power, pushing -It is likely that overloading or a for each axis are tight. If any
it with the hand causes part collision has loosened a mounting of these bolts is loose, apply
of the mechanical unit to bolt in the robot mechanical section. LOCTITE and tighten it to the
wobble. appropriate torque.
-There is a gap on the -Motor retaining bolt
mounting face of the -Reducer retaining bolt
mechanical unit. -Base retaining bolt
-Arm retaining bolt
-Casting retaining bolt
-End effecter retaining bolt

-Backlash is greater than the [Increase in backlash] -Operate one axis at a time to
tolerance stated in the -It is likely that excessive force determine which axis has the
applicable maintenance applied to the drive mechanism, due increased backlash.
manual. (See Section 3.3.) to a collision or overloading, has -Remove the motor, and
broken a gear or the inside of the check whether any of its
reducer, resulting in an increase in gears are broken. If any gear
the amount of backlash. is broken, replace it.
-It is likely that prolonged use has -Check whether any other
caused the tooth surfaces of a gear gear of the drive mechanism
and the inside of the reducer to wear is damage. If there is no
out, resulting in an increase in the damage gear, replace the
amount of backlash. reducer.
-It is likely that prolonged use -If the reducer is broken, or if
without changing the grease has a gear tooth is missing,
caused the tooth surfaces of a gear replace the relevant
and the inside of the reducer to wear component. Also, remove all
out, resulting in an increase in the the grease from the gear box
amount of backlash. and wash the inside of the
gear box.
-After replacing the gear or
reducer, add an appropriate
amount of grease.
-Using the robot within its
maximum rating prevents
problems with the drive
mechanism.
-Regularly applying the
grease with a specified type
can help prevent problems.

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B-83495EN/01 3.TROUBLESHOOTING

Symptom Description Cause Measure


Motor -The ambient temperature of [Ambient temperature] -The teach pendant can be
overheating the installation location -It is likely that a rise in the ambient used to monitor the average
increases, causing temperature prevented the motor current. Check the average
the motor to overheat. from releasing heat efficiently, thus current when the robot control
-After the robot control leading to overheating. program is running. The
program or the load was [Operating condition] allowable average current is
changed, the motor -It is likely that the robot was specified for the robot
overheated. operated with the maximum average according to its ambient
current temperature. Contact FANUC
exceeded. for further information.
-Relaxing the robot control
program and conditions can
reduce the average current,
thus preventing overheating.
-Reducing the ambient
temperature is the most
effective means of preventing
overheating.
-Having the surroundings of
the robot well ventilated
enables the robot to release
heat efficiently, thus
preventing overheating. Using
a fan to direct air at the motor
is also effective.
-If there is a source of heat
near the motor, it is advisable
to install shielding to protect
the motor from heat radiation.
-After a control parameter [Parameter] -Input an appropriate
was changed, the motor -If data input for a workpiece is parameter as described in
overheated. invalid, the robot cannot be CONTROLLER
accelerated or decelerated normally, OPERATOR’S MANUAL.
so the average current increases,
leading to overheating.
-Symptom other than stated [Mechanical section problems] -Repair the mechanical unit
above -It is likely that problems occurred in while referring to the above
the mechanical unit drive descriptions of vibration,
mechanism, thus placing an noise, and rattling.
excessive load on the motor. -Check that, when the servo
[Motor problems] system is energized, the
-It is likely that a failure of the motor brake is released.
brake resulted in the motor running If the brake remains applied
with the brake applied, thus placing to the motor all the time,
an excessive load on the motor. replace the motor.
-It is likely that a failure of the motor -If the average current falls
prevented it from delivering its rated after the motor is replaced, it
performance, thus causing an indicates that the first motor
excessive current to flow through the was faulty.
motor.

- 17 -
3.TROUBLESHOOTING B-83495EN/01

Symptom Description Cause Measure


Grease -Grease is leaking from the [Poor sealing] -If a crack develops in the
leakage mechanical unit. -Probable causes are a crack in the casting, sealant can be used
casting, a broken O-ring, a damaged as a quick-fix to prevent
oil seal, or a loose seal bolt. further grease leakage.
-A crack in a casting can occur due However, the component
to excessive force that might be should be replaced as soon
caused in collision. as possible, because the
-An O-ring can be damaged if it is crack might extend.
trapped or cut during disassembling -O-rings are used in the
or re-assembling. locations listed below.
-An oil seal might be damaged if -Motor coupling section
extraneous dust scratches the lip of -Reducer coupling section
the oil seal. -Wrist coupling section
-A loose seal bolt might allow grease -J3 arm coupling section
to leak along the threads. -Inside the wrist
-Oil seals are used in the
locations stated below.
-Inside the reducer
-Inside the wrist
-Seal bolts are used in the
locations stated below.
-Grease drain inlet and
outlet
Dropping axis -An axis drops because the [Brake drive relay and motor] -Check whether the brake
brake does not function. -It is likely that brake drive relay drive relay contacts are stuck
-An axis drops gradually contacts are stuck to each other to to each other. If they are
when it should be at rest. keep the brake current flowing, thus found to be stuck, replace the
preventing the brake from operating relay.
when the motor is deenergized. -If the brake shoe is worn out,
-It is likely that the brake shoe has if the brake main body is
worn out or the brake main body is damaged, or if oil or grease
damaged, preventing the brake from has entered the motor,
operating efficiently. replace the motor.
-It is likely that oil or grease has
entered the motor, causing the
brake to slip.
Displacement -The robot operates at a [Mechanical section problems] -If the repeatability is
point other than the taught -If the repeatability is unstable, unstable, repair the
position. probable causes are a failure in the mechanical section by
-The repeatability is not drive mechanism or a loose bolt. referring to the above
within the tolerance. -If the repeatability becomes stable it descriptions of vibration,
is likely that a collision imposed an noise, and rattling.
excessive load, leading to slipping -If the repeatability is stable,
on the base surface or the mating correct the taught program.
surface of an arm or reducer. Variation will not occur unless
-It is likely that the Pulsecoder is another collision occurs.
abnormal. -If the Pulsecoder is
abnormal, replace the motor
or the Pulsecoder.
-Displacement occurs only in [Peripheral unit displacement] -Correct the setting of the
a specific peripheral unit. -It is likely that an external force was peripheral unit position.
applied to the peripheral unit, thus -Correct the taught program.
shifting its position relative to the
robot.

- 18 -
B-83495EN/01 3.TROUBLESHOOTING

Symptom Description Cause Measure


Displacement -Displacement occurred after [Parameter] -Re-enter the previous
(Continued) a parameter was changed. -It is likely that the mastering data mastering data, which is
was rewritten in such a way that known to be correct.
the robot origin was shifted. -If correct mastering data is
unavailable, perform
mastering again.
BZAL alarm -BZAL is displayed on the - It is likely that the voltage of the -Replace the battery.
occured controller screen memory backup battery is low. -Replace the cable.
- It is likely that the Pulsecoder cable
is defected.

3.3 BACKLASH MEASUREMENT


Measurement method
1 Maintain the robot in a specified posture. (See Table 3.3 (a).)
2 Apply positive and negative loads to each axis as shown in Fig.3.3 (a).
3 Remove the loads and measure the displacement.

Measure backlash by applying positive and negative loads to each axis three times. Average the
values measured in the last two measurements for each axis, and use the averages as a measured
backlash for the respective axes.

Stop position
0

+3kgf

Firtst step
-3kgf (Do not measure)

+3kgf
0kgf Second step
L1
-3kgf (B2 =L1+ L2)
0kgf
L2
+3kgf
0kgf Third step
L3 (B3=L3+ L4)
-3kgf
0kg
L4

Fig. 3.3 (a) Backlash measurement method

Backlash B is calculated using the following expression:


B2 + B3
B=
2

- 19 -
3.TROUBLESHOOTING B-83495EN/01

Table 3.3 (a) Backlash measurement posture, position and permissible value
Measurement
J1-axis J2-axis J3-axis J4-axis J5-axis J6-axis Measurement position
axis
J1-axis Arbitrary 90° 0° 0° 0° 90° Rotation center of J5-axis
Rotation center of J3-axis
J2-axis Arbitrary 0° 90° 0° 0° 0°
of J2 arm
J3-axis Arbitrary 90° -90° 90° 0° 180° Rotation center of J5-axis
100mm from rotation
J4-axis Arbitrary 0° 90° 0° -90° 90°
center of J4-axis
180mm from rotation
J5-axis Arbitrary 90° 0° 0° -90° 0° or 180°
center of J5-axis
100mm from rotation
J6-axis Arbitrary 90° 0° 0° -90° 90° or -90°
center of J6-axis

Table 3.3 (b) Distance at axis and measurement position and permissible value for backlash
Measured Distance at axis and measurement position (mm) Permissible value (mm)
axis Standard 7L Standard 7L
J1-axis 715 910 0.41 0.52
J2-axis 330 440 0.19 0.25
J3-axis 335 420 0.20 0.25
J4-axis 100 0.16
J5-axis 180 0.18
J6-axis 100 0.15

NOTE
When measuring backlash under circumstances where the distance between the
rotation center and the dial indicator is different from those in the above table,
make displacement conversions according to the table.

100

Loading position

715 (Standard)
910 (7L) Measurement position
(J5-axis rotation center)
Fig.3.3 (b) Backlash measurement position of J1-axis

- 20 -
B-83495EN/01 3.TROUBLESHOOTING

Loading
position
330 (Standard)

Measurement
440 (7L)

position

Fig.3.3 (c) Backlash measurement position of J2-axis


335 (Standard)
420 (7L)

Measurement
position
100

Loading position
Fig.3.3 (d) Backlash measurement position of J3-axis

- 21 -
3.TROUBLESHOOTING B-83495EN/01

100
Loading position

Measurement
position

Fig.3.3 (e) Backlash measurement position of J4-axis

180
100

Measurement position
Loading position
Fig.3.3 (f) Backlash measurement position of J5-axis

Measurement
position
100

Loading position
Fig.3.3 (g) Backlash measurement position of J6-axis

- 22 -
B-83495EN/01 4.REPLACING PARTS

4 REPLACING PARTS
• When replacing a part, subsequent adjustment is required.
• When removing or mounting a motor, apply force in the direction of the shaft only. If excessive
force is applied in any other direction, the motor and/or reducer may be damaged.
• If a motor and associated parts to be assembled incur a phase mismatch, assembly might prove
impossible. Carefully check the state of the parts before removing them.
• Assemble a new O–ring and gasket for seal securing after you exchange parts for spec of seal.

CAUTION
Some gasket must not be reused. To maintain dust and drip preventive effects,
replace those old gasket with new ones and then perform assembly.

• To secure the performance of the seal, replace seal bolt to new one after replacing parts as much as
possible. If preparing it is impossible, peel off the sealant, spread LOCTITE on the internal thread,
and recycle.

NOTE
When applying LOCTITE to the important bolt tightening points, make sure that it is
applied to the entire longitudinal portion in the engaging section of the female threads. If it
is applied to the male threads, the bolts may be loosened because sufficient adhesion
cannot be obtained. Remove the dust within the bolts and tapped holes and wipe oil off
the engaging section. Make sure that there is no solvent in the tapped holes. Be sure to
wipe the excess LOCTITE after tightening bolt.

• When tightening a bolt, always observe the tightening torque, if specified those bolts for which no
tightening torque is specified must be tightened according to the table of APPENDIX.
• Assemble the reducer to the vertical direction as much as possible when you assemble it.
• When installing bolt to reducer, make the applying order a corner and tighten uniformly.
• When applying LOCTITE 518 to reducer, pay attention LOCTITE doesn’t enter inside the reducer.
• Spread it after softening grease mixing it when you do not softly spread grease easily.

- 23 -
4.REPLACING PARTS B-83495EN/01

4.1 FIGURE OF DRIVE MECHANISM


The drive mechanisms of each axis are shown in the Fig.4.1 (a) to (e).

J2 axis base

Pipe

J1 axis reducer
(Hollow shaft)

Input gear

Motor (M1)
for J1 axis

J1 base

Fig. 4.1 (a) Drive mechanism of J1-axis

Motor (M2)
for J2 axis J2 arm

J2 axis reducer

J2 base

Fig. 4.1 (b) Drive mechanism of J2-axis

- 24 -
B-83495EN/01 4.REPLACING PARTS
J3 axis reducer

J3 housing

J3 axis output pully

Belt
J2 arm

Motor (M3)
for J3 axis

J3 axis input pully

Fig. 4.1 (c) Drive mechanism of J3-axis

J4 axis reducer
(Hollow shaft) J3 arm

J3 housing

Pipe
Motor (M4)
for J4 axis
J4 axis input gear
Fig. 4.1 (d) Drive mechanism of J4-axis

- 25 -
4.REPLACING PARTS B-83495EN/01

J5 axis output pully

J6 axis housing
J5 axis input pully J5 axis reducer
Belt
J6 axis reducer
Motor (M5)
for J5 axis

J3 axis arm
J6 axis output gear
Belt
Motor (M6) J6 axis input gear
for J6 axis J6 axis output pully

J6 axis input pully


Fig. 4.1 (e) Drive mechanism of J5/J6-axis

4.2 REPLACING J1-AXIS MOTOR


Replacing procedure
1 Turn off the controller power. Then remove robot from floor plate.
2 Make it to posture in which the motor (5) can be removed.
3 Remove bolts (1) and remove the cover B (2).
4 Remove cable K101 from motor (5).
5 Cut the nylon band and remove the heat exchange plate.
6 Remove bolt (4) and motor (5). At this time, note that grease may go out.
7 Wipe the grease of the gear (11) off. At this time, pay attention not to damage the tooth side.
8 Remove O ring (10) and seal bolt (13), and remove washer plate (12), gear (11), holder (8), O-ring
(7) and key (6) sequentially.
9 Attach the new sheet (14) on the motor (5).
10 Assemble it applying the procedure in the reversed sequence. Exchanging Motor and O-ring for the
new article. At this time, pay attention to the following.
• When motor is attached, confirm the thing that the oil seal (9) is at the position, and note that
the lip cannot be turned over.
• Spread grease on surroundings about the gear.
• Apply LOCTITE 243 on the key.
• Be careful not to drop the gasket (3).
• Be sure to use heat resistance grade nylon band for mounting of the heat exchange plate.
11 Perform single axis mastering referring to Section 8.5 of operator’s manual.

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B-83495EN/01 4.REPLACING PARTS

3 2 1

8 5 4
10 7
12 11 6
13

Fig. 4.2 (a) Replacing J1-axis motor

Name Specifications Q’ty LOCTITE Torque N-m (kgf-cm)


1 BOLT A97L-0218-0496#M4X10BC 9 2.0Nm (20kgfcm)
2 COVER B A290-7142-X204 1
3 GASKET A290-7142-X205 1
4 BOLT A6-BA-5X20 3 5.6Nm (57kgfcm)
5 MOTOR A06B-0116-B855#0048 1
6 KEY A97L-0118-0402#3X3X12BN 1 LT243
7 O RING A98L-0001-0347#S46 1
8 HOLDER A290-7139-X221 1
9 OIL SEAL A98L-0040-0223#01001805 1
10 O RING A98L-0001-0347#S46 1
A290-7142-X202 (*1)
11 GEAR 1
A290-7142-X248 (*2)
12 WASHER PLATE A290-7142-X203 1
13 SEAL BOLT A97L-0218-0423#030606 3 1.3Nm (13kgfcm)
14 SHEET A290-7142-X228 1
(*1) LR Mate 200iD. ARC Mate 50iD
(*2) LR Mate 200iD/7L. ARC Mate 50iD/7L

14
Fig. 4.2 (b) Attachment of the sheet on the J1-axis motor
- 27 -
4.REPLACING PARTS B-83495EN/01

4.3 REPLACING J1-AXIS REDUCER


Replacing procedure
1 Record the Quick Master Reference Position referring to Section 8.4 of operator’s manual. ( It is set
in 0° for all axes when robot is shipped.)
2 Turn off the controller power.
3 Remove cover B and J1 motor referring to Section 4.2 (It is not necessary to remove the gear.)
4 Remove plated bolt (15), And remove J2 base cover (16).
5 Remove the connector that relays cable K101 and cable K102, K103, K104, K105, K106,
K107,K108 and K109 referring to Fig.5.2 in Chapter 5.
6 Pull out cable K101 to the J1 base side. At this time, pull out the cable after it pushes into the pipe
on the tip of the part of the relayed connector and it passes it. Do not pull it out forcibly with the
relayed connector caught.
7 Remove bolt (4), (5) and remove J1 base (16) by using removal tap. At this time, pay attention that
there is a possibility that grease goes out. (Refer to Fig.4.3 (d))
8 Wipe the grease of the wave generator (8) off. At this time, do not damage the tooth side.
9 Remove bolt (10) and reducer (11).
10 Keep the horizontal and install a new main body of the reducer in J2 base. At this time, be sure to
put O-ring (14) after it exchanges it for the new article.
11 Fill grease to the reducer. Grease in inside of reducer, gear and bearing of wave generator. (Refer to
Fig.4.3 (e).
12 Apply sealant on the J1 base referring to Fig.4.3 (b).
13 Attach new wave generator (8) to the reducer. At this time, be sure to put wave washer (12).
14 Phase to reducer and assemble J1 base (6) referring to Fig.4.3 (c). At this time, be sure to put O-ring
(9). Assemble bolt (5) after previously assembling all bolt (4).
15 Put J1 motor, cable and cover in the reverse order of 4-6. Be careful not to drop the gasket (17).

CAUTION
Do not apply grease to the O-ring (9). Otherwise, hardening of sealant is
prevented, causing a grease leak.

16 Pass the cable K101 through J2 base side, and connect it with the relay connector. At this time, pull
out the cable after it pushes into the pipe on the tip of the part of the relayed connector and it passes
it. Do not pull it out forcibly with the relayed connector caught.
17 Attach J2 base cover (16) with plated bolt (15). Confirm that the gasket (16) does not fall out.
18 Attach J1 motor referring to Section 4.2.
19 Attach the cover B.
20 Attach robot to floor plate.
21 Perform quick mastering and perform single axis mastering for J1-axis referring to Section 8.4 and
8.5 of operator’s manual.

NOTE
When the influence of the damaged pieces generated from broken reducer is
concerned about, exchange gear of J1-axis motor shaft.

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B-83495EN/01 4.REPLACING PARTS

15

16

17
6

11 10
14
13 12

5 4

8 7
9

1
2 3

Fig. 4.3 (a) Replacing J1-axis reducer

Name Specifications Q’ty LOCTITE Torque N-m (kgf-cm)


1 SEAL BOLT A97L-0218-0546#030606EN 4 1.3Nm (13kgfcm)
2 COVER U A290-7142-X319 1
3 GASKET A290-7142-X317 1
4 BOLT A6-BA-4X12 7 4.5Nm (46kgfcm)
5 BOLT A6-BA-4X20 9 4.5Nm (46kgfcm)
6 J1 BASE A290-7142-X201 1
7 PIPE A290-7142-X312 1
WAVE
8 (It is attached to the J1 REDUCER) 1
GENERATOR
9 O RING (It is attached to the J1 REDUCER) 1
10 BOLT A97L-0218-0546#043016BC 12 4.5Nm (46kgfcm)
A97L-0218-0951#70 (*1)
11 REDUCER 1
A97L-0218-0980#80 (*2)
12 WAVE WASHER (It is attached to the J1 REDUCER) 1
13 PIPE A290-7142-X311 1
14 O RING (It is attached to the J1 REDUCER) 1
15 PLATED BOLT A97L-0218-0496#M4X10BC 5 2.0Nm (20kgfcm)
16 J2 BASE COVER A290-7142-X306 1
17 GASKET A290-7142-X324 1
(*1) LR Mate 200iD. ARC Mate 50iD
(*2) LR Mate 200iD/7L. ARC Mate 50iD/7L

- 29 -
4.REPLACING PARTS B-83495EN/01

Apply LOCTITE 518 to the part.

Fig. 4.3 (b) Applying the sealant to the J1-axis reducer

Mark is applied to the


tapped holes for M4X20.
(Tapped holes without the mark are for M4X12.)

Fig. 4.3 (c) Assembled phase of J1-axis reducer

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B-83495EN/01 4.REPLACING PARTS

Removal taps (M4)

Fig. 4.3 (d) Position of removal taps to remove J1 base.

4BNo.2

4BNo.2

Fig.4.3 (e) Grease applying area of the J1-axis

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4.REPLACING PARTS B-83495EN/01

4.4 REPLACING J2-AXIS MOTOR


Replacing procedure
1 Record the Quick Master Reference Position referring to Section 8.4 of operator’s manual. ( It is set
in 0° for all axes when robot is shipped.)
2 Turn off the controller power.
3 Remove plated bolt (1). And remove J2 base cover (2).
4 Cut the nylon band, which connect cable and clamp (5).
5 Remove the connector that relays cable K101 and cable K102, K103, K104, K105, K106,
K107 ,K108 and K109 referring to Fig.5.3.1 (b) in Chapter 5.
6 Remove bolt (4) and clamp (5).
7 Remove seal bolt (6) and support (7). Remove gasket (19), too.
8 Remove the plated bolt (8) and J2 arm cover (9).
9 Cut the nylon band of the clamp (11).
10 Remove plated bolt (20). And remove cover S (21), gasket (26). At this time, pay attention that
grease may go out.
11 Remove seal bolt (22), washer (23), collar (24),wave generator (25).
12 Remove the seal bolt (13) , and remove the motor (14) which O–ring (17) , key (16) and the shaft
(15) are attached.

CAUTION
When the motor is removed, the J2 arm moves downward by its weight. Hold the
arm so that the arm does not collide with any other objects.

13 Remove cable K102 and K103 from motor (14).


14 Assemble it applying the procedure in the reversed sequence after exchanging Motor, O-ring, gasket
(19),(26) and shaft (15) and the sheet (12) for the new article. At this time, pay attention to the
following.
• Spread LOCTITE 638 referring to Fig.4.4 (b) when you attach shaft (15).
• Be sure to attach wave generator (21) after attaching motor (14). Spread grease inside of
reducer before assembling it.
• Pay attention the phase when you apply the cover S (21) referring to Fig.4.4 (c).
• Refer to Fig.4.4 (d) when attaching the sheet (12).
• Apply LOCTITE 243 when attaching the key (16).
• Be careful not to drop the gasket (3) ,(10).
15 Perform quick mastering and perform single axis mastering for J2-axis referring to Section 8.4 and
8.5 of operator’s manual.

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B-83495EN/01 4.REPLACING PARTS

10 9
8

11

K103 K102 7 3 2
21 1
20 26 14
25 17 13 12
22 24 16 15
5
23

19 6
18
4

Fig. 4.4 (a) Replacing J2-axis motor

Name Specifications Q’ty LOCTITE Torque N-m (kgf-cm)


1 PLATED BOLT A97L-0218-0496#M4X10BC 6 2.0Nm (20kgfcm)
2 J2 BASE COVER ASSY A290-7142-V303 1
3 GASKET A290-7142-X324 1
4 BOLT A6-BA-4X8 2
5 CLAMP A290-7142-X321 1
6 SEAL BOLT A97L-0218-0423#041414 7 4.5Nm (46kgfcm)
7 SUPPORT ASSY A290-7142-V302 1
8 PLATED BOLT A97L-0218-0496#M4X10BC 6 2.0Nm (20kgfcm)
9 J2 ARM COVER A290-7142-X307 1
10 GASKET A290-7142-X325 1
11 CLAMP A290-7142-X322 1
12 SHEET A290-7142-X330 1
13 SEAL BOLT A97L-0218-0423#051212 4 5.6Nm (57kgfcm)
14 MOTOR A06B-0116-B855#0048 1
15 SHAFT A290-7139-X322 1
16 KEY A97L-0118-0402#3X3X12BN 1 LT243
17 O RING JB-OR1A-G45 1
18 PIN A6-PS-4X10S 2
19 GASKET A290-7142-X315 1
20 PLATED BOLT A97L-0218-0496#M4X22BC 4 4.5Nm (46kgfcm)
21 COVER S A290-7142-X305 1
22 SEAL BOLT A97L-0218-0423#031616 1 1.3Nm (13kgfcm)
23 WASHER A290-7120-X532 1
24 COLLAR A97L-0218-0763#410 1
(It is attached to the J2
25 WAVE GENERATOR 1
REDUCER)
26 GASKET A290-7142-X316 1

- 33 -
4.REPLACING PARTS B-83495EN/01

Spread grease on the inside diameter


A

A
Section A
Fig. 4.4 (b) Apply LOCTITE 638 to shaft

Pay attention to
the assembled phase.

Fig. 4.4 (c) Assembled phase of cover S

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B-83495EN/01 4.REPLACING PARTS

35

12
Fig.4.4 (d) Attachment of the sheet (12)

4.5 REPLACING J2-AXIS REDUCER


Replacing procedure
1 Record the Quick Master Reference Position referring to Section 8.4 of operator’s manual. ( It is set
in 0° for all axes when robot is shipped.)
2 Turn off the controller power.
3 Remove the robot from floor plate and knock down it sidewise. (Because you must reassemble
reducer in a horizontal state.)
4 Remove plated bolt (1). And remove J2 base cover assy (2).
5 Remove the connector that relays cable K101 and cable K102, K103, K104, K105, K106,
K107 ,K108 and K109 referring to Fig.5.3.1 (b) in Chapter 5.
6 Remove bolt (4) and clamp (5).
7 Cut the nylon band, which connect cable and clamp (5).
8 Remove seal bolt (6) and support (7). Remove gasket (11), too.
9 Remove plated bolt (24), then remove cover S (23) and gasket (17). At this time, pay attention that
there is a possibility that grease goes out.
10 Remove seal bolt (22), washer (21), spacer (20) and wave generator (18).
11 Remove seal bolt (8), motor (9) and O-ring (10).
12 Remove bolt (19) and remove the J2 arm which reducer (14) is attached.
13 Remove seal bolt (16) and remove reducer (14) from J2 arm.
14 Exchange reducer, O-ring, gasket for new parts in the following order.
15 Attach new reducer to the J2 arm (18) with seal bolt (16).
16 Attach J2 motor (9) to the J2 arm. Be sure to make the reducer the horizontal about the procedure of
17 and 18.
17 Attach the J2 arm with bolts (19). Be sure to attach the O-ring (15),too.
18 Apply grease to inside of reducer, gear and bearing of wave generator. (See Fig.4.5 (b).)
19 Attach the wave generator (18).
20 Attach cover S (23). At this time, pay attention to the phase referring to Fig.4.4 (c).
21 Attach the support (7) with seal bolt (6). Replace the gasket (11) by new one.
22 Fix the cables on the clamp (5) with nylon bands and attach it to the support (7) with bolt (4).
23 Attach J2 base cover assy (2). At this time, be carful not to drop the gasket (3).
24 Attach robot to floor plate.
25 Perform quick mastering and perform single axis mastering for J2-axis referring to Section 8.4 and
8.5 of operator’s manual.

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4.REPLACING PARTS B-83495EN/01

NOTE
When the influence of the damaged pieces generated from broken reducer is
concerned about, exchange gear of J2-axis motor shaft.

24

23
22
21
20

18 19

17

16
15
14
13

12

10

11

8
7
6
5
4
3
2

Fig. 4.5 (a) Replacing J2-axis reducer

- 36 -
B-83495EN/01 4.REPLACING PARTS

Name Specifications Q’ty LOCTITE Torque N-m (kgf-cm)


1 PLATED BOLT A97L-0218-0496#M4X10BC 5 2.0Nm (20kgfcm)
2 J2 BASE COVER ASSY A290-7142-V303 1
3 GASKET A290-7142-X324 1
4 BOLT A6-BA-4X8 2
5 CLAMP A290-7142-X321 1
6 SEAL BOLT A97L-0218-0423#041414 7 4.5Nm (46kgfcm)
7 SUPPORT ASSY A290-7142-V302 1
8 SEAL BOLT A97L-0218-0423#051212 4 5.6Nm (57kgfcm)
9 MOTOR A06B-0116-B855#0048 1
10 O RING JB-OR1A-G45 1
11 GASKET A290-7142-X315 1
12 PIN A6-PS-4X10S 2
(It is attached to the J2 1
13 O RING
REDUCER)
A97L-0218-0952#100 (*1) 1
14 REDUCER
A97L-0218-0952#120 (*2)
(It is attached to the J2 1
15 O RING
REDUCER)
16 SEAL BOLT A97L-0218-0546#043516BC 12 4.5Nm (46kgfcm)
17 GASKET A290-7142-X316 1
(It is attached to the J2 1
18 WAVE GENERATOR
REDUCER)
19 BOLT A6-BA-4X20 12 4.5Nm (46kgfcm)
20 SPACER A97L-0218-0794#410 1
21 WASHER A290-7210-X532 1
22 SEAL BOLT A97L-0218-0423#031616 1 1.3Nm (13kgfcm)
23 COVER S A290-7142-X305 1
24 PLATED BOLT A97L-0218-0496#M4X22BC 4 4.5Nm (46kgfcm)
(*1) LR Mate 200iD. ARC Mate 50iD
(*2) LR Mate 200iD/7L. ARC Mate 50iD/7L

4BNo.2

Fig. 4.5 (b) Applying the grease to the J2-axis reducer

- 37 -
4.REPLACING PARTS B-83495EN/01

4.6 REPLACING J3-AXIS MOTOR


Replacing procedure

1 Turn off the controller power.


2 Remove plated bolt (4). And remove J2 arm cover (5).
3 Loosen tension adjusting bolts a little and lower the tension of the belt and remove belt (7) referring
to Fig.4.6 (b).

CAUTION
When removing the belt, put the part beyond the J3 housing on a workbench to
prevent the arm from dropping

4 Remove the plated bolt (1) and remove the J2 arm cover (2).
5 Remove the J2 base cover and remove the all relays of K101 and air tubes referring to Subsection
5.3.1. (Refer to Fig.5.3.1 (a),(b).)
6 Remove the bolt (8) and remove the motor plate (9) which is combined to the motor.
7 Remove the seal bolt (10) , washer plate (11) and the pulley (12).
8 Remo the bolt (15) then remove the motor (14) from the motor plate (9).
9 Remove the cable K104 and K105 from the motor (14).
10 Assemble it in the reversed sequence after exchanging motor by the new article. At this time, pay
attention to the following.
• Adjust the tension of the belt referring to Section 6.1 after the installation of the belt.
• Be careful not to drop the gasket (3) ,(6).
11 Perform single axis mastering referring to Section 8.5 of operator’s manual.

- 38 -
B-83495EN/01 4.REPLACING PARTS

5 6 3 2
7
4 1

9 15
12 14
8 11
10 13

K104
K105

Fig. 4.6 (a) Replacing J3-axis motor

Name Specifications Q’ty LOCTITE Torque N-m (kgf-cm)


1 PLATED BOLT A97L-0218-0496#M4X10BC 6 2.0Nm (20kgfcm)
2 J2 ARM COVER A290-7142-X307 1
3 GASKET A290-7142-X325 1
4 PLATED BOLT A97L-0218-0496#M4X10BC 6 2.0Nm (20kgfcm)
5 J2 ARM COVER A290-7142-X307 1
6 GASKET A290-7142-X325 1
A98L-0040-0285#006-095 (*1)
7 BELT 1
A98L-0040-0285#006-100 (*2)
8 FLANGE BOLT A97L-0218-0504#M5X12 3
9 MOTOR PLATE A290-7142-X308 1
10 SEAL BOLT A97L-0218-0423#030606 3 1.3Nm (13kgfcm)
11 WASHER PLATE A290-7142-X203 1
A290-7142-X309 (*1)
12 PULLEY J3-1 1
A290-7142-X333 (*2)
13 KEY A97L-0118-0402#3X3X12BN 1 LT243
14 MOTOR A06B-0115-B855#0048 1
15 BOLT A6-BA-5X12 4 5.6Nm (57kgfcm)
(*1) LR Mate 200iD. ARC Mate 50iD
(*2) LR Mate 200iD/7L. ARC Mate 50iD/7L

- 39 -
4.REPLACING PARTS B-83495EN/01

Tension
adjusting bolt

Fig. 4.6 (b) Adjusting tension of J3 belt

4.7 REPLACING J3-AXIS REDUCER


Replacing procedure
1 Record the Quick Master Reference Position referring to Section 8.4 of operator’s manual. ( It is set
in 0° for all axes when robot is shipped.)
2 Turn off the controller power.
3 Remove the plated bolt (1) and remove the J2 base cover assy (2).
4 Cut the nylon bands and remove the relay connectors.
5 Remove the bolt (4) and the clamp (5).
6 Remove the seal bolt (6) and the support assy (7).
7 Remove the plated bolt (10) and the J2 arm cover (11).
8 Remove the plated bolt (18) and the J3 cover (19).
9 Remove the relay of the connector and cut the nylon band at the clamp (21).
10 Remove the plated bolt (22) and the J3 arm cover (23).
11 Pull out the air tubes and cut the nylon bands of the clamp (25).
12 Remove the seal bolt (13) and plated bolt (14),(15) and remove the J2 arm 2 (16).
13 Remove the J2 arm cover and the belt referring to procedure 1-3 of Section 4.6.

CAUTION
When removing the belt, put the part beyond the J3 housing on a workbench to
prevent the arm from dropping

14 Remove the seal bolt (26) , the washer (27) and the pulley (28).
15 Remove bolt (29) and J2 arm which reducer (34) is attached. Note that grease may go out.
16 Remove seal bolt (33) and reducer (34).
17 Replace reducer by new one and install to J3 arm unit horizontally. At this time, be sure to put
wave washer (36) and O-ring (35).
18 Apply Harmonic grease 4B No.2 to inside of reducer, gear and bearing of wave generator. Refer to
Fig.4.7 (f).
19 Attach wave generator (32) to reducer.
20 Spread sealant to the reducer referring to Fig.4.7 (d) and Section 4.20.
21 Attach J3 arm unit which reducer is attached. At this time, be sure to put O-ring (30).
- 40 -
B-83495EN/01 4.REPLACING PARTS

CAUTION
Do not apply grease to the O-ring (30). Otherwise, hardening of sealant is
prevented, causing a grease leak.

22 Install pulley (28) and belt.


23 Attach the J2 arm (2), support (7) as the original state. At this time, replace gasket (9) by new one.
24 Adjust the tension of the belt referring to Section 6.1 after the installation of the belt.
25 Attach the J2 arm cover referring Section 4.6.
26 Attach the J2 arm 2, the J2 base cover, the support and the J2 arm cover as the original state. Spread
sealant on the J2 arm 2 and J2 arm mounting face of another part. Spread sealant on the J2 arm
referring to Fig.4.7 (e).
Be careful not to drop the gasket (3),(12),(20) and (24).
27 Perform quick mastering and perform single axis mastering to J3-axis referring to Section 8.4 and
8.5 of operator’s manual.

3
4
10
5
6
11
7
12
14 15
13
16
8
9
17

Fig. 4.7 (a) Replacing J3-axis reducer

- 41 -
4.REPLACING PARTS B-83495EN/01

Name Specifications Q’ty LOCTITE Torque N-m (kgf-cm)


1 PLATED BOLT A97L-0218-0496#M4X10BC 5 2.0Nm (20kgfcm)
2 J2 BASE COVER ASSY A290-7142-V303 1
3 GASKET A290-7142-X324 1
4 BOLT A6-BA-4X8 2
5 CLAMP J2-1 A290-7142-X321 1
6 SEAL BOLT A97L-0218-0423#041414 7 4.5Nm (46kgfcm)
7 SUPPORT ASSY A290-7142-V302 1
8 PIN A6-PS-4X10S 2
9 GASKET A290-7142-X315 1
10 PLATED BOLT A97L-0218-0496#M4X10BC 6 2.0Nm (20kgfcm)
11 J2 ARM COVER A290-7142-X307 1
12 GASKET A290-7142-X325 1
13 BOLT A6-BA-4X14 4 4.5Nm (46kgfcm)
2 (*1)
14 PLATED BOLT A97L-0218-0496#M4X30BC 4.5Nm (46kgfcm)
4 (*2)
15 PLATED BOLT A97L-0218-0496#M4X45BC 3 4.5Nm (46kgfcm)
A290-7142-V311 (*1)
16 J2 ARM 2 ASSY 1
A290-7142-V314 (*2)
17 PIN A6-PS-4X10S 5
(*1) LR Mate 200iD. ARC Mate 50iD
(*2) LR Mate 200iD/7L. ARC Mate 50iD/7L
22

23

24 19
20 18

21 25

Fig. 4.7 (b) Replacing J3-axis reducer (2/3)

- 42 -
B-83495EN/01 4.REPLACING PARTS

Name Specifications Q’ty LOCTITE Torque N-m (kgf-cm)


18 PLATED BOLT A97L-0218-0496#M4X10BC 4 2.0Nm (20kgfcm)
19 J3 COVER A290-7142-X404 1
20 GASKET A290-7142-X409 1
21 CLAMP A290-7142-X415 1
22 PLATED BOLT A97L-0218-0496#M4X10BC 7
23 J3 ARM COVER A290-7142-X405 1
24 GASKET A290-7142-X410 1
25 CLAMP A290-7142-X416 1

37

34
29 33 35
30
31 32 36

26 27
28

Fig. 4.7 (c) Replacing J3-axis reducer (3/3)

Name Specifications Q’ty LOCTITE Torque N-m (kgf-cm)


26 SEAL BOLT A97L-0218-0423#030606 1 1.3Nm (13kgfcm)
27 WASHER A290-7210-X532 1
A290-7142-X310 (*1)
28 PULLEY J3-2 1
A290-7142-X334 (*2)
29 BOLT A6-BA-3X16 15 2.0Nm (20kgfcm)
30 O RING (It is attached to the J3 REDUCER) 1
31 KEY A97L-0118-0402#3X3X9BN 1 LT243
32 WAVE GENERATOR (It is attached to the J3 REDUCER) 1
33 BOLT A97L-0218-0546#032204BC 12 2.0Nm (20kgfcm)
34 J3 REDUCER A97L-0218-0953#80 1
35 O-RING (It is attached to the J3 REDUCER) 1
36 WAVE WASHER (It is attached to the J3 REDUCER) 1
37 J3 HOUSING A290-7142-X401 1
(*1) LR Mate 200iD. ARC Mate 50iD
(*2) LR Mate 200iD/7L. ARC Mate 50iD/7L

- 43 -
4.REPLACING PARTS B-83495EN/01

Apply LOCTITE on part


Do not apply LOCTITE inside the reducer.
Fig. 4.7 (d) Applying sealant on the J3-axis reducer

Pay attention to
the sealant applying area.

Remove the grease of the


sealant and apply primer.

Apply LOCTITE 518 on part

Fig.4.7 (e) Applying sealant on the J2 arm

- 44 -
B-83495EN/01 4.REPLACING PARTS

4BNo.2

Fig.4.7 (f) Grease applying area of the J3-axis

4.8 REPLACING J4-AXIS MOTOR


Replacing procedure
1 Turn off the controller power.
2 Remove plated bolt (1). And remove J3 cover (2).
3 Remove bolt (4), remove the motor (5) with the gear . Note that grease may go out.

CAUTION
When the motor is removed, the J3 arm can be rotated. Do as the J3 arm is put on the
stand so that the arm should not collide with surroundings.

4 Wipe the grease of the gear (11) off. At this time, pay attention not to damage the tooth surface.
5 Remove cable K107 and K111 from motor (5).
6 Remove seal bolt (13), washer plate (12), gear (11), key (10), holder (7) with oil seal (8) and O-ring
(6).
7 Assemble it in the reversed sequence after exchanging motor-ring and gasket for the new article.
At this time, pay attention to the followings.
• Confirm the thing that the oil seal (8) is at appropriate position, and note that the lip cannot be
turned over.
• Spread Harmonic grease on surroundings of the gear referring to Fig.4.9 (e).
• Be careful not to drop the gasket (3).
• Apply sealant on the motor shaft before attaching the washer (12) and the seal bolt (13)
referring to Fig.4.8 (b) and Section 4.20 .
8 Perform single axis mastering referring to Section 8.5 of operator’s manual.

- 45 -
4.REPLACING PARTS B-83495EN/01

3 2 1

8
13 11
12 10
9 7 6 5 4

Fig. 4.8 (a) Replacing J4-axis motor

Name Specifications Q’ty LOCTITE Torque N-m (kgf-cm)


1 PLATED BOLT A97L-0218-0496#M4X10BC 4 2.0Nm (20kgfcm)
J3 COVER
2 A290-7142-V404 1
ASSY
3 GASKET A290-7142-X409 1
4 BOLT A6-BA-5X16 3 5.6Nm (57kgfcm)
5 MOTOR A06B-0114-B855#0048 1
6 O RING A98L-0001-0347#S46 1
7 HOLDER A290-7142-X407 1
8 OIL SEAL A98L-0040-0223#01502505 1
9 O RING A98L-0001-0347#S46 1
10 KEY A97L-0118-0402#3X3X12BN 1 LT243
11 GEAR J4-1 A290-7142-X406 1
12 WASHER A290-7142-X420 1
13 SEAL BOLT A97L-0218-0423#030606 1 1.3Nm (13kgfcm)

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B-83495EN/01 4.REPLACING PARTS

Apply LOCTITE 518 on part

Fig.4.8 (b) Applying sealant to the J4-axis motor shaft

4.9 REPLACING J4-AXIS REDUCER


Replacing procedure
1 Record the Quick Master Reference Position referring to Section 8.4 of operator’s manual. ( It is set
in 0° for all axes when robot is shipped.)
2 Turn off the controller power.
3 Remove J3 arm cover referring to Section 4.10.
4 Remove the J3 cover referring to Section 4.8.
5 Cut the nylon band at the clamp inside the J3 arm.
6 Cut the nylon band at the clamp inside the J3 housing and remove relay connector and air tube.
7 Pull out the air tubes to the J3 housing side.
8 Pull out the cable to the J3 arm side through the pipe. At this time, pull out the cable after it pushes
into the pipe on the tip of the part of the relayed connector and it passes it. Do not pull it out forcibly
with the relayed connector caught.
9 Remove bolt (1) and clamp (2).
10 Remove the J4-axis motor referring to Section 4.8.
11 Remove bolt (3), (4) and J3 arm. Pay attention not to damage oil seal (7). Note that there is a
possibility that grease goes out.
12 Wipe the grease of the reducer (8) off. At this time, pay attention not to damage the tooth surface.
13 Remove plated bolt (6) and reducer (8).
14 Remove seal bolt (5) , pipe (8) and J4 pipe (9).
15 Assemble it applying the procedure in the reversed sequence after exchanging reducer for the new
article.
• When installing reducer, spread grease on teeth of Wave generator, and be sure to install O-ring
(7). (In case of J4-axis reducer, wave generator is assembled in reducer when it is shipped.)
Also, pay attention to the phase of bolts referring to Fig.4.9 (c).
• Spread Harmonic grease 4BNo.2 on surroundings of the gear referring to Fig.4.9 (e).
• When installing J3 arm, confirm that the oil seal (5) is at appropriate position, and note that the
lip cannot be turned over.
• Spread sealant to the each part referring to Fig.4.9 (b) and Section 4.20.
• Apply grease referring to Fig.4.9 (e).

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4.REPLACING PARTS B-83495EN/01

CAUTION
Do not apply grease to the O-ring (7). Otherwise, hardening of sealant is
prevented, causing a grease leak.

12 Perform quick mastering and perform single axis mastering for J4-axis referring to Section 8.4 and
8.5 of operator’s manual.
NOTE
When the influence of the damaged pieces generated from broken reducer is
concerned about, exchange gear of J4-axis motor shaft.

8 6
10 9 5 3
1

7 4
2

Fig. 4.9 (a) Replacing J4-axis reducer

Name Specifications Q’ty LOCTITE Torque N-m (kgf-cm)


1 BOLT A6-BA-4X8 2
2 CLAMP A290-7142-X415 1
3 BOLT A6-BA-3X30 12 2.0Nm (20kgfcm)
4 BOLT A6-BA-3X14 2 2.0Nm (20kgfcm)
5 OIL SEAL A98L-0040-0049#02503507 1
A97L-0218-0496#M3X25BC or
6 PLATED BOLT 9 2.0Nm (20kgfcm)
A97L-0218-0496#M3X28BC (*)
7 O RING (It is attached to the J4 REDUCER) 1
8 REDUCER A97L-0218-0954#80 1
9 J4 PIPE A290-7142-X421 1
10 SEAL BOLT A97L-0218-0423#030606 4 1.3Nm (13kgfcm)

(*) Length of the bolts is different depending on the manufacturing date.

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B-83495EN/01 4.REPLACING PARTS

Apply LOCTITE 518 on part

Fig. 4.9 (b) Applying of the sealant

M3X30 (12)

M3X14 (2)

Fig. 4.9 (c) Assembled phase of J4-axis reducer

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4.REPLACING PARTS B-83495EN/01

J4-axis reducer J3 arm

Apply LOCTITE on part


Fig.4.9 (d) Applying sealant on the J4-axis reducer

4BNo.2

Gear

Fig.4.9 (e) Grease applying area of the J4-axis

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B-83495EN/01 4.REPLACING PARTS

4.10 REPLACING J5-AXIS MOTOR


NOTE
If wrist axes (J5/J6-axis) motors or reducers are replaced, estimation accuracy
may go down. Perform the calibration for load estimation before performing load
estimation. Refer to Chapter 9 “LOAD ESTIMATION” in R-30iB/R-30iB Mate
Controller Optional Function OPERATOR’S MANUAL (B-83284EN-2).

Replacing procedure
1 Turn off the controller power.
2 Remove plated bolt (1). And remove J3 arm cover (2).
3 Remove plated bolt (5) . And remove J3 arm cover (6).
4 Remove the J3 cover, then cut the nylon band of the clamp J4 (A290-7142-X415) in the J3 housing
referring to Section 4.8 and Fig.5.3.2 (c).
5 Remove the 2 M4X8 bolts of the clamp (A290-7142-X416) of the J3 arm root side, then cut the
nylon band which fix the cables referring to Fig.5.3.2 (a).

CAUTION
When the belt is removed, the wrist moves to bellow side. Do as the wrist is put on the
stand so that the wrist should not collide with surroundings.

6 Remove bolt (13) and motor (8).


7 Remove cable K113, K114 from motor (8).
8 Remove seal bolt (12), washer (11), motor pulley (10) and key (9).
9 Assemble it in the reversed sequence after exchanging motor and gasket for the new article.
• Adjust the tension of the belt referring to Section 6.1 after the installation of the belt.
• Be careful not to drop the gasket (3), (7).
10 Perform single axis mastering referring to Section 8.5 of operator’s manual. At this time, perform
not only J5-axis but also J6-axis.

5 6 7 3 2 1
8 13
10 4
9 12
11

Fig. 4.10 (a) Replacing J5-axis motor


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4.REPLACING PARTS B-83495EN/01

Tension adjusting
14
bolt

Fig. 4.10 (b) Replacing J5-axis motor

Name Specifications Q’ty LOCTITE Torque N-m (kgf-cm)


1 PLATED BOLT A97L-0218-0496#M4X10BC 7 2.0Nm (20kgfcm)
2 J3 ARM COVER A290-7142-X405 1
3 GASKET A290-7142-X410 1
4 BELT A98L-0040-0286#004-157 1
5 PLATED BOLT A97L-0218-0496#M4X10BC 7 2.0Nm (20kgfcm)
6 J3 ARM COVER A290-7142-X405 1
7 GASKET A290-7142-X410 1
8 MOTOR A06B-0117-B855#0049 1
9 KEY A97L-0118-0402#3X3X6BN 1 LT243
10 PULLEY J5-1 A290-7142-X411 1
11 WASHER A290-7142-X420 1
12 SEAL BOLT A97L-0218-0423#030606 1 1.3Nm (13kgfcm)
13 BOLT A97L-0218-0504#M5X12 4 5.6Nm (57kgfcm)
14 SEAL BOLT A97L-0218-0423#030606 3 1.3Nm (13kgfcm)

4.11 REPLACING J5-AXIS REDUCER (Standard)


NOTE
If wrist axes (J5/J6-axis) motors or reducers are replaced, estimation accuracy
may go down. Perform the calibration for load estimation before performing load
estimation. Refer to Chapter 9 “LOAD ESTIMATION” in R-30iB/R-30iB Mate
Controller Optional Function OPERATOR’S MANUAL (B-83284EN-2).

Replacing procedure
1 Turn off the controller power.
2 Remove both side of J3-arm cover referring to Section 4.10.
3 Remove the J3 cover, then cut the nylon band of the clamp J4 (A290-7142-X415) in the J3 housing
referring to Section 4.8 and Fig.5.3.2 (c).
4 Remove the 2 M4X8 bolts of the clamp (A290-7142-X416) of the J3 arm root side, then cut the
nylon band which fix the cables referring to Fig.5.3.2 (a).
5 Remove the seal bolt (14) and remove the J3 arm 2 (15) from the J3 arm 1 (16). At this time, pay
attention not to damage the oil seal (6).
6 Remove the J6-axis motor cables.
7 Remove belt (1) referring to Section 4.10.

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B-83495EN/01 4.REPLACING PARTS

CAUTION
When the belt is removed, the wrist moves to bellow side. Do as the wrist is put
on the stand so that the wrist should not collide with surroundings.

8 Remove seal bolt (2), washer plate (3) and pulley (4).
9 Remove key (7) and bolt (5).
10 Remove plated bolt (9) and remove reducer (11). At this time, note that grease may go out.
11 Replace reducer by new one, and assemble robot applying the procedure in the reversed sequence.
At this time, pay attention below.
• Apply grease to inside of reducer, gear and bearing of wave generator and install it horizontally.
(Refer to Fig.4.11 (d)). Be sure to install O-ring (8) and (12) and wave washer (13).
• Apply grease to the lip of the Oil seal (6)
• Adjust the tension of the belt referring to Section 6.1 after the installation of the belt.
• Spread sealant to the J3 arm referring to Fig.4.11 (c) and Section 4.20.
• Spread sealant to the reducer referring to Fig.4.11 (b) and Section 4.20.

CAUTION
Do not apply grease to the O-ring (8). Otherwise, hardening of sealant is
prevented, causing a grease leak.

12 Perform quick mastering and perform single axis mastering for J5/J6-axis referring to Section 8.4
and 8.5 of operator’s manual.

15
16
1

14

12 11 9
5

13 7 3 2
10 4
8
6

Fig. 4.11 (a) Replacing J5-axis reducer

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4.REPLACING PARTS B-83495EN/01

Name Specifications Q’ty LOCTITE Torque N-m (kgf-cm)


1 BELT A98L-0040-0286#004-104 1
2 SEAL BOLT A97L-0218-0423#030606 3 1.3Nm (13kgfcm)
3 WASHER PLATE A290-7139-X231 1
4 PULLEY J5-2 A290-7142-X412 1
5 BOLT A6-BA-3X8 12 2.0Nm (20kgfcm)
6 OIL SEAL A98L-0040-0223#01001805 1
7 KEY A97L-0118-0402#3X3X6BN 1 LT243
8 O RING (It is attached to the J5 REDUCER) 1
9 PLATED BOLT A97L-0218-0496#M3X22BC 9 2.0Nm (20kgfcm)
10 WAVE GENERATOR (It is attached to the J5 REDUCER) 1
11 REDUCER A97L-0218-0955#50 1
12 O-RING (It is attached to the J5 REDUCER) 1
13 WAVE WASHER (It is attached to the J5 REDUCER) 1
14 SEAL BOLT A97L-0218-0423#041616 7 4.5Nm (45kgfcm)
15 J3 ARM 2 A290-7142-X403 1
16 J3 ARM 1 A290-7142-X402 1

Apply LOCTITE 518 to dotted line area of the O ring (8) side.
Do not put LOCTITE inside the reducer.

Fig. 4.11 (b) Spread range of sealant to J5-reducer

- 54 -
B-83495EN/01 4.REPLACING PARTS

A A

Note to the selant applying area

LT518

Section A-A
Note)
Remove the sealant, apply LOCTITE 518
on the one side, and apply primar on the
other side and assemble them.
Remove the excess sealant completely.

Apply LOCTITE 518 on part.

Fig.4.11 (c) Applying the sealant on the J3 arm (Standard)

- 55 -
4.REPLACING PARTS B-83495EN/01

4BNo.2

Fig.4.11 (d) Grease applying area of the J5-axis

4.12 REPLACING J5-AXIS REDUCER (7L)


NOTE
If wrist axes (J5/J6-axis) motors or reducers are replaced, estimation accuracy
may go down. Perform the calibration for load estimation before performing load
estimation. Refer to Chapter 9 “LOAD ESTIMATION” in R-30iB/R-30iB Mate
Controller Optional Function OPERATOR’S MANUAL (B-83284EN-2).

Replacing procedure
1 Turn off the controller power.
2 Remove both side of J3-arm cover referring to Section 4.10.
3 Remove the air tubes of inside the J3 arm.
4 Cut the nylon band which fix cables inside the J3 arm.
5 Remove the J3 cover, then cut the nylon band of the clamp J4 (A290-7142-X415) in the J3 housing
referring to Section 4.8 and Fig.5.3.2 (c).
6 Remove the 2 M4X8 bolts of the clamp (A290-7142-X416) of the J3 arm root side, then cut the
nylon band which fix the cables referring to Fig.5.3.2 (a).
7 Remove the seal bolt (14), then remove the J3 arm 2 (17) from the J3 arm 1 (18). At this time, pay
attention not to damage the oil seal (6). Note that grease may go out.
8 Remove belt (1) referring to Section 4.10.
9 Remove the unit over the J4-axis reducer from the J3 housing referring to Section 4.9.

CAUTION
When the belt is removed, the wrist moves to bellow side. Do as the wrist is put on the
stand so that the wrist should not collide with surroundings.

10 Remove seal bolt (2), washer plate (3) and pulley (4).
11 Remove key (7) and bolt (5).
12 Remove the seal bolt (14),(15) and (16), and remove the J3 arm 2 (17) from the J3 arm 1 (18). At
this time, pay attention not to damage the oil seal (6). Note that grease may go out.
13 Remove the plated bolt (9) and remove the reducer (11). Note that grease may go out.

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B-83495EN/01 4.REPLACING PARTS
14 Replace reducer by new one, and assemble robot applying the procedure in the reversed sequence.
At this time, pay attention below.
• Apply grease to inside of reducer, gear and bearing of wave generator and install it horizontally.
(Refer to Fig.4.11 (d).) Be sure to install O-ring (8) and (12) and wave washer (13).
• Apply grease to the lip of the Oil seal (6)
• Adjust the tension of the belt referring to Section 6.1 after the installation of the belt.
• Spread sealant to the J3 arm referring to Fig.4.12 (b) and Section 4.20.
• Spread sealant to the reducer referring to Fig.4.11 (b) and Section 4.20.

CAUTION
Do not apply grease to the O-ring (8). Otherwise, hardening of sealant is
prevented, causing a grease leak.

15 Perform single axis mastering to J5-axis and J6-axis referring to Section hapter 8 of operator’s
manual.

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4.REPLACING PARTS B-83495EN/01

17

16
18

15
1

14

12 11 9
5

13 7 3 2
10 8 4
6

Fig. 4.12 (a) Replacing J5-axis reducer (7L)

Name Specifications Q’ty LOCTITE Torque N-m (kgf-cm)


1 BELT A98L-0040-0286#004-104 1
2 SEAL BOLT A97L-0218-0423#030606 3 1.3Nm (13kgfcm)
3 WASHER PLATE A290-7139-X231 1
4 PULLEY J5-2 A290-7142-X412 1
5 BOLT A6-BA-3X8 12 2.0Nm (20kgfcm)
6 OIL SEAL A98L-0040-0223#01001805 1
7 KEY A97L-0118-0402#3X3X6BN 1 LT243
8 O RING (It is attached to the J5 REDUCER) 1
9 PLATED BOLT A97L-0218-0496#M3X22BC 9 2.0Nm (20kgfcm)
10 WAVE GENERATOR (It is attached to the J5 REDUCER) 1
11 REDUCER A97L-0218-0955#50 1
12 O-RING (It is attached to the J5 REDUCER) 1
13 WAVE WASHER (It is attached to the J5 EDUCER) 1
14 SEAL BOLT A97L-0218-0423#041616 5 4.5Nm (45kgfcm)
15 SEAL BOLT A97L-0218-0546#042516BC 4 4.5Nm (45kgfcm)
16 SEAL BOLT A97L-0218-0546#041212BC 2 4.5Nm (45kgfcm)
17 J3 ARM 2 A290-7142-X403 1
18 J3 ARM 1 A290-7142-X402 1

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B-83495EN/01 4.REPLACING PARTS

Apply LOCTITE 518 to dotted lin area of the O ring side.


Do not put LOCTITE inside the reducer.
Fig. 4.12 (b) Spread range of sealant to J5-reducer

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4.REPLACING PARTS B-83495EN/01

A A

LT518

Section A-A
Note to the sealant applying area
Note)
Remove the sealant, apply LOCTITE 518
on the one side, and apply primar on the
other side and assemble them.
Remove the excess sealant completely.

Apply LOCTITE 518 on part.

Fig.4.12 (c) Applying the sealant on the J3 arm (7L)

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B-83495EN/01 4.REPLACING PARTS

4.13 REPLACING J6-AXIS MOTOR


NOTE
If wrist axes (J5/J6-axis) motors or reducers are replaced, estimation accuracy
may go down. Perform the calibration for load estimation before performing load
estimation. Refer to Chapter 9 “LOAD ESTIMATION” in R-30iB/R-30iB Mate
Controller Optional Function OPERATOR’S MANUAL (B-83284EN-2).

Replacing procedure
1 Turn off the controller power.
2 Remove both side of J3 arm cover of J3 arm referring to Section 4.10.
3 Loosen tension adjusting bolt and lower tension and remove belt (1) referring to Fig. 6.1 (b). Loose
the bolt (9) and remove pulley if it is difficult to remove the belt.

CAUTION
When the belt (1) is removed, the wrist moves to bellow side. Do as the wrist is put on
the stand so that the wrist should not collide with surroundings.

4 Loosen flange socket bolt (2) and lower tension and remove J6 belt (3).

CAUTION
When the belt (3) is removed, the wrist become rotatable, When end effector is attached,
fix it so that the wrist should not collide with surroundings.

5 Remove the flange socket bolt (2) and the motor (4).
6 Remove cable K116, K117 from motor (4).
7 Remove seal bolt (8), washer (7), motor pulley (6) and key (7).
8 Assemble it in the reversed sequence after exchanging motor and gasket for the new article.
・ Adjust the tension of the belt referring to Section 6.1 after the installation of the belt.
9 Perform single axis mastering referring to Section 8.5 of operator’s manual. At this time, perform
not only J6-axis but also J5-axis.

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4.REPLACING PARTS B-83495EN/01

1
A

2 4
76 5
8

Fig. 4.13 (a) Replacing J6-axis motor

Tension adjusting bolt Tension adjusting bolt


9

View A View B
Fig. 4.13 (b) Replacing J6-axis motor

Name Specifications Q’ty LOCTITE Torque N-m (kgf-cm)


1 BELT A98L-0040-0286#004-157 1
FLANGE SOCKET
2 A97L-0218-0504#M5X12 4 5.6Nm (56kgfcm)
BOLT
3 BELT A98L-0040-0286#004-157 1
4 MOTOR A06B-0117-B855#0049 1
5 KEY A97L-0118-0402#3X3X6BN 1 LT243
6 PULLEY J6-1 A290-7142-X429 1
7 WASHER A290-7142-X420 1
8 SEAL BOLT A97L-0218-0423#030606 1 1.3Nm (13kgfcm)
9 SEAL BOLT A97L-0218-0423#030606 1 1.3Nm (13kgfcm)

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B-83495EN/01 4.REPLACING PARTS

4.14 REPLACING WRIST UNIT (Standard)


NOTE
If wrist axes (J5/J6-axis) motors or reducers are replaced, estimation accuracy
may go down. Perform the calibration for load estimation before performing load
estimation. Refer to Chapter 9 “LOAD ESTIMATION” in R-30iB/R-30iB Mate
Controller Optional Function OPERATOR’S MANUAL (B-83284EN-2).

Replacing procedure
1 Turn off the controller power.
2 Replacing both side of J3 arm cover of J3 arm referring to Section 4.10.
3 Remove the 2 M4X8 bolts of the clamp (A290-7142-X416) of the J3 arm root side, then cut the
nylon band which fix the cables referring to Fig.5.3.2 (a).
4 Remove the J3 cover, then cut the nylon band of the clamp J4 (A290-7142-X415) in the J3 housing
referring to Section 4.8 and Fig.5.3.2 (c).
5 Remove belt (1), (8) referring to Section 4.12.

CAUTION
When the belt (1), (8) is removed, the wrist moves to bellow side or rotate. Do as the
wrist is put on the stand so that the wrist should not collide with surroundings.

6 Remove seal bolt (13), J3 arm 2 (14).


7 Remove relay of cable K116 and cable K106 of J6-axis motor.
8 Remove seal bolt (2), washer plate (3) and pulley (4).
9 Remove bolt (6), wrist unit (18) and key (5). At this time, pay attention not to damage oil seal (7).
Pay attention that grease may go out, too.
10 Replace wrist unit (16) by new one and attach it. Attach reducer horizontally after apply greasing to
gear of reducer. At this time, be sure to replace O-ring (15), too. Apply grease to the lip of the oil
seal (7).
11 Assemble it in the reverse order of 3-9.
12 Adjust belt referring to Section 6.1.
13 Install J3 arm cover.
14 Perform single axis mastering referring to Section 8.5 of operator’s manual. At this time, perform
not only J6-axis but also J5-axis.

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4.REPLACING PARTS B-83495EN/01

13 14
1

15 7
4 3
9 10 11 12 5 2

16
Fig. 4.14 Replacing wrist unit (Standard)

Name Specifications Q’ty LOCTITE Torque N-m (kgf-cm)


1 BELT A98L-0040-0286#004-157 1
2 SEAL BOLT A97L-0218-0423#030606 3 1.3Nm (13kgfcm)
3 WASHER PLATE A290-7139-X231 1
4 PULLEY J5-2 A290-7142-X412 1
5 KEY A97L-0118-0402#3X3X6BN 1 LT243
6 BOLT A6-BA-3X8 12 2.0Nm (20kgfcm)
7 OIL SEAL A98L-0040-0223#01001805 1
8 BELT A98L-0040-0286#004-104 1
9 SEAL BOLT A97L-0218-0423#030606 1 1.3Nm (13kgfcm)
10 WASHER A290-7142-X420 1
11 PULLEY J6-2 A290-7142-X414 1
12 KEY A97L-0118-0402#3X3X6BN 1 LT243
13 SEAL BOLT A97L-0218-0423#041616 7 4.5Nm (46kgfcm)
14 J3 ARM 2 A290-7142-X403 1
15 O RING (It is attached to the J5 REDUCER) 1
16 WRIST UNIT A290-7142-V501 1

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B-83495EN/01 4.REPLACING PARTS

4.15 REPLACING WRIST UNIT (7L)


NOTE
If wrist axes (J5/J6-axis) motors or reducers are replaced, estimation accuracy
may go down. Perform the calibration for load estimation before performing load
estimation. Refer to Chapter 9 “LOAD ESTIMATION” in R-30iB/R-30iB Mate
Controller Optional Function OPERATOR’S MANUAL (B-83284EN-2).

Replacing procedure
1 Turn off the controller power.
2 Replacing both side of J3 arm cover of J3 arm referring to Section 4.10.
3 Remove the 2 M4X8 bolts of the clamp (A290-7142-X416) of the J3 arm root side, then cut the
nylon band which fix the cables referring to Fig.5.3.2 (a).
4 Remove the J3 cover, then cut the nylon band of the clamp J4 (A290-7142-X415) in the J3 housing
referring to Section 4.8 and Fig.5.3.2 (c).
5 Remove belt (1), (8) referring to Section 4.10 and Section 4.12.

CAUTION
When the belt (1), (8) is removed, the wrist moves to bellow side or rotate. Do as the
wrist is put on the stand so that the wrist should not collide with surroundings.

6 Remove the unit over the J4-axis reducer from the J3 housing referring to Section 4.9.
7 Remove the seal bolt (13),(14) and (15), and remove the J3 arm 2 (16).
8 Remove seal bolt (2), washer plate (3) and pulley (4).
9 Remove bolt (6), wrist unit (16) and key (5). At this time, pay attention not to damage oil seal (7).
Pay attention that grease may go out, too.
10 Replace wrist unit (17) by new one and attach it. Attach reducer horizontally after apply greasing to
gear of reducer. At this time, be sure to replace O-ring (18), too. Apply grease to the lip of the oil
seal (7).
11 Assemble it in the reverse order of 3-9.
12 Adjust belt referring to Section 6.1.
13 Install J3 arm cover.
14 Perform single axis mastering referring to Section 8.5 of operator’s manual. At this time, perform
not only J6-axis but also J5-axis.

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4.REPLACING PARTS B-83495EN/01

15 16

14

13
8

7 4 3
12 5 2

9 10
11
18 6

17
Fig. 4.15 Replacing wrist unit (7L)

Name Specifications Q’ty LOCTITE Torque N-m (kgf-cm)


1 BELT A98L-0040-0286#004-157 1
2 SEAL BOLT A97L-0218-0423#030606 3 1.3Nm (13kgfcm)
3 WASHER PLATE A290-7139-X231 1
4 PULLEY J5-2 A290-7142-X412 1
5 KEY A97L-0118-0402#3X3X6BN 1 LT243
6 BOLT A6-BA-3X8 12 2.0Nm (20kgfcm)
7 OIL SEAL A98L-0040-0223#01001805 1
8 BELT A98L-0040-0286#004-104 1
9 SEAL BOLT A97L-0218-0423#030606 1 1.3Nm (13kgfcm)
10 WASHER A290-7142-X420 1
11 PULLEY J6-2 A290-7142-X414 1
12 KEY A97L-0118-0402#3X3X6BN 1 LT243
13 SEAL BOLT A97L-0218-0423#041616 5 4.5Nm (46kgfcm)
14 SEAL BOLT A97L-0218-0546#042516BC 4 4.5Nm (46kgfcm)
15 SEAL BOLT A97L-0218-0546#041212BC 2 4.5Nm (46kgfcm)
16 J3 ARM 2 A290-7142-X434 1
17 O RING (It is attached to the J5 REDUCER) 1
18 WRIST UNIT A290-7142-V501 1

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B-83495EN/01 4.REPLACING PARTS

4.16 REPLACING J6-AXIS REDUCER


NOTE
If wrist axes (J5/J6-axis) motors or reducers are replaced, estimation accuracy
may go down. Perform the calibration for load estimation before performing load
estimation. Refer to Chapter 9 “LOAD ESTIMATION” in R-30iB/R-30iB Mate
Controller Optional Function OPERATOR’S MANUAL (B-83284EN-2).

Replacing procedure
1 Make to posture that J6 turns to the right upper and turn off the controller power as shown in
Fig.4.16 (a).
2 Remove bolt (1) and reducer. At this time, note that grease may go out.
3 Remove seal bolt (3), washer (4) , wave generator (6) and the key (5).
4 Remove O-ring (7).
5 Apply greasing to bearing of wave generator (6) to which attach new reducer and install to the robot.
6 Grease inside and gear of reducer (2) and wave generator by using the injection syringe.(Refer to
Fig.4.16 (c))
7 Install new reducer (2) to the robot. At this time, replace O-ring (7) by new one, too.
8 Perform single axis mastering referring to Section 8.5 of operator’s manual.

2
3
4
5
6
7

Fig. 4.16 (a) Replacing J6-axis reducer

Name Specifications Q’ty LOCTITE Torque N-m (kgf-cm)


1 PLATED BOLT A97L-0218-0496#M3X25BC 8 2.0Nm (20kgfcm)
2 REDUCER A97L-0218-0956#50 1
3 SEAL BOLT A97L-0218-0423#030808 1 1.3Nm (13kgfcm)
4 WASHER A290-7210-X532 1
5 KEY A97L-0118-0402#3X3X6BN 1
6 WAVE GENERATOR (It is attached to the J6 REDUCER) 1
7 O RING (It is attached to the J6 REDUCER) 1

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4.REPLACING PARTS B-83495EN/01

M3X25

Fig. 4.16 (b) Assembling phase of J6-axis reducer

4BNo.2

Fig.4.16 (c) Grease applying area of the J6-axis

4.17 REPLACING J3 BELT


Replacing procedure
1 Turn off the controller power.
2 Remove plated bolt (1). And remove J2 arm cover (2).
3 Loosen tension adjusting bolt and lower tension and remove belt (4) referring to Fig.4.17.

CAUTION
When removing the belt (4), put the part beyond the J3 housing on a workbench
to prevent the arm from dropping.

4 Replace belt and gasket to new one and do the reversed sequence. At this time, pay attention below.
• Adjust the tension of the belt referring to Section 6.1 after the installation of the belt.
• Be careful not to drop the gasket (3).
5 Perform single axis mastering referring to Section 8.5 of operator’s manual.

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B-83495EN/01 4.REPLACING PARTS

2 3
4
1

Tension adjusting bolt

Fig. 4.17 Replacing J3 belt

Name Specifications Q’ty LOCTITE Torque N-m (kgf-cm)


1 PLATED BOLT A97L-0218-0496#M4X10BC 6 2.0Nm (20kgfcm)
2 J2 ARM COVER A290-7142-X307 1
3 GASKET A290-7142-X325 1
A98L-0040-0285#006-095 (*1)
4 BELT 1
A98L-0040-0293#006-100 (*2)
(*1) LR Mate 200iD. ARC Mate 50iD
(*2) LR Mate 200iD/7L. ARC Mate 50iD/7L

4.18 REPLACING J5/J6 BELT


NOTE
If wrist axes (J5/J6-axis) motors or reducers are replaced, estimation accuracy
may go down. Perform the calibration for load estimation before performing load
estimation. Refer to Chapter 9 “LOAD ESTIMATION” in R-30iB/R-30iB Mate
Controller Optional Function OPERATOR’S MANUAL (B-83284EN-2).

Replacing procedure

1 Turn off the controller power.


2 Remove plated bolt (1). And remove J3 arm cover (2).
3 Remove bolt/plated bolt (5). And remove J3 arm cover (6).
4 In case of replacing J5 belt, loosen tension adjusting bolt and lower tension and remove belt
referring to Fig.6.1 (b).
In case of replacing J6 belt, loosen tension adjusting bolt and lower tension and remove belt
referring to Fig.6.1 (c).

CAUTION
When the belt (4) is removed, the wrist moves to bellow side or rotate. Do as the wrist is
put on the stand so That the wrist should not collide with surroundings.

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4.REPLACING PARTS B-83495EN/01

CAUTION
When the belt (8) is removed, the wrist become possible to rotate. When end effector is
attached, fix it so that the wrist should not collide with surroundings.

5 Replace belt and gasket to new one and install in the reversed sequence. At this time, pay attention
below.
• Adjust the tension of the belt referring to Section 6.1 after the installation of the belt.
• Be careful not to drop the gasket (3) and (7).
6 Perform single axis mastering referring to Section 8.5 of operator’s manual. When replacing the J5
belt, perform not only J5-axis but also J6-axis when replacing J5 belt.

5 6 7 3 2 1

Fig. 4.18 Replacing J5/J6 belt

Name Specifications Q’ty LOCTITE Torque N-m (kgf-cm)


1 PLATED BOLT A97L-0218-0496#M4X10BC 7 2.0Nm (20kgfcm)
2 J3 ARM COVER A290-7142-X405 1
3 GASKET A290-7142-X410 1
4 BELT A98L-0040-0286#004-104 1
5 PLATED BOLT A97L-0218-0496#M4X10BC 7 2.0Nm (20kgfcm)
6 J3 ARM COVER A290-7142-X405 1
7 GASKET A290-7142-X410 7
8 BELT A98L-0040-0286#004-157 1

4.19 REPLACING SOLENOID VALVE


Replacing procedure
1 Turn off the controller power.
2 Remove plated bolt (1) and remove the J2 arm cover (2).
3 Remove relay of air tube (φ6mm,φ4mm) and take solenoid valve out.
4 Remove the bolts (4), (5) then remove the solenoid valve.
5 Replace solenoid valve by new one, and assemble it in the reversed sequence. Be careful not to drop
the gasket (3).
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B-83495EN/01 4.REPLACING PARTS

3 2 1

5
4
6

7
Fig. 4.19 Replacing Solenoid valve

Name Specifications Q’ty LOCTITE Torque N-m (kgf-cm)


1 PLATED BOLT A97L-0218-0496#M4X10BC 6 2.0Nm (20kgfcm)
2 J2 ARM COVER A290-7142-X307 1
3 GASKET A290-7142-X325 1
4 BOLT A6-BA-4X8 2
5 BOLT A6-BA-4X8 2
6 SV PLATE A290-7142-X327 1
A97L-0218-0130#D3B or
A97L-0218-0130#D3R or
7 SOLENOID VALVE A97L-0218-0130#D3 or 1
A97L-0218-0130#D2 or
A97L-0218-0130#D1

4.20 SEALANT APPLICATION


Washing and degreasing the surfaces to be sealed
1 After dismounting the reducer from the member which installed the reducer, apply releasant
(LOCTITE Gasket Remover etc.) to the arm’s surface from which the reducer was dismounted, then
wait until the sealant (LOCTITE 518) becomes softened (for about 10 minutes). Remove the
softened sealant from the surface using a spatula.
2 Blow air onto the surface to be sealed to remove dust from the tapped holes.
3 Sufficiently degrease the reducer’s surface to be sealed and the arm’s surface to be sealed, using a
cloth dampened with oil and grease remover. Do not spray oil and grease remover directly onto the
surface.
4 Polish the surface of member which installed the reducer to be sealed with an oil stone, and degrease
it with removal and cleaner again.

- 71 -
4.REPLACING PARTS B-83495EN/01

CAUTION
Oil may drip from the inside of the reducer. After degreasing, make sure that no
oil is dripping.

Applying sealant
5 Make sure that the reducer and the member which installed the reducer are dry (with no oil and
grease remover remaining). If they are still wet with oil and grease remover, wipe them dry. Always
use a new surface of a cloth so that the grease once wiped up with the cloth will not get on the
degreased surface. Make sure that no ingredient of oil and grease remover is left in the threaded
holes or on any other portion. If ingredient is left, it may prevent stiffening of sealant.
6 Apply sealant (LOCTITE 518) to the surfaces.

CAUTION
The portions to which sealant is to be applied vary from one axis to another. See
descriptions about reducer replacement for the relevant axes for details.

Assembling
7 To prevent dust from sticking to the portions to which sealant was applied, mount the reducer as
quickly as possible after sealant application. Be careful not to touch the applied sealant. If sealant
was wiped off, apply again.
8 After mounting the reducer, fasten it with bolts and washers quickly so that the mated surfaces get
closer.
9 After attaching the reducer, wipe off any excessive sealant that comes out from the sealed section
with a cloth or spatula. Do not use oil and grease remover.

CAUTION
Do not grease or move the reducer before the sealant sets, as it may allow
grease to leak. Before greasing or moving, wait for about at least one hour after
the reducer is mounted.

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B-83495EN/01 5.REPLACING CABLES

5 REPLACING CABLES
Replace the cables every four years (15360 hours). When the cable is broken or damaged or shows signs
of wear, replace it according to this chapter.

Precautions to be observed when handling the Pulsecoder cable


The Pulsecoder cable is provided with a marking tie, as shown below, to warn against disconnecting the
cable during transportation, installation, or maintenance.
If the cable with the marking tie is disconnected, mastering must be performed again. Therefore, do not
disconnect the cable except when replacement of the motor, the Pulsecoder, the reducer, and the cable are
necessary.

BATTERY BACKUP

DON'T

DISCONNECT

コネクタ取外不可

Fig. 5 marking label

- 73 -
5.REPLACING CABLES B-83495EN/01

5.1 CABLE WIRING


Followings are the routing of the robot cables.

K118
(EE) K116
K204 (OPTION) (J6 AXIS POWER)
(CAMERA/FORCE SENSOR) K117
(J6 AXIS PULSECODER)

K106
(POWER)
K107
(PULSECODER)
K108
(RO, EE)
K202 (OPTION)
(CAMERA) K113
K203 (OPTION) (J5 AXIS POWER)
(FORCE SENSOR) K109 K114
(RO) (J5 AXIS PULSECODER)

K111
(J4 AXIS POWER)

K104
(J3 AXIS POWER)
K105
(J3 AXIS PULSECODER)

K102
(J2 AXIS POWER)
K103
(J2 AXIS PULSECODER)

K131 (OPTION)
(BATTERY)
K201 (OPTION)
(CAMERA/FORCE SENSOR)

K101
(POWER, PULSECODER)

Fig.5.1 (a) Routing of the robot cables (Standard)

- 74 -
B-83495EN/01 5.REPLACING CABLES

K118
(EE) K116
K204 (OPTION) (J6 AXIS POWER)
(CAMERA/FORCE SENSOR) K117
(J6 AXIS PULSECODER)

K106
(POWER)
K107
(PULSECODER)
K108
(RO, EE)
K202 (OPTION)
(CAMERA)
K203 (OPTION)
(FORCE SENSOR)
K113
K109 (J5 AXIS POWER)
(RO) K114
K111 (J5 AXIS PULSECODER)
(J4 AXIS POWER)

K104
(J3 AXIS POWER)
K105
(J3 AXIS PULSECODER)

K102
(J2 AXIS POWER)
K103
(J2 AXIS PULSECODER)

K119/K131 (OPTION)
(BATTERY)
K201 (OPTION)
(CAMERA/FORCE SENSOR)

K101
(POWER, PULSECODER)

Fig.5.1 (b) Routing of the robot cables (7L)

5.2 CABLE FORMING


When replacing cables, clamp the cable at the position specified in Fig.5.2 using a clamp or a nylon band.
Otherwise, cables can be loosened or pulled by force to cause their disconnection. Refer to the Fig.5.2 for
the cable clamp.

- 75 -
5.REPLACING CABLES B-83495EN/01

Relay in the J2 base


Clamp
J2-1 M2M

M2M
M2M1

M2M1 K102
K102 M2BK

M2BK
M3M Relay in the J3 housing

M3M
M3M1

M3M1 K104
K104 M3BK M4M

M3BK
Clamp

M4M
J2-1

M4M1

M4M1 K111
K111
M4BK

M456M1

M456M K106

M4BK
K106 M5M

M5M
M5M1

M5M1 K113
K113 M5BK

M5BK
M1M
M1M

M6M

M6M
Clamp
M1BK J2-1

M6M1

M6M1 K116
M1BK

K116
M2P M6BK

M6BK
M2P1
BATTERY BACKUP

M2P1 K103
BATTERY BACKUP

M2P
DON'T

Clamp
DISCONNECT DON'T
DISCONNECT
コネ ク タ 取 外 不可
R l N ^ Žæ ŠO s Â

Clamp J1-2 K103


J1-1
K101

M3P
M3P1

BATTERY BACKUP

M3P1 K105
BATTERY BACKUP

M3P
DON'T
DISCONNECT DON'T
コネ ク タ 取 外 不可 DISCONNECT
コ ネ クタ 取 外 不 可

K105
M4P

M4P
BATTE RY BACKUP
DON'T
DISC ONNECT
コ ネ ク タ 取 外不 可

Clamp Relay in the J3 housing


J2-1
K101 M1P M5P
M1P

BATTERY BACKUP
DON'T
M456P

M5P1
M456P K107

DISCONNEC T BATTERY BACKUP

M5P1 K114
BATTERY BACKUP
コ ネ ク タ 取 外不 可 BATTERY BACKUP

M5P
DON'T DON'T
DISCONNECT DON'T
DISC ONNECT
DISCONNECT
コネ ク タ 取 外不 可 コ ネ クタ 取 外 不 可
コネ ク タ 取 外 不可

K107 K114

Clamp M6P

M6P1 K117

M6P
BATTERY BACKUP

M6P1
BATTERY BACKUP DON'T
DON'T DISCONNECT

J2-1
DISC ONNECT コ ネ クタ 取 外 不 可

コ ネ クタ 取外 不 可

K117
EE
EE1

EE1 K108

EE2

EE2 K118

EE
K108 K118
-
+

YV2
YV1

YV1 K109

YV2

K109

Fig.5.2 Cable externals chart of mechanical unit

5.3 CABLE AND AIR TUBE REPLACEMENT


This section describes a procedure for periodically replacing all the (full-option) mechanical unit cables.
See Section 5.1 for the configuration of the mechanical unit cables.
You must perform mastering after cable replacement. Refer to Chapter 6 MASTERING or chapter 8
OPERATOR’S MANUAL in advance. (If Pulsecoder cable is not replaced, mastering is not necessary.)

5.3.1 Replacing Cable K101 and Air Tube (Connector panel to J2


base)
Replacing procedure
1 Record the Quick Master Reference Position referring to Section 8.4 of operator’s manual. ( It is set
in 0° for all axes when robot is shipped.)
2 Turn off the controller power and remove cable of controller side from connector plate of back of
J1-axis.
3 Remove robot from floor plate, knock down the robot sidewise.
4 Remove J2 base cover (2) referring to Fig.5.3.1 (a).
5 Remove all relay of cable K102, K103, K104, K105, K106, K107, K108 ,K109 and K101.Remove
relay of air tube similarly.
6 If necessary, remove cover B. (See Fig.5.3.1 (c))
7 Cut the nylon band which connect cable and air tube to clamp J1-2 referring to Fig.5.3.1 (b).
8 Cut the nylon band of battery box terminal and remove cable.
9 Remove connector plate referring to Fig.5.3.1 (e), (f).
10 Pull cable and air tube in J2 base to J1 base side. In this time pull out the cable after it pushes into
the pipe on the tip of the part of the relayed connector and it passes.

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B-83495EN/01 5.REPLACING CABLES
11 Replace cable and air tube for the new article and assemble them applying steps above in reversed
sequence. Confirm that the gasket (3) does not fall out.
12 Perform quick mastering referring to Section 8.4 of operator’s manual.

3 2 1

Fig.5.3.1 (a) Remove the J2 base cover

Name Specifications Q’ty LOCTITE Torque N-m (kgf-cm)


1 PLATED BOLT A97L-0218-0496#M4X10BC 5 2.0Nm(20kgfcm)
2 J2 BASE COVER A290-7142-X306 1
3 GASKET A290-7142-X324 1

- 77 -
5.REPLACING CABLES B-83495EN/01

ClampJ2-1
A290-7142-X321 Match the marking
AIR 2
Pulsecoder line (φ6 white)
cable K108
cable K109
B (blueXwhite) AIR 1
(φ6 black)
Power line J2/J3 Power line
(redXwhite) (redXwhite)

Nylon band

J2/J3 Pulsecoder line


(blueXwhite)
Joint
A97L-0142-0214#KQ2L0600 (2)
Detail B

A
Nylon band

Power line
Sheet (redXwhite)
A290-7142-X328 (1)
(Tie up it with cables
on A290-7142-X320 Pulsecoder line Nylon band
with a nylon band) (blueXwhite)

Clamp J1-2 AIR 2


A290-7142-X320 (1) (O6 white)
Match the marking
Bolt
A6-BA-4X8 (2) AIR 1
(O6 black)
Detail A
Fig.5.3.1 (b) Replace the cable in J2 base

3 2 1

Fig.5.3.1 (c) Removing the cover B

Name Specifications Q’ty LOCTITE Torque N-m (kgf-cm)


1 PLATED BOLT A97L-0218-0496#M4X10BC 9 2.0Nm(20kgfcm)
2 COVER B A290-7142-X204 1
3 GASKET A290-7142-X205 1

- 78 -
B-83495EN/01 5.REPLACING CABLES

Bolt
A6-BA-4X8 (2)
Tie up with nylon bands.

Washer bolt
A97L-0218-0606#M4X6 (2)
- +

+
-

Tightening torque
0.40Nm (4.1kgfcm)
Battery box terminal side

Washer bolt
A97L-0218-0606#M4X6

Apply threebond No.1401B


Pulsecoder line on the connector head of brake and power.
(blueXwhite)
Power line
(redXwhite)
AIR 2
(O6 white)
AIR 1
(O6 black) Nylon band

Match the marking


Detail A

Fig.5.3.1 (d) Replace the cable in J1 base

Position of No.1 pin


(Example of mechanical unit cable
A05B-1142-H301)

4 3 1

Fig.5.3.1 (e) Replace the parts of connector plate (back side connector plate)

Name Specifications Q’ty LOCTITE Torque N-m (kgf-cm)


1 PLATED BOLT A97L-0218-0496#M4X10BC 5 2.0Nm(20kgfcm)
2 PLATED BOLT A97L-0218-0546#040808BC 4
3 CON.PLATE (*) A290-7142-X206 1
4 GASKET A290-7139-X251 1
(*) Specifications differs depend on the mechanical unit cables.

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5.REPLACING CABLES B-83495EN/01

4 3 1

Position of No.1 pin


(Example of mechanical unit
cable A05B-1142-H351)

Fig.5.3.1 (f) Replace the parts of connector plate (bottom connector plate)

Name Specifications Q’ty LOCTITE Torque N-m (kgf-cm)


1 PLATED BOLT A97L-0218-0496#M4X12BC 9 2.0Nm(20kgfcm)
2 PLATED BOLT A97L-0218-0546#040808BC 4
3 CON.PLATE (*) A290-7142-X212 1
4 GASKET A290-7139-X205 1
(*) Specifications differs depend on the mechanical unit cables.

AIR 1
(O6 black)
AIR 2
(O6 white)

Power line
(redXwhite)
Pulsecoder line
(blueXwhite)
Plated bolt
A97L-0218-0546#040808BC (4)

Clamp J1-1
A290-7142-X220
AIR 1
(O6 black)
Match the marking

AIR 2
(O6 white)

CABLE K101
A660-8018-T491
Pulsecoder line
(blueXwhite)
Power line
(redXwhite)
Tie up with nylon bands

Fig.5.3.1 (g) Clamp of J1 base

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B-83495EN/01 5.REPLACING CABLES

5.3.2 Replacing Cable K106, K107, K108,K109 and Air Tube (J2
base to J3 housing)
1 Record the Quick Master Reference Position referring to Section 8.4 of operator’s manual. ( It is set
in 0° for all axes when robot is shipped.)
2 Turn off the controller power and remove cable of controller side from connector plate of back of
J1-axis.
3 Remove the J3 cover and the gasket referring to Fig.5.3.2 (b).
4 Cut the nylon band, which connect cable to clamp J4-2 referring to Fig.5.3.2 (a).
5 Remove relay of K106 and K111, K113 and K116. Remove relay of K107 and K114, K117.
Remove relay of K108 and K118.
6 Remove the relay of the air tube inside the J2 arm.
7 Remove the relay of the cable K109 and the solenoid valve.
8 Remove the air tube of the solenoid valve.
9 Cut the nylon band, which connect cables and air tubes to clamp J4 referring to Fig.5.3.2 (c).
10 Remove the J2 arm cover and the gasket referring to Fig.5.3.2 (e).
11 Cut the nylon band, which connect cables and air tubes to clamp J3-1 referring to Fig.5.3.2 (d).
12 Cut the nylon band, which connect cables and air tubes to clamp J2-2 referring to Fig.5.3.2 (d).
13 Remove the J2 base cover and the gasket referring to Section 4.4.
14 Cut the nylon band, which connect cables and air tubes to clamp J2-1 referring to Fig.5.3.2 (d).
15 Remove relay to K101 and air tube.
16 Pull out the cable from the upper side and the lower side of the guide arm. In this time, pull out it
after it passes it on the tip of the part of the connector.
17 Replace cable and air tube for the new article and assemble them applying steps above in reversed
sequence. Note that the gasket does not fall out.
18 Perform quick mastering referring to Section 8.4 of operator’s manual.

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5.REPLACING CABLES B-83495EN/01

Power line
(redXwhite)
Pulsecoder line
Nylon band
(blueXwhite)

Air tube
(φ3.2)

Joint
A97L-0118-0108#S23-M5 (1)
Section A-A
A A

Clamp J4-2
A290-7142-X416
Bolt
M4X8 (2)
Fig.5.3.2 (a) Clamp of J3 arm part

2 1
3

Fig.5.3.2 (b) Removing the J3 cover

Name Specifications Q’ty LOCTITE Torque N-m (kgf-cm)


1 PLATED BOLT A97L-0218-0496#M4X10BC 4 2.0Nm(20kgfcm)
2 J3 COVER A290-7142-X404 1
3 GASKET A290-7142-X409 1
- 82 -
B-83495EN/01 5.REPLACING CABLES

Pulsecoder line
(blueXwhite) Air tube
(φ3.2)
Power line
(redXwhite)
Pulsecoder line Air tube
(blueXwhite) (φ3.2)
Power line Match the marking
(redXwhite)

Nylon band
Clamp J4
A290-7142-X415
Detail B
Match the marking
Nylon band

Nylon band
Section A
Section C-C
C C

B
A

Fig.5.3.2 (c) Clamp of J3 housing part

- 83 -
5.REPLACING CABLES B-83495EN/01

Nylon band
Pulsecoder line
(blueXwhite) Match the marking.
Power line
(redXwhite)
Joint
A97L-0118-0108#H23-06 (1) Clamp J3-1
(for AIR 1 black φ3.2→φ6) A290-7142-X323

When H002 - H006,H012 - H016


are specified. AIR 1
(φ3.18 black)
C cable K109
(blueXwhite)
AIR 1
Pulsecoder line (φ6 black)
cable K108
cable K109
Detail C
B B (blueXwhite)
Power line
(redXwhite)
Power line
(redXwhite) J2J3 Pulsecoder line
(blueXwhite)
AIR 2
(φ6 white) Sheet
A290-7142-X326
Clamp J2-2
A290-7142-X322
Nylon band
Section B-B
Match the marking.

A AIR 1
(φ6 black)

Joint
A97L-0142-0214#KQ2L0600 (2)
AIR 2
(φ6 white)

Match the marking. AIR 2


Pulsecoder line (φ6 white)
cable K108
cable K109 AIR 1
(blueXwhite) (φ6 black)

Power line J2J3 Power line


(redXwhite) (redXwhite)
J2/J3 Pulsecoder line
(blueXwhite)
Nylon band

Cable K109
Detail A
Fig.5.3.2 (d) Clamp of J2 arm/J2 base part

- 84 -
B-83495EN/01 5.REPLACING CABLES

3 2
1

Fig.5.3.2 (e) Removing the J2 arm cover

Name Specifications Q’ty LOCTITE Torque N-m (kgf-cm)


1 SEAL BOLT A97L-0218-0496#M4X10BC 6 2.0Nm(20kgfcm)
2 J2 ARM COVER A290-7142-X307 1
3 GASKET A290-7142-X325 1

5.3.3 Replacing Cable K102, K103, K104, K105, K109, K110, K111,
K112, K113
1 Turn off the controller power.
2 In case of cable K102 and K103, remove J2-axis motor.
In case of cable K104 and K105, remove J3-axis motor.
In case of cable K111, remove J4-axis motor.
In case of cable K113 or K114, remove J5-axis motor.
In case of cable K116 or K117, remove J6-axis motor.
See Chapter 4 about removing procedure of each motor.
3 Replace cable by new one and assemble it applying steps above in reversed sequence.
4 Install motor referring to Chapter 4.
5 In case of replacing K103 or K104 or K105 or K110 or K111 or K112 or K113 or K114 or K116 or
K117, perform single axis mastering referring to Section 8.5 of operator’s manual.

5.3.4 Replacing Cable K118


1 Turn off the controller power.
2 Remove the J3 cover and the gasket referring to Fig5.3.2 (b).
3 Cut the nylon bands which fix the cable inside the J3 housing and remove the relay of the cables.
4 Remove the J3 arm cover and the gasket referring to Fig.5.3.4. (a).
5 Cut the nylon bands which fix the cable inside the J3 arm.
6 Remove the washer bolt (3) , connector panel (4) and the gasket (5), then pull out cables (2) from the
J3 arm.
7 Remove relay of K108 and remove cable K118.
8 Replace cable by new one, and assemble it applying steps above in reversed sequence. Be sure to
replace the gasket (5) of Fig.5.3.4 (b) by new one.

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5.REPLACING CABLES B-83495EN/01

1
Fig.5.3.4 (a) Removing the J3 arm cover

Name Specifications Q’ty LOCTITE Torque N-m (kgf-cm)


1 PLATED BOLT A97L-0218-0496#M4X10BC(*2) 7 2.0Nm(20kgfcm)
3 J3 ARM COVER A290-7142-X405 1
4 GASKET A290-7142-X410 1

1
2
3
4
5

Fig.5.3.4 (b) Replacing the cable K118

Name Specifications Q’ty LOCTITE Torque N-m (kgf-cm)


1 CAP A97L-0118-0757#F 1
2 CABLE K118 A660-2007-T608 1
3 WASHER BOLT A97L-0318-0407#M4X6EN 4 2.0Nm(20kgfcm)
4 J3 CON.PLATE S A290-7142-X417 1
5 GASKET A290-7142-X418 1

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B-83495EN/01 5.REPLACING CABLES

5.3.5 Replacing Air Tube


Replacing procedure of air tube between connector plate to J2 base
1 See Subsection 5.3.1.

Replacing procedure of air tube between J2 base to J3 housing


1 See Subsection 5.3.2.

Replacing procedure of air tube between J3 housing to J3 arm


1 Turn off the controller power.
2 Remove J3 arm cover. (See Fig.5.3.4 (a))
3 Remove air tube from panel union on J3 motor.
4 Cut the nylon band, which connects air tube to clamp J4-2 referring to Fig.5.3.2 (a).
5 Remove J3 cover. (See Fig.5.3.2 (b))
6 Cut the nylon band which connects air tube to clamp J4 referring to Fig.5.3.2 (c).
7 Remove the J2 arm cover and the gasket (See Fig.5.3.2 (e).)
8 In case of replacing black tube, remove the air tube from the tube diameter change joint.
In case of replacing air tubes from the solenoid valve, remove the air tubes from the solenoid valve.
(See Fig.5.3.2 (d).)
9 Replace air tube by new one, and install them applying steps above in reversed sequence. When
gasket is attached , be sure to replace gasket.

585
345 190

AIR 1
(φ6 black)

565
325 190
AIR 2
(φ6 white)

connector panel← → J2

Fig.5.3.5 (a) Marking of air tube (connector panel to J2 base)

340

AIR 1
(φ6 black) 210 (Standard)
50 320 (7L) 80

480

AIR 2
(φ6 white)
210 (Standard)
60 320 (7L) 210

J1← → J3

Fig.5.3.5 (b) Marking of air tube (J2 base to J3 housing)

- 87 -
5.REPLACING CABLES B-83495EN/01

930

135 (Standard)
150 160 215 220 (7L) 270
AIR 1
(φ3.18 black)

J2← → J4

Fig.5.3.5 (c) Marking of air tube (J3 housing to J3 arm)

135 (Standard)
150 160 215 220 (7L) 270
AIR 1
(φ3.18 white)

J2← → J4

Fig.5.3.5 (d) Marking of air tube (when A05B-1142-H001 is specified)

Marking

Air tube 135 (Standard)


(O3.18mm blue for 1B) 270 220 (7L) 215 160

270 215 160

Air tube 135 (Standard)


(O3.18mm red for 1A) 220 (7L)

Fig.5.3.5 (e) Marking of air tube (solenoid valve) (when A05B-1142-H002,H012 are specified)

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B-83495EN/01 5.REPLACING CABLES

Marking

Air tube 135 (Standard)


(O3.18mm blue for 1B) 270 220 (7L) 215 160

Air tube 135 (Standard)


(O3.18mm green for 2B) 270 220 (7L) 215 160

270 215 160


Air tube 135 (Standard)
(O3.18mm yellow for 2A) 220 (7L)

270 215 160


135 (Standard)
Air tube 220 (7L)
(O3.18mm red for 1A)

Fig.5.3.5 (f) Marking of air tube (solenoid valve) (when A05B-1142-H003,H013 are specified)

Marking
Air tube 135 (Standard)
(O3.18mm blue for 1B) 270 220 (7L) 215 160

Air tube 135 (Standard)


(O3.18mm green for 2B) 270 220 (7L) 215 160

Air tube 135 (Standard)


(O3.18mm orange for 3B) 270 220 (7L) 215 160

270 215 160


135 (Standard)
Air tube 220 (7L)
(O3.18mm clear for 3A)

270 215 160


135 (Standard)
Air tube 220 (7L)
(O3.18mm yellow for 2A)

270 215 160


135 (Standard)
Air tube 220 (7L)
(O3.18mm red for 1A)
Fig.5.3.5 (g) Marking of air tube (solenoid valve)
(when A05B-1142-H004,H005,H006,H014,H015,H016 are specified)

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5.REPLACING CABLES B-83495EN/01

Air tube
Plug A97L-0218-0010#BFL930R0 (1)
A97L-0218-0019 (1) (O3.18mm white) Half union
A97L-0118-0108#S23-M5 (1)

Joint
A97L-0118-0108#H23-06 (1)

Air tube
(O6mm white) Detail A white

Fig.5.3.5 (h) Removing the air tubes of the solenoid valve (WhenA05B-1142-H001,H001 is specified)

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B-83495EN/01 5.REPLACING CABLES

Solenoid valve kit


A290-7142-V002 (for A05B-1142-H002) or
A290-7142-V003 (for A05B-1142-H003) or
A290-7142-V004 (for A05B-1142-H004) or
Check valve A290-7142-V005 (for A05B-1142-H005) or
A97L-0218-0026#04B-M5 A290-7142-V006 (for A05B-1142-H006) or
A290-7142-V012 (for A05B-1142-H012) or
A290-7142-V013 (for A05B-1142-H013) or
A290-7142-V014 (for A05B-1142-H014) or Half union
A290-7142-V015 (for A05B-1142-H015) or A97L-0118-0108#S23-M5 (6)
A290-7142-V016 (for A05B-1142-H016)
Bolt
A6-BA-4X8 (2)

Cable K109
Air tube A660-2007-T602
(O6mm white)

clear orange yellow green red blue


(*1) (*1) (*2) (*2) (*3) (*3)

Detail A

(*1) When A05B-1142-H004,H005,H006,H014,H015,H016 are specified


(*2) When A05B-1142-H003,H004,H005,H006,H013,H014,H015,H016 are specified
(*3) When A05B-1142-H002,H003,H004,H005,H006,H012,H013,H014,H015,H016 are specified

Fig.5.3.5 (i) Removing the air tubes of the solenoid valve (When solenoid valve option is specified)

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6.ADJUSTMENTS B-83495EN/01

6 ADJUSTMENTS
Each part of the mechanical units of a robot is set to the best condition before the robot is shipped to the
customer. The customer does not need to make adjustments on the robot when it is delivered.

6.1 ADJUSTING TENSION OF BELT


Please use the following tension meters for the tension adjustment of the belt.

Instrument Specifications Vendor Manufacturer model No. Application


Tension meter A97L-0218-0700 Mitsuboshi Belting Ltd. DOCTOR TENSION TYPE-Ⅲ Adjustment of belt
tension

1 Place the robot in the posture to avoid uneven belt tension.


(recommended posture: J3=80º,J5=±90º)
2 Remove the bolt and arm cover (refer to Chapter 4).
3 When Gasket is attached, remove gasket, too.
4 Adjust it so that it may loosen tension-adjusting bolts and the tension may reach a specified value.
5 Attach arm cover. When gasket is attached, be sure to replace gasket by new one. In this time,
tighten the bolt with the specified torque.

Tension
adjusting bolt
(Tightening torque 5.6Nm (57kgfcm)

Fig. 6.1 (a) Adjusting tension of J3 belt

Table. 6.1 (a) Measurement condition of J3 belt


30 – 40N (Standard)
BELT TENSION
49 – 65N (7L)
0.0367kg (Standard)
MASS
0.029kg (7L)
WIDTH 6mm
SPAN 167.5mm

NOTE
The tension of the belt deteriorates slowly, but this is a normal phenomenon.
If belt is adjusted frequently. it shorten the life of belt, please don’t adjust belt
except case of replacing motor, reducer etc.

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B-83495EN/01 6.ADJUSTMENTS

Tension
adjusting bolt
(Tightening torque 5.6Nm (57kgfcm)

Fig. 6.1 (b) Adjusting tension of J5 belt

Tension
adjusting bolt
(Tightening torque 5.6Nm (57kgfcm)

Fig. 6.1 (c) Adjusting tension of J6 belt

Table 6.1 (b) Measurement condition of J5 belt


BELT TENSION 15.6 – 20.6N
MASS 0.02083kg
WIDTH 4mm
SPAN 187mm

Table 6.1 (c) Measurement condition of J6 belt


BELT TENSION 15.6 – 20.6N
MASS 0.02083kg
WIDTH 4mm
SPAN 116mm

- 93 -
APPENDIX
B-83495EN01 APPENDIX A.SPARE PARTS LIST

A SPARE PARTS LIST


Table A (a) List of basic cable (Standard)
Name Specifications Remarks
K101 A660-8018-T491 RMP
K102 A660-4005-T364 J2 power
K103 A660-2007-T599 J2 Pulsecoder
K104 A660-4005-T365 J3 power
K105 A660-2007-T600 J3 Pulsecoder
K106 A660-4005-T366 Relay of J4, J5, J6 power
J4 Pulsecoder
K107 A660-4005-T367 Relay of J5, J6 Pulsecoder
Relay of end effector
K108 A660-2007-T601 Relay of EE
K109 A660-2007-T602 YV
K111 A660-4005-T368 J4 power
K113 A660-4005-T369 J5 power
K114 A660-2007-T605 J5 Pulsecoder
K116 A660-4005-T370 J6 power
K117 A660-2007-T607 J6 Pulsecoder
K118 A660-2007-T608 EE12P
External battery cable 5m
K131 A660-8016-T944
(When external battery option is selected)
External battery cable 7m
K131 A660-8016-T945
(When external battery option is selected)
External battery cable 14m
K131 A660-8016-T946
(When external battery option is selected)

Table A (b) List of basic cable (7L)


Name Specifications Remarks
K101 A660-8018-T491 RMP
K102 A660-4005-T364#L J2 power
K103 A660-2007-T599#L J2 Pulsecoder
K104 A660-4005-T365#L J3 power
K105 A660-2007-T600#L J3 Pulsecoder
K106 A660-4005-T366#L Relay of J4, J5, J6 power
J4 Pulsecoder
K107 A660-4005-T367#L Relay of J5, J6 Pulsecoder
Relay of end effector
K108 A660-2007-T601#L Relay of EE
K109 A660-2007-T602#L YV
K111 A660-4005-T368 J4 power
K113 A660-4005-T369#L J5 power
K114 A660-2007-T605#L J5 Pulsecoder
K116 A660-4005-T370#L J6 power
K117 A660-2007-T607#L J6 Pulsecoder
K118 A660-2007-T608#L EE12P
External battery cable 5m
K131 A660-8016-T944
(When external battery option is selected)
External battery cable 7m
K131 A660-8016-T945
(When external battery option is selected)
External battery cable 14m
K131 A660-8016-T946
(When external battery option is selected)
- 97 -
A.SPARE PARTS LIST APPENDIX B-83495EN/01

Table A (c) Motor


Name Specifications Remarks
βiSR1/6000(*) A06B-0116-B855#0048 J1,J2-axis
βiSR0.5/6000 A06B-0115-B855#0048 J3-axis
βiSR0.4/4000 A06B-0114-B855#0048 J4-axis
βiSR0.2/4000 A06B-0117-B855#0049 J5,J6-axis
(*) When J2-axis motor is replaced, please order shaft “A290-7139-X322” at the same time.

Table A (d) Reducer


Name Specifications Remarks
Harmonic drive A97L-0218-0951#70 J1-axis (Standard)
Harmonic drive A97L-0218-0980#80 J1-axis (7L)
Harmonic drive A97L-0218-0952#100 J2-axis (Standard)
Harmonic drive A97L-0218-0952#120 J2-axis (7L)
Harmonic drive A97L-0218-0953#80 J3-axis
Harmonic drive A97L-0218-0954#80 J4-axis
Harmonic drive A97L-0218-0955#50 J5-axis
Harmonic drive A97L-0218-0956#50 J6-axis

NOTE
When arranging in the reducer machine unit, the waving generator is built into
the main body of the reducer machine beforehand as for J4-axis reducer. As for
other reducers, the waving generator is separated from the main body of the
reducer machine.

Table A (e) Gear


Name Specifications Remarks
GEAR J1-1 A290-7142-X202 J1-axis (Standard)
GEAR J1-1 A290-7142-X248 J1-axis (7L)
GEAR J4-1 A290-7142-X406 J4-axis

Table A (f) Pulley, shaft, key


Name Specifications Remarks
Pulley J3-1 A290-7142-X309 J3-axis motor (Standard)
Pulley J3-2 A290-7142-X310 J3-axis reducer (Standard)
Pulley J3-1 A290-7142-X333 J3-axis motor (7L)
Pulley J3-2 A290-7142-X334 J3-axis reducer (7L)
Pulley A290-7142-X411 J5-axis motor
Pulley A290-7142-X412 J5-axis reducer
Pulley A290-7142-X429 J6-axis motor
Pulley A290-7142-X414 J6-axis bevel gear
Shaft A290-7139-X322 J2-axis
Key A97L-0118-0402#3X3X12BN Motor, pulley, gear (4 pcs/1 robot)
Key A97L-0118-0402#3X3X6BN Motor, pulley, gear (5 pcs/1 robot)
key A97L-0118-0402#3X3X9BN J3-axis reducer

Table A (g) Belt


Name Specifications Remarks
Belt A98L-0040-0285#006-095 J3-axis motor (Standard)
Belt A98L-0040-0286#004-104 J5-axis motor (Standard,7L)
Belt A98L-0040-0286#004-157 J6-axis motor (Stanard,7L)
Belt A98L-0040-0293#006-100 J3-axis motor (7L)

- 98 -
B-83495EN01 APPENDIX A.SPARE PARTS LIST
Table A (h) Gasket
Name Specifications Remarks
Gasket A290-7139-X253 Battery box cover
Gasket A290-7142-X315 J2 base
Gasket A290-7142-X316 Cover S
Gasket A290-7142-X324 J2 base cover
Gasket A290-7142-X325 J2 arm cover 2 pcs/1 robot
Gasket A290-7142-X409 J3 cover
Gasket A290-7142-X410 J3 arm cover 2 pcs/1 robot

Table A (i) O-RING


Name Specifications Remarks
O-RING A98L-0001-0347#S46 J1,J4-axis motor 4 pcs/1 robot
O-RING JB-OR1A-G45 J2-axis motor

Table A (j) Seal bolt


Name Specifications Remarks
Seal bolt A97L-0218-0423#030606 J4 pipe 4 pcs/1 robot
Seal bolt A97L-0218-0423#030606 Support 7 pcs/1 robot
Seal bolt A97L-0218-0423#051212 J2-axis motor 4 pcs/1 robot
Seal bolt A97L-0218-0546#032204BC J3-axis reducer 12 pcs/1 robot
Seal bolt A97L-0218-0546#043016BC J1-axis reducer 12 pcs/1 robot
Seal bolt A97L-0218-0546#043516BC J2-axis reducer 12 pcs/1 robot
Seal bolt A97L-0318-0405#040606EN J2 - J6-axis grease inlet 5 pcs/1 robot
Seal bolt A97L-0318-0406#081010EN J1-axis grease inlet

Table A (k) Spring pin, Stopper, Wrist unit, Sheet, Shaft


Name Specifications Remarks
Spring pin A6-PS-8X20S J3 stopper
Stopper A290-7142-X427 J3 stopper
Wrist unit A290-7142-V501 With J5/J6-axis reducer

Sheet A290-7142-X228 J1-axis motor


A290-7142-X330 J2-axis motor
Shaft A290-7139-X322 J2-axis motor

Table A (l) Air tube


Name Specifications Remarks
3.18mm BLACK AIR1
Air tube A97L-0218-0010#AFL3R003
J2 arm to J3 arm
6mm BLACK AIR1
Air tube A97L-0218-0114#ABL3R003
J2 base to J3 casing
6mm BLACK AIR1
Air tube A97L-0218-0114#ABL3R003
Connector plate to J2 base
Air tube A97L-0218-0114#BBL3R003 6mm WHITE AIR2
6mm WHITE AIR2
Air tube A97L-0218-0114#BBL3R003
Connector plate to J2 base
Air tube 3.18mm WHITE AIR2
A97L-0218-0114#BFL3R003
(H001,H011) J2 arm to J3 casing
Air tube 4mm WHITE EXHAUST
(H002,H003,H004,H005, J2 arm to J3 casing
A97L-0218-0010#BAL3R003
H006,H012,H013,H014,H0
15,H016)

- 99 -
A.SPARE PARTS LIST APPENDIX B-83495EN/01

Name Specifications Remarks


Air tube 3.18mm RED 1A
(H002,H003,H004,H005, J2 arm to J3 casing
A97L-0218-0010#CFL3R003
H006,H012,H013,H014,H0
15,H016)
Air tube 3.18mm RED 1B
(H002,H003,H004,H005, J2 arm to J3 casing
A97L-0218-0010#DFL3R003
H006,H012,H013,H014,H0
15,H016)
Air tube 3.18mm YELLOW 2A
(H003,H004,H005,H006, A97L-0218-0010#EFL3R003 J2 arm to J3 casing
H013,H014,H015,H016)
Air tube 3.18mm GREEN 2B
(H003,H004,H005,H006, A97L-0218-0010#FFL3R003 J2 arm to J3 casing
H013,H014,H015,H016)
Air tube 3.18mm CLEAR 3A
(H004,H005,H006,H014, A97L-0218-0010#GFL3R003 J2 arm to J3 casing
H015,H016)
Air tube 3.18mm ORANGE 3B
(H004,H005,H006,H014, A97L-0218-0010#HFL3R003 J2 arm to J3 casing
H015,H016)

Table A (m) Solenoid valve (Either the following is installed by the option specification)
(except H001, H011)
Name Specifications Remarks
Solenoid valve A97L-0218-0130#D1 Double solenoidX1 (2 positionX1)
Solenoid valve A97L-0218-0130#D2 Double solenoidX2 (2 positionX2)
Solenoid valve A97L-0218-0130#D3 Double solenoidX3 (2 positionX3)
Solenoid valve A97L-0218-0130#D3R Double solenoidX3
(3 position (exhaust center) X3)
Solenoid valve A97L-0218-0130#D3B Double solenoidX3
(3 position (closed center) X3)

Table A (n) Battery


Name Specifications Remarks
Battery A98L-0031-0027 C battery/1.5V 4pcs/ per 1 robot
(When battery built-in option is selected)
Battery A98L-0031-0005 D battery/1.5V 4pcs/ per 1 robot
(When external battery option is selected)

Table A (o) Grease


Name Specifications Remarks
Grease A98L-0040-0230 Harmonic grease 4BNo.2
Greasing kit A05B-1142-K021
Grease in tube A05B-1139-K022

- 100 -
B-83495EN01 APPENDIX B.CIRCUIT DIAGRAM, AIR PRESSURE DIAGRAM

B CIRCUIT DIAGRAM, AIR PRESSURE


DIAGRAM

- 101 -
B.CIRCUIT DIAGRAM, AIR PRESSURE DIAGRAM APPENDIX B-83495EN/01

A63L-0001-0865#1
A63L-0001-0864#CS J1 MOTOR (βiSR1/6000)
M1M
2 J1V1 1 J1U1
3 J1W1 4 J1G1
A63L-0001-0865#2
A63L-0001-0864#CS
M1BK
2 BK(J1) 1 BKC(J1)
3 4

A63L-0001-0848#E10SL1
A63L-0001-0850 M1P 4 6V(BT1)
8 1
5 XPRQJ1
9 5V(J1) 2
6 PRQJ1
10 0V(J1) 3
7 0V(BT1)

A63L-0001-0865#1
A63L-0002-0066#R06DX A63L-0001-0864#CS J2 MOTOR (βiSR1/6000)
A63L-0002-0066#CRM
F06DX
M2M1 CTM M2M
A1 J2U1 B1 J2G1 K102 2 J2V1 1 J2U1
A2 BK(J2) B2 J2V1 A660-4005-T364 3 J2W1 4 J2G1
A3 J2W1 B3 BKC(J2) A660-4005-T364#L
A63L-0001-0865#2
A63L-0001-0864#CS
( X-KEY
BLACK ) M2BK
2 BK(J2) 1 BKC(J2)
3 4
A63L-0002-0205#6SB
A63L-0002-0205#2428SCFA A63L-0001-0848#E10SL1
M2P1 6PB
2428PCFA A63L-0001-0850 M2P 4 6V(BT2)
1 6V(BT2) 4 0V(BT2) 8 1
5 XPRQJ2
2 PRQJ2 5 XPRQJ2 9 5V(J2) 2
6 PRQJ2
3 5V(J2) 6 0V(J2) K103 10 0V(J2) 3
7 0V(BT2)
A660-2007-T599
( BLACK ) A660-2007-T599#L

A63L-0001-0865#1
A63L-0002-0066#R06DYW A63L-0001-0864#CS J3 MOTOR (βiSR0.5/6000)
A63L-0002-0066#CRM
F06DYW
M3M1 CTM M3M
A1 J3U1 B1 J3G1 K104 2 J3V1 1 J3U1
J1 CONNECTOR PANEL A2 BK(J3) B2 J3V1 A660-4005-T365
A660-4005-T365#L
3 J3W1 4 J3G1
A3 J3W1 B3 BKC(J3) A63L-0001-0865#2
A63L-0001-0864#CS
RMP Han 72DD
(2.5SQ 10A) ( Y-KEY
WHITE ) M3BK
1 BK(J1) 13 BK(J2) 25 BK(J3) 37 BK(J4) 49 BK(J5) 61 BK(J6) 2 BK(J3) 1 BKC(J3)
2 J1U1 14 J2U1 26 J3U1 38 50 62 BKC(J1-J6) 3 4
3 J1V1 15 J2V1 27 J3V1 39 J4U1 51 J5U1 63 J6U1 A63L-0002-0205#7SW
4 J1W1 16 J2W1 28 J3W1 40 J4V1 52 J5V1 64 J6V1 A63L-0002-0205#2428SCFA A63L-0001-0848#E10SL1
5 J1G1 17 J2G1 29 J3G1 41 J4W1 53 J5W1 65 J6W1 K101 M3P1 7PW
2428PCFA A63L-0001-0850 M3P 4 6V(BT3)
6 XROT 18 24VF(OT,A1,A2) 30 XHBK 42 J4G1 54 J5G1 66 J6G1 A660-8018-T491 2 PRQJ3 1 6V(BT3) 8 1
5 XPRQJ3
7 RI1 19 RI2 31 RI3 43 RI4 55 RI5 67 0V(A1,A2,B1-B6) 5 XPRQJ3 4 0V(BT3) 3 5V(J3) 9 5V(J3) 2
6 PRQJ3
8 RO1 20 RO2 32 RO3 44 RO4 56 RO5 68 RI6 7 6 0V(J3) K105 10 0V(J3) 3
7 0V(BT3)
9 RI7 21 RI8 33 RO7 45 RO8 57 69 RO6 A660-2007-T600
10 5V(J1,J2) 22 5V(J3,J4) 34 5V(J5,J6) 46 0V(J1,J2) 58 0V(J3,J4) 70 0V(J5,J6) ( WHITE ) A660-2007-T600#L
11 PRQJ1 23 PRQJ2 35 PRQJ3 47 PRQJ4 59 PRQJ5 71 PRQJ6
12 XPRQJ1 24 XPRQJ2 36 XPRQJ3 48 XPRQJ4 60 XPRQJ5 72 XPRQJ6
G SG
F20DX
M456M CTM
A1 J4U1 B1 J4G1
A63L-0002-0066#R20DX A2 BK(J4) B2 J4V1
A63L-0002-0066#CRM
A3 J4W1 B3 BKC(J4)
A4 B4
A5 J5G1 B5 J5U1
A6 J5V1 B6 BK(J5) K106
A660-4005-T366
A7 BKC(J5) B7 J5W1 A660-4005-T366#L
X-KEY
( BLACK ) A8
A9
J6U1
BK(J6)
B8
B9
J6G1
J6V1
A10 J6W1 B10 BKC(J6)

BATTERY A63L-0002-0205#13SB
6V
(BT1,BT2,BT3,
A63L-0002-0205#2428SCFA
M456P 13PB
2428PCFA
3 2 XPRQJ4 1 PRQJ4
BT4,BT5,BT6)
7 6V(BT4-BT6) 6 0V(BT4-BT6) 5 XPRQJ5 4 PRQJ5
+ 11 5V(J4) 10 0V(J4) 9 XPRQJ6 8 PRQJ6
K107
A660-4005-T367
13 5V(J5,J6) 12 0V(J5,J6) A660-4005-T367#L

( 単二電池
SIZE C ) ( BLACK )

-
0V A63L-0002-0205#13SW
(BT1,BT2,BT3, 13PW
BT4,BT5,BT6)
A63L-0002-0205#2428SCFA
EE1 2428PCFA
3 24VF(A1,A2) 2 RI2 1 RI1
7 RI6 6 RI5 5 RI4 4 RI3
K108
11 0V(A1,A2) 10 XHBK 9 RO8 8 RO7
A660-2007-T601
13 RI8 12 RI7 A660-2007-T601#L
( WHITE )

A63L-0002-0205#7SB
A63L-0002-0205#2428SCFA 7PB
YV1 2428PCFA
2 RO2 1 RO1
5 RO5 4 RO4 3 RO3 K109
7 0V(B1-B6) 6 RO6 A660-2007-T602
A660-2007-T602#L
( BLACK )

注)
NOTE)

(**):使用されていない信号
SIGNALS ARE NOT USED
**#L:ロングアームタイプでのケーブル仕様
CABLE SPEC. IN CASE OF LONG ARM TYPE

Fig. B (a) Circuit diagram (Standard cable)

- 102 -
B-83495EN01 APPENDIX B.CIRCUIT DIAGRAM, AIR PRESSURE DIAGRAM

A63L-0001-0865#1
A63L-0002-0066#R08DX
A63L-0001-0864#CS J4 MOTOR (βiSR0.4/6000)
A63L-0002-0066#CRM
M4M1 F08DX
CTM M4M
A1 J4U1 B1 J4G1 K111 2 J4V1 1 J4U1
A2 BK(J4) B2 J4V1 A660-4005-T368 3 J4W1 4 J4G1
A3 J4W1 B3 BKC(J4) A63L-0001-0865#2
A4 B4 A63L-0001-0864#CS
( X-KEY
BLACK ) M4BK
2 BK(J4) 1 BKC(J4)
3 4

A63L-0001-0848#E10SL1
A63L-0001-0850 M4P 4 6V(BT4)
8 1
5 XPRQJ4
9 5V(J4) 2
6 PRQJ4
10 0V(J4) 3
7 0V(BT4)

A63L-0001-0865#1
A63L-0002-0066#R06DX A63L-0001-0864#CS J5 MOTOR (βiSR0.2/6000)
A63L-0002-0066#CRM
F06DX
M5M1 CTM M5M
A1 J5U1 B1 J5G1 K113 2 J5V1 1 J5U1
A2 BK(J5) B2 J5V1 A660-4005-T369 3 J5W1 4 J5G1
A3 J5W1 B3 BKC(J5) A660-4005-T369#L
A63L-0001-0865#2
A63L-0001-0864#CS
( X-KEY
BLACK ) M5BK
2 BK(J5) 1 BKC(J5)
3 4
A63L-0002-0205#6SB
A63L-0002-0205#2428SCFA A63L-0001-0848#E10SL1
M5P1 6PB
2428PCFA A63L-0001-0850 M5P 4 6V(BT5)
1 6V(BT5) 4 0V(BT5) 8 1
5 XPRQJ5
2 PRQJ5 5 XPRQJ5 9 5V(J5) 2
6 PRQJ5
3 5V(J5) 6 0V(J5) K114 10 0V(J5) 3
7 0V(BT5)
A660-2007-T605
( BLACK ) A660-2007-T605#L

A63L-0001-0865#1
A63L-0002-0066#R06DYW A63L-0001-0864#CS J6 MOTOR (βiSR0.2/6000)
A63L-0002-0066#CRM
F06DYW
M6M1 CTM M6M
A1 J6U1 B1 J6G1 K116 2 J6V1 1 J6U1
A2 BK(J6) B2 J6V1 A660-4005-T370 3 J6W1 4 J6G1
A3 J6W1 B3 BKC(J6) A660-4005-T370#L
A63L-0001-0865#2
A63L-0001-0864#CS
( Y-KEY
WHITE ) M6BK
2 BK(J6) 1 BKC(J6)
3 4
A63L-0002-0205#7SW
A63L-0002-0205#2428SCFA A63L-0001-0848#E10SL1
M6P1 7PW
2428PCFA A63L-0001-0850 M6P 4 6V(BT6)
2 PRQJ6 1 6V(BT6) 8 1
5 XPRQJ6
5 XPRQJ6 4 0V(BT6) 3 5V(J6) 9 5V(J6) 2
6 PRQJ6
7 6 0V(J6) K117 10 0V(J6) 3
7 0V(BT6)
A660-2007-T607
( WHITE ) A660-2007-T607#L

A63L-0002-0205#13SB
J3 CONNECTOR PANEL
A63L-0002-0205#2428SCFA
EE2 13PB
2428PCFA EE A63L-0002-0072#12SN
3 24VF(A1,A2) 2 RI2 1 RI1 8 RO8 9 24VF(A1) 1 RI1
7 RI6 6 RI5 5 RI4 4 RI3 7 RO7 12 0V(A2) 10 24VF(A2) 2 RI2
K118
11 0V(A1,A2) 10 (XHBK) 9 RO8 8 RO7 6 RI6 11 0V(A1) 3 RI3
A660-2007-T608
13 (RI8) 12 (RI7) A660-2007-T608#L 5 RI5 4 RI4
( BLACK )

A05B-1142-H002,-H012
YV2 13PB
2428PCFA
3 2 RO2 1 R01
7 6 5 4
SOLENOID VALVE
11 10 9 0V(B2) 8 0V(B1)
A97L-0218-0130#D1
13 12

A05B-1142-H003,-H013
YV2 13PB
2428PCFA
3 R03 2 RO2 1 R01
7 6 5 4 RO4
SOLENOID VALVE
11 0V(B4) 10 0V(B3) 9 0V(B2) 8 0V(B1)
A97L-0218-0130#D2
13 12

A05B-1142-H004,-H014
YV2 13SB
2428SCFA YV2 13PB
2428PCFA
1 R01 2 RO2 3 R03 3 R03 2 RO2 1 R01
4 RO4 5 RO5 6 RO6 7 7 6 RO6 5 RO5 4 RO4
8 0V(B1) 9 0V(B2) 10 0V(B3) 11 0V(B4) 11 0V(B4) 10 0V(B3) 9 0V(B2) 8 0V(B1) SOLENOID VALVE
A97L-0218-0130#D3
12 0V(B5) 13 0V(B6) 13 0V(B6) 12 0V(B5)

A05B-1142-H005
YV2 13PB
2428PCFA
3 R03 2 RO2 1 R01
7 6 RO6 5 RO5 4 RO4
11 0V(B4) 10 0V(B3) 9 0V(B2) 8 0V(B1) SOLENOID VALVE
A97L-0218-0130#D3B
13 0V(B6) 12 0V(B5)

A05B-1142-H006
YV2 13PB
2428PCFA
:可動部用
7
3 R03
6 RO6
2 RO2
5 RO5
1 R01
4 RO4
SOLENOID VALVE
MOVABLE
11 0V(B4) 10 0V(B3) 9 0V(B2) 8 0V(B1)
A97L-0218-0130#D3R
13 0V(B6) 12 0V(B5)

- 103 -
B.CIRCUIT DIAGRAM, AIR PRESSURE DIAGRAM APPENDIX B-83495EN/01

J1 CONNECTOR PANEL

K101
A660-8018-T491

BATTERY
6V
(BT1,BT2,BT3,
BT4,BT5,BT6)
GB2 GB2
+ A
6V(BT1,BT2,BT3,
A
6V(BT1,BT2,BT3, TERMINAL
BT4,BT5,BT6) BT4,BT5,BT6)
単一電池 0V(BT1,BT2,BT3, 0V(BT1,BT2,BT3,
( SIZE D ) K131
B
BT4,BT5,BT6)
B
BT4,BT5,BT6) K119
A660-8016-T498 A660-8018-T493
C C
A65L-0001-0337#102P
-
0V
(BT1,BT2,BT3, A63L-0001-0648#610SL3SJ A63L-0001-0648#610SL3SJ
BT4,BT5,BT6)

Fig.B (b) Circuit diagram (when remote type battery is specified)

J3 CONNECTOR PANEL
A63L-0002-0205#13SW A63L-0002-0205#13SB
A63L-0002-0205#2428SCFA
EE1 13PW
2428PCFA
A63L-0002-0205#2428SCFA
EE2 13PB
2428PCFA EE A63L-0002-0072#20SN
3 24VF(A1,A2) 2 RI2 1 RI1 3 24VF(A1,A2) 2 RI2 1 RI1 5 RO1 11 RI1
7 RI6 6 RI5 5 RI4 4 RI3 7 RI6 6 RI5 5 RI4 4 RI3 1 0V(B1) 6 RO2 12 RI2 17 XHBK
K108
11 0V(A1,A2) 10 XHBK 9 RO8 8 RO7 A660-2007-T601 11 0V(A1,A2) 10 XHBK 9 (RO8) 8 (RO7) 2 0V(B2) 7 RO3 13 RI3 18 24VF(A1)
13 RI8 12 RI7 13 (RI8) 12 (RI7) 3 0V(A1) 8 RO4 14 RI4 19 24VF(A1)

( WHITE ) ( BLACK ) 4 0V(A2) 9


10
RO5
RO6
15
16
RI5
RI6
20 24VF(A2)

A63L-0002-0205#7SB A63L-0002-0205#13SB
13PB
A63L-0002-0205#2428SCFA
YV1 7PB
2428PCFA
A63L-0002-0205#2428SCFA
YV2 2428PCFA
3 R03 2 RO2 1 R01
5 RO5
2 RO2
4 RO4
1 RO1
3 RO3 K109
7 6 RO6 5 RO5
11 (0V(B4)) 10 (0V(B3)) 9 0V(B2)
4
8
RO4
0V(B1)
K120 :可動部用
( BLACK )
7 0V(B1-B6) 6 RO6 A660-2007-T602

( BLACK )
13 (0V(B6)) 12 (0V(B5))
A660-4005-T371
MOVABLE

Fig.B (c) Circuit diagram (when EE20P is specified)

A63L-0002-0205#13SB
13PB
A63L-0002-0205#2428SCFA
CAM-A 2428PCFA
J1 CONNECTOR PANEL 7 LED+
3 LED-
6 TRG
2 SHIELD 1 12V
5 GND(TRG) 4 0V
K202
CAM1 LF13WBR-11P
11 GND(VIDEO) 10 VIDEO 9 GND(VD) 8
13 GND(HD) 12 HD
VD
A660-2007-T609
D LED+ C LED- B 12V A 0V
4 GND(VIDEO) 3 TRG 2 GND(VD,TRG) 1 VD ( BLACK )
7 VIDEO 6 GND(HD) 5 HD

K201
A63L-0002-0205#5SB
FS1 LF10WBR-4P
A05B-1142-D001
A63L-0002-0205#2428SCFA
1
2
0V
TX2
4
3
24V
TX1
FS-A 5PB
2428PCFA
3 TX1 2 TX2 1 0V
5 DRAIN 4 24V K203
A660-2007-T610

( BLACK )

A63L-0002-0205#13SB
13PB
A63L-0002-0205#2428SCFA
CAM3 2428PCFA
3 LED- 2 SHIELD 1 12V J3 CONNECTOR PANEL
7 LED+ 6 TRG 5 GND(TRG) 4 0V
K204
11 GND(VIDEO) 10
13
VIDEO 9 GND(VD) 8
GND(HD) 12 HD
VD
A05B-1142-D002 CAM2 LF13WBR-11S
A 0V B 12V C LED- D LED+
1 VD 2 GND(VD,TRG) 3 TRG 4 GND(VIDEO)
5 HD 6 GND(HD) 7 VIDEO

A63L-0002-0205#5SB FS2 LF07WBR-6S


A63L-0002-0205#2428SCFA 6 1 0V
FS-B 5PB
2428PCFA
5
4 24V
2
3
TX2
TX1
3 TX1 2 TX2 1 0V
5 DRAIN 4 24V

:可動部用
MOVABLE
Fig.B (d) Circuit diagram (camera cable / sensor cable)

- 104 -
B-83495EN01 APPENDIX B.CIRCUIT DIAGRAM, AIR PRESSURE DIAGRAM

J3 CONNECTOR PANEL
CAM2 LF13WBR-11S CAM3 HR10-10R-12P(01)
A 0V B 12V C (LED-) D (LED+) 1 0V 9 TRG
1 VD 2 GND(VD,TRG) 3 TRG 4 GND(VIDEO) K251 2 12V 10 8 GND(TRG)
5 HD 6 GND(HD) 7 VIDEO A660-2007-T614 3 GND(VIDEO) 11 TRG 12 GND(VD) 7 VD
4 VIDEO 5 GND(HD) 6 HD

J3 CONNECTOR PANEL
CAM2 LF13WBR-11S CAM3 HR10-10R-12P(01)
A 0V B 12V C LED- D LED+ 1 0V 9 TRG
1 VD 2 GND(VD,TRG) 3 TRG 4 GND(VIDEO) K252 2 12V 10 8 GND(TRG)
5 HD 6 GND(HD) 7 VIDEO A660-4005-T400 3 GND(VIDEO) 11 TRG 12 GND(VD) 7 VD
4 VIDEO 5 GND(HD) 6 HD

LED LF07WBR-3P
1 LED+ 3 LED-
2

Fig.B (e) Circuit diagram (camera cable)

J3 CONNECTOR PANEL FORCE SENSOR(6AXES)


FS2 LF07WBR-6S
FS3
6 1 0V LF10WBR-4P
5 2 TX2 SENSOR CABLE 1 0V 4 24V
4 24V 3 TX1 A660-2007-T615 2 TX2 3 TX1

J3 CONNECTOR PANEL FORCE SENSOR(3AXES)


FS2 LF07WBR-6S FS3 LF10WBR-12P
6 1 0V 1 9 0V
5 2 TX2 SENSOR CABLE 2 10 8
4 24V 3 TX1 A660-2007-T691 11 24V 12
3 7 TX2
4 6
5 TX1

Fig. B (f) Circuit diagram (force sensor cable)

- 105 -
B.CIRCUIT DIAGRAM, AIR PRESSURE DIAGRAM APPENDIX B-83495EN/01

J1 connector plate J3 arm


AIR 1
J1 connector plate
AIR 2 J2 arm
Exhaust port

RO1

RO2

B1 A1

Fig. B(g) Air pressure diagram


(Double solenoid valve×1 A05B-1142-H002,H012 is specified)

J1 connector plate J3 arm


AIR 1
J1 connector plate
AIR 2 J2 arm
Exhaust port

RO3
RO1

RO2
RO4

B2 A2 B1 A1

Fig. B(h) Air pressure diagram


(Double solenoid valve×2 A05B-1142-H003,H013 is specified)

- 106 -
B-83495EN01 APPENDIX B.CIRCUIT DIAGRAM, AIR PRESSURE DIAGRAM

J1 connector plate J3 arm


AIR 1
J1 connector plate
AIR 2 J2 arm
Exhaust port

RO5 RO3
RO1

RO2
RO6 RO4

B3 A3 B2 A2 B1 A1

Fig. B(i) Air pressure diagram


(Double solenoid valve×3 A05B-1142-H004,H014 is specified)

J1 connector plate
AIR 1 J3 arm

J1 connector plate J2 arm


AIR 2 Exhaust port

RO5 RO3 RO1

RO6 RO4 RO2

B3 A3 B2 A2 B1 A1

Fig. B(j) Air pressure diagram


(Double solenoid valve×3 A05B-1142-H005,H015 is specified)

- 107 -
B.CIRCUIT DIAGRAM, AIR PRESSURE DIAGRAM APPENDIX B-83495EN/01

J1 connector plate
AIR 1 J3 arm

J1 connector plate J2 arm


AIR 2 Exhaust port

RO5 RO3 RO1

RO6 RO4 RO2

B3 A3 B2 A2 B1 A1

Fig. B(k) Air pressure diagram


(Double solenoid valve×3 A05B-1142-H006,H016 is specified)

- 108 -
B-83495EN/01 APPENDIX C.PERIODIC MAINTENANCE TABLE

C PERIODIC MAINTENANCE TABLE

- 109 -
C.PERIODIC MAINTENANCE TABLE APPENDIX B-83495EN/01

FANUC Robot LR Mate 200iD, ARC Mate 50iD ,LR Mate 200iD/7L,
ARC Mate 50iD/7L Periodic Maintenance Table

3 6 9 1 2
Working time (H) Check Grease
First
check months months months years years
time amount
Items 320 960 1920 2880 3840 4800 5760 6720 7680 8640 9600 10560
Check the exposed
1 connector.(loosening)
0.2H ― ○ ○ ○

2 Tighten the end effector bolt. 0.2H ― ○ ○ ○


Tighten the cover and main
3 bolt.
2.0H ― ○ ○ ○
Check the mechanical
4 stopper.
0.1H ― ○ ○ ○
Mechanical unit

5 Remove spatter and dust etc. 1.0H ― ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○


Check hand cable and
6 external battery cable (option) 0.1H ― ○ ○ ○
Replacing battery.
(if built-in batteries are 0.1H ― ● ●
specified)
7
Replacing battery.
(if external batteries are 0.1H ― ●
specified)
8 Greasing the reducers. 0.5H 14ml

Replacing cable of mechanical


9 unit *1 4.0H ―
Check the robot cable, teach
10 pendant cable and robot 0.2H ― ○ ○ ○
connecting cable
Controller

11 Cleaning the ventilator 0.2H ― ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

12 Replacing battery *1 0.1H ―


*1 Refer to manual of controller.
*2 ●: requires order of parts
○: does not require order of parts

- 110 -
B-83495EN/01 APPENDIX C.PERIODIC MAINTENANCE TABLE

3 4 5 6 7 8
years years years years years years
11520 12480 13440 14400 15360 16320 17280 18240 19200 20160 21120 22080 23040 24000 24960 25920 26880 27840 28800 29760 30720 Item

○ ○ ○ ○ ○ 1

○ ○ ○ ○ ○ 2

○ ○ ○ ○ ○ 3

○ ○ ○ ○ ○ 4

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ 5

○ ○ ○ ○ ○ 6

Overhaul
● ● ● ● ●
7
● ● ● ●

● 8

● 9

○ ○ ○ ○ ○ 10

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ 11

● 12

- 111 -
D.MOUNTING BOLT TORQUE LIST APPENDIX B-83495EN/01

D MOUNTING BOLT TORQUE LIST


NOTE
When applying LOCTITE to the important bolt tightening points, make sure that it is
applied to the entire longitudinal portion in the engaging section of the female threads. If it
is applied to the male threads, the bolts may be loosened because sufficient adhesion
cannot be obtained. Remove the dust within the bolts and tapped holes and wipe oil off
the engaging section. Make sure that there is no solvent in the tapped holes. Be sure to
wipe the excess LOCTITE after tightening bolt.
Use bolt which strengths are below.
But if it is specified in text, obey it.
Hexagon socket head bolt made by steel
Size is M22 or less : Tensile strength 1200N/mm2 or more
Size is M24 or more : Tensile strength 1000N/mm2 or more
All size of bolt of the plating : Tensile strength 1000N/mm2 or more

Hexagon bolt, stainless bolt, special shape bolt (button bolt, low-head bolt, flush bolt .etc)
Tensile strength 400N/mm2 or more

If no tightening torque is specified for a bolt, tighten it according to this table.


Recommended bolt tightening torques Unit: Nm
Hexagon socket head
button bolt
Hexagon socket head
Hexagon socket head Hexagon socket head Hexagon bolt
bolt
Nominal bolt (stainless) flush bolt (steel)
(Steel)
diameter Low-head bolt
(steel)
Tightening torque Tightening torque Tightening torque Tightening torque
Upper limit Lower limit Upper limit Lower limit Upper limit Lower limit Upper limit Lower limit
M3 1.8 1.3 0.76 0.53 ―――― ―――― ―――― ―――
M4 4.0 2.8 1.8 1.3 1.8 1.3 1.7 1.2
M5 7.9 5.6 3.4 2.5 4.0 2.8 3.2 2.3
M6 14 9.6 5.8 4.1 7.9 5.6 5.5 3.8
M8 32 23 14 9.8 14 9.6 13 9.3
M10 66 46 27 19 32 23 26 19
M12 110 78 48 33 ―――― ―――― 45 31
(M14) 180 130 76 53 ―――― ―――― 73 51
M16 270 190 120 82 ―――― ―――― 98 69
(M18) 380 260 160 110 ―――― ―――― 140 96
M20 530 370 230 160 ―――― ―――― 190 130
(M22) 730 510 ―――― ―――― ―――― ―――― ―――― ――――
M24 930 650 ―――― ―――― ―――― ―――― ―――― ――――
(M27) 1400 960 ―――― ―――― ―――― ―――― ―――― ――――
M30 1800 1300 ―――― ―――― ―――― ―――― ―――― ――――
M36 3200 2300 ―――― ―――― ―――― ―――― ―――― ――――

- 112 -
B-83495EN/01 APPENDIX E.OPTIONAL CONNECTOR WIRING PROCEDURE

E OPTIONAL CONNECTOR WIRING


PROCEDURE
Source of information: Hirose Electric Co., Ltd.

NOTE1
NOTE2

NOTE1) Corresponds to A05B-1137-J057.


NOTE2) Corresponds to A05B-1137-J058 and A05B-1139-J059.

- 113 -
B-83495EN/01 INDEX

INDEX
REPLACING J2-AXIS REDUCER................................ 35
<Number> REPLACING J3 BELT................................................... 68
1.5-YEAR (5760 HOURS) CHECKS ...............................6 REPLACING J3-AXIS MOTOR.................................... 38
1-YEAR (3840 HOURS) CHECKS ..................................6 REPLACING J3-AXIS REDUCER................................ 40
3-MONTH (960 HOURS) CHECKS ................................6 REPLACING J4-AXIS MOTOR.................................... 45
4-YEAR (15360 HOURS) CHECKS ................................6 REPLACING J4-AXIS REDUCER................................ 47
REPLACING J5/J6 BELT .............................................. 69
<A> REPLACING J5-AXIS MOTOR.................................... 51
ADJUSTING TENSION OF BELT ................................ 92 REPLACING J5-AXIS REDUCER (7L)........................ 56
ADJUSTMENTS ............................................................ 92 REPLACING J5-AXIS REDUCER (Standard) .............. 52
REPLACING J6-AXIS MOTOR.................................... 61
<B> REPLACING J6-AXIS REDUCER................................ 67
BACKLASH MEASUREMENT .................................... 19 REPLACING PARTS..................................................... 23
REPLACING SOLENOID VALVE ............................... 70
<C> REPLACING THE BATTERIES (1-YEAR
CABLE AND AIR TUBE REPLACEMENT ................. 76
PERIODIC INSPECTION IF BUILT-IN
CABLE FORMING ........................................................ 75
BATTERIES ARE SPECIFIED) (1.5-YEAR
CABLE WIRING............................................................ 74
PERIODIC INSPECTION IF EXTERNAL
CHECKS AND MAINTENANCE ...................................1
BATTERIES ARE SPECIFIED)................................... 9
CIRCUIT DIAGRAM, AIR PRESSURE DIAGRAM.. 101
REPLACING WRIST UNIT (7L) .................................. 65
REPLACING WRIST UNIT (Standard)......................... 63
<D>
REPLENISH THE GREASE OF THE DRIVE
DAILY CHECKS..............................................................1
MECHANISM (4 YEARS (15360 HOURS)
CHECKS).................................................................... 11
<F>
FAILURES, CAUSES AND MEASURES..................... 13
<S>
FIGURE OF DRIVE MECHANISM .............................. 24
SAFETY PRECAUTIONS ............................................ s-1
FIRST 1-MONTH (320 HOURS) CHECK.......................3
SEALANT APPLICATION ........................................... 71
FIRST 3-MONTH (960 HOURS) CHECKS ....................3
SPARE PARTS LIST ..................................................... 97
<M>
<T>
MAINTENANCE .............................................................7
TROUBLESHOOTING .................................................. 13
MOUNTING BOLT TORQUE LIST ........................... 112

<O>
OPTIONAL CONNECTOR WIRING PROCEDURE . 113
OVERVIEW ................................................................... 13

<P>
PERIODIC MAINTENANCE ..........................................9
PERIODIC MAINTENANCE TABLE......................... 109
PREFACE ......................................................................p-1

<R>
Replacing Air Tube ......................................................... 87
Replacing Cable K101 and Air Tube (Connector panel
to J2 base).................................................................... 76
Replacing Cable K102, K103, K104, K105, K109,
K110, K111, K112, K113............................................ 85
Replacing Cable K106, K107, K108,K109 and Air
Tube (J2 base to J3 housing) ....................................... 81
Replacing Cable K118 .................................................... 85
REPLACING CABLES .................................................. 73
REPLACING J1-AXIS MOTOR .................................... 26
REPLACING J1-AXIS REDUCER................................ 28
REPLACING J2-AXIS MOTOR .................................... 32
i-1
B-83495EN/01 REVISION RECORD

REVISION RECORD
Edition Date Contents
01 Sep., 2013

r-1
B-83495EN/01

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