i
i
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®, i RVision®, 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-J3 i B Controller™, SYSTEM R-J3 i C Controller™,
SYSTEM R-30 i A Controller™, SYSTEM R-30 i A Mate Controller™, SYSTEM
R-30 i B Controller™, SYSTEM R-30 i B 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”.

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.
Safety is essential whenever robots are used. Keep in mind the following factors with regard to safety:
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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.
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
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.
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 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
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 s-1

PRECAUTIONS
2
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 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). s-2

B-83495EN/01 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. s-3

PRECAUTIONS
RP1
Pulsecoder
RI/RO,XHBK,XROT
RM1
Motor power/brake
EARTH
Dual chain
Single chain
Safety fence
Interlocking device and safety plug that are activated if the gate is opened.
Fig. 3 (a) Safety fence and safety gate
Emergency stop board or Panel board
EAS1
EAS11
EAS2
EAS21
（Note）
In case of R-30iA i B Mate
Terminals EAS1,EAS11,EAS2,EAS21 are provided on the are provided on the operation box or on the terminal block of the printed circuit boar d.
Refer to the ELECTRICAL CONNCETIONS Chapter of
CONNECTION of on the emergency stop board or connector panel.
(in case of Open air type) or R-30 B Mate controller (Open Air) maintenance manual
Termianls FENCE1,FENCE2 ar e provided
Panel board
FENCE1
FENCE2
Refer to controller maintenance manual for details.
Fig. 3 (b) Limit switch circuit diagram of the safety fence s-4

B-83495EN/01 PRECAUTIONS
Hook for safety belt
Fence
Steps
Trestle
Footstep for maintenance
Fig.3 (c) Footstep for maintenance
3.1
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
External stop button
Single chain
External stop button o r Pane l boa rd
EES1
EES11
EES2
EES21
(Note)
Connect EES1 and EES11, EES2 and EES21
In case R-30 i B, R-30 i B Mate
EES1,EES11,EES2,EES21 are on the emergenc y stop board
Connect EES1and EES11,EES2 and EES21or EMGIN1and EMGIN2.
Refer to the ELECTRICAL CONNCETIONS Chapter of
In case of R-30iA
CONNECTION of
R-30 i B controller maintenance manual (B-83195EN) or
R-30 i B Mate controller maintenance manual (B-83525EN) or R-30 i B Mate controller (Open Air) maintenance manual
(B-83525EN) for details.
Refer to the maintenance manual of the controller for details.
Panel board
EMGIN1
EMGIN2
Fig.3.1 Connection diagram for external emergency stop button s-5

PRECAUTIONS
3.2
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-30 i
A 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-30 i
B/R-30 i
B 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. s-6

B-83495EN/01 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.
Mode
AUTO mode
T1, T2 mode
Teach pendant enable switch
On
Off
On
Off
Software remote condition
Local
Remote
Local
Remote
Local
Remote
Local
Remote
Teach pendant
Not allowed
Not allowed
Not allowed
Not allowed
Allowed to start
Allowed to start
Not allowed
Not allowed
Operator panel Peripheral device
Not allowed
Not allowed
Allowed to start
Not allowed
Not allowed
Not allowed
Not allowed
Not allowed
Not allowed
Not allowed
Not allowed
Allowed to start
Not allowed
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
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. s-7

PRECAUTIONS
(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
－ Inside the controller
－ Reducer
－ Gearbox
－ Wrist
(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 s-8

B-83495EN/01 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
4.1
(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
(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

PRECAUTIONS
(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
5.1
(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
(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
(1) Keep the work areas of the robot clean, and operate the robot in an environment free of grease, water, and dust.
5.4
(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
6.1
(1) To control the pneumatic, hydraulic and electric actuators, carefully consider the necessary time delay after issuing each control command up to actual motion and ensure safe control.
(2) Provide the end effector with a limit switch, and control the robot system by monitoring the state of the end effector. s-10

B-83495EN/01 PRECAUTIONS
7
The following three robot stop types exist:
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.
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.
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.
Stop pattern
Mode
Emergency stop button
External
Emergency stop
FENCE open SVOFF input
Servo disconnect
AUTO P-Stop
A T1
T2
P-Stop
P-Stop
AUTO P-Stop
B T1 P-Stop
T2 P-Stop
AUTO C-Stop
C T1 P-Stop
T2 P-Stop
P-Stop: Power-Off stop
C-Stop: Controlled stop
-: Disable
P-Stop C-Stop C-Stop P-Stop
P-Stop
P-Stop
-
-
C-Stop
C-Stop
P-Stop
P-Stop
P-Stop P-Stop P-Stop P-Stop
P-Stop - P-Stop P-Stop
P-Stop - P-Stop P-Stop
C-Stop C-Stop C-Stop C-Stop
P-Stop - C-Stop P-Stop
P-Stop - C-Stop P-Stop s-11

PRECAUTIONS
The following table indicates the Stop pattern according to the controller type or option configuration.
Option R-30 i
B/ R-30 i
B Mate
Standard A (*)
Controlled stop by E-Stop (A05B-2600-J570) C
(*) R-30 i
B / R-30 i
B Mate does not have servo disconnect. / R-30 i
B 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.
When "Controlled stop by E-Stop" (A05B-2600-J570) option (In case of R-30 i
A/R-30 i
A 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
SRVO-002 Teach pendant E-stop
SRVO-007 External emergency stops
Operator panel emergency stop is pressed.
Teach pendant emergency stop is pressed.
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-30 i A or R-30 i A 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. s-12

B-83495EN/01 PRECAUTIONS
8
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

PRECAUTIONS
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
This manual explains maintenance procedures for the mechanical units of the following robots:
Model name
FANUC Robot LR Mate 200 i
D
FANUC Robot ARC Mate 50 i D
FANUC Robot LR Mate 200 i
D/7L
FANUC Robot ARC Mate 50 i D/7L
Mechanical unit specification No.
A05B-1142-B201
A05B-1142-B251
A05B-1142-B301
A05B-1142-B351
Maximum load
7kg
Remarks
NOTE
The following abbreviations are used herein.
STANDARD : LR Mate 200 i
D, ARC Mate 50 i
D
7L : LR Mate 200 i
D/7L, ARC Mate 50 i
D/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.
TYPE
NO.
DATE
(1)
(4)
(3)
(2)
WEIGHT
(5) kg
Position of label indicating mechanical unit specification number
TABLE 1 ）
(1) (2) (4) (5)
CONTENTS -
WEIGHT kg
TYPE No. DATE
(Without controller)
LETTERS
FANUC Robot
LR Mate 200 i
D
A05B-1142-B201 25
FANUC Robot ARC
Mate 50 i
D
FANUC Robot
LR Mate 200 i D/7L
FANUC Robot ARC
Mate 50 i
D/7L
A05B-1142-B351
NO. IS
PRODUCTION
MONTH ARE
Position of label indicating mechanical unit specification number
27 p-1

PREFACE
B-83495EN/01
For the FANUC Robot series, the following manuals are available:
Safety handbook B-80687EN
All persons who use the FANUC Robot and system designer must read and understand thoroughly this handbook
R-30 i
B Mate OPERATOR’S MANUAL controller Basic Operation
B-83284EN
Alarm Code List
B-83284EN-1
Optional Function
B-83284EN-2
Intended readers :
All persons who use FANUC Robot, system designer
Topics :
Safety items for robot system design, operation, maintenance
Intended readers :
Operator, programmer, maintenance person, system designer
Topics :
Robot functions, operations, programming, setup, interfaces, alarms
Use :
Robot operation, teaching, system design
Standard : B-83525EN
Open Air : B-83555EN
Mechanical unit
Operator’s manual
FANUC Robot
LR Mate 200 i D
ARC Mate 50 i
D
B-83494EN
Maintenance person, system designer
Topics :
Installation, connection to peripheral equipment, maintenance
Use :
Installation, start-up, connection, maintenance
Intended readers:
System designer, Maintenance person
Topics:
Installation, connection to controller, maintenance
Use:
Installation, start-up, connection, maintenance p-2

B-83495EN/01
TABLE OF CONTENTS
SAFETY PRECAUTIONS............................................................................s-1
PREFACE ....................................................................................................p-1
1 CHECKS AND MAINTENANCE ............................................................. 1
1.3 FIRST 3-MONTH (960 HOURS) CHECKS .................................................... 3
1.5 1-YEAR (3840 HOURS) CHECKS................................................................. 6
1.7 4-YEAR (15360 HOURS) CHECKS............................................................... 6
1.8 MAINTENANCE............................................................................................. 7
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
4.1 FIGURE DRIVE MECHANISM .............................................................. 24 c-1

TABLE OF CONTENTS
B-83495EN/01
5 REPLACING CABLES .......................................................................... 73
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
B CIRCUIT DIAGRAM, AIR PRESSURE DIAGRAM ............................. 101
D MOUNTING BOLT TORQUE LIST ..................................................... 112 c- 2

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

1.CHECKS AND MAINTENANCE
B-83495EN/01
Fig. 1.1 (a) Check parts of oil leak
Item
1
Check items
When air control set is provided.
Air pressure
Check points
Check air pressure using the pressure gauge on the air regulator as shown in Fig.1.1 (b). If it does not meet the specified pressure of
0.49MP
a (5 kg/cm 2 ), adjust it using the regulator pressure setting handle.
3 hose
Drain
4
5
When air purge kit is provided.
Supply pressure
Dryer
6
Drain
Repair leaks, or replace parts, as required.
Check drain and release it. When quantity of the drain is remarkable, examine the setting of the air dryer to the air supply side.
Check the supply pressure using the air purge kit shown in Fig.1.1 (c).
If it does not meet the specified pressure of 10 KPa (0.1 kgf/cm 2 ), adjust it using the regulator pressure setting handle.
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.
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
2-7x11
Length round hole
1.CHECKS AND MAINTENANCE
Dew point checker
(
Air outlet
O 6 Air tube)
Pressure gauge
Pneumatic air outlet
(
Air inlet
O 10 air tube)
Pressure adjustment knob
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 motor heating
2 Changing repeatability
3 Peripheral devices for proper operation
4 Brakes for each axis
Check whether the robot moves along and about the axes smoothly without unusual vibration or sounds. Also check whether the temperature of the motors are excessively high.
Check to see that the stop positions of the robot have not deviated from the previous stop positions.
Check whether the peripheral devices operate properly according to commands from the robot.
Check that the end effector drops within 2 mm when the power is cut.
1.2
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
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)
2
Retightening external main bolts Retighten the end-effecter mounting bolts and external main bolts.(NOTE 2)
- 3 -

1.CHECKS AND MAINTENANCE
B-83495EN/01
Item
3
Check items
Check the mechanical stopper
Check points
Check the spring ping of J1/J3-axis mechanical stopper is not transformed, if it is transformed, replace it to new one. (NOTE 3)
4
5
6
Cleaning and checking each part Clean each part (remove chips, etc.) and check component parts for cracks and flaws. (NOTE 4)
Check the end effector (hand) cable and external battery cable
(option)
Confirm whether there is any damage to the cable.
Check the robot cable, teach pendant cable and robot connecting cable
Check whether the cable connected to the teach pendant and robot is unevenly twisted.
•
Robot connection cables, earth terminal and user cables
•
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
- 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.
Check the spring pin of J1/J3-axis mechanical stopper is not transformed, if it is transformed, replace it to new one.
- 4 -

B-83495EN/01
J3-axis mechanical stopper
Spec.：
J3 stopper：A290-7142-X427
spring pin：A6-PS-8X20S
Note： When assembling J3 stopper to
spring pin, apply cemedine super X
（clear）.
1.CHECKS AND MAINTENANCE
J1-axis mechanical stopper
Spec.：
spring pin：A6-PS-8X20S
Section A-A
A A
Fig. 1.3 (b) Check of mechanical stopper
- 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
- 5 -

1.CHECKS AND MAINTENANCE
B-83495EN/01
1.4
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
1 Ventilation portion of controller
Check points
If the ventilation portion of the controller is dusty, tum off power and clean the unit.
1.5
Check the following items in the cycle that is shorter between every year and 3840 hours of operating.
Check points Item Check itmes
1 Connector used in mechanical unit
2 Retightening external main bolts
3 Check the mechanical stopper
4 Cleaning and checking each part
(See Section 1.3)
(See Section 1.3)
(See Section 1.3)
(See Section 1.3)
5 Check the end effector (hand) cable and external battery cable (option)
6 Replacing battery
7 Check the robot cable, teach pendant cable and robot connecting cable
(See Section 1.3)
Replace battery in the mechanical unit. (See Section 2.1)
(See Section 1.3)
1.6
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
(if external batteries are specified)
Replace the batteries in the mechanical unit.
(See Section 2.1.)
1.7
Check the following items about once in the cycle that is shorter between every four years an 15360 hours.
Item Check itmes
1 Greasing of reducers of each-axis
2 Replace the mechanical unit cable
Check points
Supply grease with each axis reducer (See Section 2.2)
Please refer to Chapter 5 about replacing method.
- 6 -

B-83495EN/01
1.CHECKS AND MAINTENANCE
1.8
The following tools and instruments are required for the maintenance procedures contained in this manual.
Instrument Specifications Vendor
Tension meter A97L-0218-0700 Mitsuboshi Belting Ltd.
Manufacturer model No.
DOCTOR TENSION
TYPEⅢ
Application
Adjustment of belt tension
Instruments Accuracy/Tolerance Applications
Dial gauge accuracy
Slide calipers
1/100 mm
150 mm
Measurement of positioning and backlash
(b) Tools
・ Torque wrench
・ Cross tip (+) screwdrivers
・ Flat tip (–) screwdrivers
・ Nut driver
・ Hexagon wrench set
・ Monkey wrench
・ 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
Large, medium, and small sizes
Large, medium, and small sizes
W idth across flats 7 (for grease nipple)
W idth across flats 2.5, 3, 4 (for replacing parts)
Middle, little
- 7 -

1.CHECKS AND MAINTENANCE
B-83495EN/01
Fig 1.8 example of cylinder
- 8 -

B-83495EN/01
2.PERIODIC MAINTENANCE
2
2.1
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.
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
(
)
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 O 5mm
(Max O 5.5mm)
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
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
Specified grease Greasing points Greasing amount
J1-axis reducer
J2-axis reducer
J3-axis reducer
J4-axis reducer
J5-axis reducer
J6-axis reducer
2.7g(3ml)
2.7g(3ml)
1.8g(2ml)
1.8g(2ml)
1.8g(2ml)
1.8g(2ml)
For grease replacement, use the arbitrary postures.
Harmonic grease 4BNo.2
Spec: A98L-0040-0230
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))
- 11 -

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
Seal bolt M4X6
J1-axis reducer grease inlet
Seal bolt M8X10
Parts name
Seal bolt
Seal bolt
Fig.2.2 Applying grease of the reducer
Table 2.2 (b) Spec. of seal bolts
Specifications
A97L-0318-0405#040606EN
A97L-0318-0406#081010EN
Remarks
J2 - J6-axis grease inlet 5 pcs/1 robot
J1-axis grease inlet
- 12 -

B-83495EN/01
3.TROUBLESHOOTING
3
3.1
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
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
Vibration
Noise
-The J1 base lifts off the floor plate as the robot operates.
-There is a gap bfetween the
J1 base and floor plate.
-A J1 base retaining bolt is loose.
-Apply epoxy to the floor surface and re-install the plate.
-Vibration becomes more serious when the robot adopts a specific posture.
-If the operating speed of the robot is reduced, vibration stops.
-Vibration is most noticeable when the robot is accelerating.
-Vibration occurs when two or more axes operate at the same time.
Cause
[J1 base fastening]
-It is likely that the robot J1 base is not securely fastened to the floor plate.
-Probable causes are a loose bolt, an insuffcient degree of surface flatness, or foreign material caught between the floor plate and floor plate.
-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.
[Rack or floor]
-It is likely that the rack or floor is not suffciently rigid.
-If the rack or floor is not sufficiently rigid, reaction from the robot deforms the rack or floor, leading to vibration.
[Overload]
-It is likely that the load on the robot is greater than the maximum rating.
-It is likely that the robot control program is too demanding for the robot hardware.
-It is likely that the ACCELERATION value is excessive.
Measure
-If a bolt is loose, apply
LOCTITE and tighten it to the appropriate torque.
-Adjust the floor plate surface flatness to within the specified tolenrance.
-If there is any foreign material between the J1 base and floor plate, remove it.
-Reinforce the rack or floor to make it more rigid.
-If it is impossible to reinforce the rack or floor, modify the robot control program; doing so might reduce the amount of vibration.
-Check the maximum load that the robot can handle once more. If the robot is found to be overloaded, reduce the load, or modify the robot control program.
-Vibration in a specific portion can be reduced by modifying the robot control program while slowig the robot and reducing its acceleration (to minimize the influenece on the entire cycle time).
- 13 -

3.TROUBLESHOOTING
B-83495EN/01
Symptom Description
Vibration
Noise
(Continued)
-Vibration was first noticed after the robot collided with an object or the robot was overloaded for a long period.
-The grease of the vibrating axis has not been replenished for a long period.
Cause
[Broken gear, bearing, or reducer]
- It is likely that collision or overload applied an excessive force on the drive mechanism, thus damaging the geartooth surface or rolling surface of a bearing, or reducer.
- It is likely that prolonged use of the robot while overloaded caused fretting of the gear tooth surface or rolling surface of a bearing, or reducer due to resulting metal fatigue.
- It is likely that foreign material caught in a gear, bearing, or within a reducer caused damage on the gear tooth surface or rolling surface of the bearing, or reducer.
- It is likely that, because the grease has not been 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.
Measure
-Operate one axis at a time to determine which axis is vibrating.
-Remove the motor, and replace the gear , the bearing, and the reducer. For the spec. of parts and the method of replacement, contact
FANUC.
-Using the robot within its maximum rating prevents problems with the drive mechanism.
-Regularly greasing with a specified type can help prevent problems.
- 14 -

B-83495EN/01
3.TROUBLESHOOTING
Symptom Description
Vibration
Noise
(Continued)
-The cause of problem cannot be identified from examination of the floor, rack, or mechanical section.
Cause
[Controller, cable, and motor]
-If a failure occurs in a controller circuit, preventing control commands from being supplied to the motor normally, or preventing motor information from being sent to the controller normally, vibration might occur.
-If the Pulsecoder develops a fault, vibration might occur because information about the motor position cannot be transferred to the controller accurately.
-If the motor becomes defective, vibration might occur because the motor cannot deliver its rated performance.
-If a power line in a movable cable of the mechanical section has an intermittent break, vibration might occur because the motor cannot accurately respond to commands.
-If a Pulsecoder wire in a movable part of the mechanical section has an intermittent break, vibration might occur because commands cannot be sent to the motor accurately.
-If a connection cable between them has an intermittent break, vibration might occur.
-If the power cable between them has an intermittent break, vibration might occur.
-If the power source voltage drops below the rating, vibration might occur.
-If a robot control parameter is set to an invalid value, vibration might occur.
Measure
-Refer to the Controller
Maintenance Manual for troubleshooting related to the controller and amplifier.
-Replace the Pulsecoder for the motor of the axis that is vibrating, and check whether the vibration still occurs.
-Also, replace the motor of the axis that is vibrating, and check whether vibration still occurs. For the method of replacement, contact FANUC.
-Check that the robot is supplied with the rated voltage.
-Check whether the sheath of the power cord is damaged. If so, replace the power cord, and check whether vibration still occurs.
-Check whether the sheath of the cable connecting the mechanical section and controller is damaged. If so, replace the connection cable, and check whether vibration still occurs.
-If vibration occurs only when the robot assumes a specific posture, it is likely that a cable in the mechanical unit is broken.
-Shake the movable part cable while the robot is at rest, and check whether an alarm occurs. If an alarm or any other abnormal condition 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.
- 15 -

3.TROUBLESHOOTING
B-83495EN/01
Symptom Description
Vibration
Noise
(Continued)
-There is some relationship between the vibration of the robot and the operation of a machine near the robot.
Rattling -While the robot is not supplied with power, pushing it with the hand causes part of the mechanical unit to wobble.
-There is a gap on the mounting face of the mechanical unit.
Cause
[Noise from a nearby machine]
-If the robot is not grounded properly, electrical noise is induced on the grounding wire, preventing 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.
[Mechanical section coupling bolt]
-It is likely that overloading or a collision has loosened a mounting bolt in the robot mechanical section.
Measure
-Connect the grounding wire firmly to ensure a reliable ground potential and prevent extraneous electrical noise.
-Check that the following bolts for each axis are tight. If any of these bolts is loose, apply
LOCTITE and tighten it to the appropriate torque.
-Motor retaining bolt
-Reducer retaining bolt
-Base retaining bolt
-Arm retaining bolt
-Casting retaining bolt
-End effecter retaining bolt
-Backlash is greater than the tolerance stated in the applicable maintenance manual. (See Section 3.3.)
[Increase in backlash]
-It is likely that excessive force applied to the drive mechanism, due to a collision or overloading, has broken a gear or the inside of the reducer, resulting in an increase in the amount of backlash.
-It is likely that prolonged use has caused the tooth surfaces of a gear and the inside of the reducer to wear out, resulting in an increase in the amount of backlash.
-It is likely that prolonged use without changing the grease has caused the tooth surfaces of a gear and the inside of the reducer to wear out, resulting in an increase in the amount of backlash.
-Operate one axis at a time to determine which axis has the increased backlash.
-Remove the motor, and check whether any of its gears are broken. If any gear is broken, replace it.
-Check whether any other gear of the drive mechanism is damage. If there is no damage gear, replace the reducer.
-If the reducer is broken, or if a gear tooth is missing, replace the relevant component. Also, remove all the grease from the gear box and wash the inside of the gear box.
-After replacing the gear or reducer, add an appropriate amount of grease.
-Using the robot within its maximum rating prevents problems with the drive mechanism.
-Regularly applying the grease with a specified type can help prevent problems.
- 16 -

B-83495EN/01
3.TROUBLESHOOTING
Symptom Description
Motor -The ambient temperature of overheating the installation location increases, causing the motor to overheat.
-After the robot control program or the load was changed, the motor overheated.
-After a control parameter was changed, the motor overheated.
-Symptom other than stated above
Cause
[Ambient temperature]
-It is likely that a rise in the ambient temperature prevented the motor from releasing heat efficiently, thus leading to overheating.
[Operating condition]
-It is likely that the robot was operated with the maximum average current exceeded.
Measure
-The teach pendant can be used to monitor the average current. Check the average current when the robot control program is running. The allowable average current is specified for the robot according to its ambient temperature. Contact FANUC 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.
-Input an appropriate parameter as described in
CONTROLLER
OPERATOR’S MANUAL.
[Parameter]
-If data input for a workpiece is invalid, the robot cannot be accelerated or decelerated normally, so the average current increases, leading to overheating.
[Mechanical section problems]
-It is likely that problems occurred in the mechanical unit drive mechanism, thus placing an excessive load on the motor.
[Motor problems]
-It is likely that a failure of the motor brake resulted in the motor running with the brake applied, thus placing an excessive load on the motor.
-It is likely that a failure of the motor prevented it from delivering its rated performance, thus causing an excessive current to flow through the motor.
-Repair the mechanical unit while referring to the above descriptions of vibration, noise, and rattling.
-Check that, when the servo system is energized, the brake is released.
If the brake remains applied to the motor all the time, replace the motor.
-If the average current falls after the motor is replaced, it indicates that the first motor was faulty.
- 17 -

3.TROUBLESHOOTING
B-83495EN/01
Symptom Description
Grease leakage
-Grease is leaking from the mechanical unit.
Dropping axis -An axis drops because the
Displacement brake does not function.
-An axis drops gradually when it should be at rest.
-The robot operates at a point other than the taught position.
-The repeatability is not within the tolerance.
-Displacement occurs only in a specific peripheral unit.
Cause
[Poor sealing]
-Probable causes are a crack in the casting, a broken O-ring, a damaged oil seal, or a loose seal bolt.
-A crack in a casting can occur due to excessive force that might be caused in collision.
-An O-ring can be damaged if it is trapped or cut during disassembling or re-assembling.
-An oil seal might be damaged if extraneous dust scratches the lip of the oil seal.
-A loose seal bolt might allow grease to leak along the threads.
[Brake drive relay and motor]
-It is likely that brake drive relay contacts are stuck to each other to keep the brake current flowing, thus preventing the brake from operating when the motor is deenergized.
-It is likely that the brake shoe has worn out or the brake main body is damaged, preventing the brake from operating efficiently.
-It is likely that oil or grease has entered the motor, causing the brake to slip.
[Mechanical section problems]
-If the repeatability is unstable, probable causes are a failure in the drive mechanism or a loose bolt.
-If the repeatability becomes stable it is likely that a collision imposed an excessive load, leading to slipping on the base surface or the mating surface of an arm or reducer.
-It is likely that the Pulsecoder is abnormal.
[Peripheral unit displacement]
-It is likely that an external force was applied to the peripheral unit, thus shifting its position relative to the robot.
-Check whether the brake drive relay contacts are stuck to each other. If they are found to be stuck, replace the relay.
Measure
-If a crack develops in the casting, sealant can be used as a quick-fix to prevent further grease leakage.
However, the component should be replaced as soon as possible, because the crack might extend.
-O-rings are used in the locations listed below.
-Motor coupling section
-Reducer coupling section
-Wrist coupling section
-J3 arm coupling section
-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
-If the brake shoe is worn out, if the brake main body is damaged, or if oil or grease has entered the motor, replace the motor.
-If the repeatability is unstable, repair the mechanical section by referring to the above descriptions of vibration, noise, and rattling.
-If the repeatability is stable, correct the taught program.
Variation will not occur unless another collision occurs.
-If the Pulsecoder is abnormal, replace the motor or the Pulsecoder.
-Correct the setting of the peripheral unit position.
-Correct the taught program.
- 18 -

B-83495EN/01
3.TROUBLESHOOTING
Symptom Description
Displacement -Displacement occurred after
(Continued) a parameter was changed.
Cause
[Parameter]
-It is likely that the mastering data was rewritten in such a way that the robot origin was shifted.
BZAL alarm occured
-BZAL is displayed on the controller screen
- It is likely that the voltage of the memory backup battery is low.
- It is likely that the Pulsecoder cable is defected.
3.3
Measure
-Re-enter the previous mastering data, which is known to be correct.
-If correct mastering data is unavailable, perform mastering again.
-Replace the battery.
-Replace the cable.
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
-3kgf
Firtst step
(Do not measure)
L
1
+3kgf
0kgf Second step
-3kgf
0kgf
L
2
L
3
+3kgf
0kgf
Third step
(B =L + L )
-3kgf
0kg
L
4
Fig. 3.3 (a) Backlash measurement method
Backlash B is calculated using the following expression:
B=
B
2
+
2
B
3
- 19 -

3.TROUBLESHOOTING
B-83495EN/01
Measurement axis
Table 3.3 (a) Backlash measurement posture, position and permissible value
J1-axis J2-axis J3-axis J4-axis J5-axis J6-axis Measurement position
Rotation center of J5-axis
Rotation center of J3-axis
J2-axis Arbitrary 0° of J2 arm
180° Rotation center of J5-axis
J5-axis
J6-axis
Arbitrary
Arbitrary
0° 90° 0° -90° 90°
100mm from rotation center of J4-axis
90° 0° 0° -90° 0° or 180°
180mm from rotation center of J5-axis
90° 0° 0° -90° 90° or -90°
100mm from rotation center of J6-axis
Table 3.3 (b) Distance at axis and measurement position and permissible value for backlash
Measured axis
Distance at axis and measurement position (mm) Permissible value (mm)
J1-axis 715
J2-axis 330
910
440
J3-axis 335 420
J4-axis 100
J5-axis 180
J6-axis 100
0.41
0.19
0.20
0.52
0.25
0.25
0.16
0.18
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.
Fig.3.3 (b) Backlash measurement position of J1-axis
- 20 -

B-83495EN/01
3.TROUBLESHOOTING
Loading position
Measurement position
Fig.3.3 (c) Backlash measurement position of J2-axis
Fig.3.3 (d) Backlash measurement position of J3-axis
- 21 -

3.TROUBLESHOOTING
B-83495EN/01
Fig.3.3 (e) Backlash measurement position of J4-axis
Fig.3.3 (f) Backlash measurement position of J5-axis
Fig.3.3 (g) Backlash measurement position of J6-axis
- 22 -

B-83495EN/01
4.REPLACING PARTS
4
•
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
4.1
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
Motor (M2) for J2 axis
J1 base
Fig. 4.1 (a) Drive mechanism of J1-axis
J2 arm
B-83495EN/01
J2 axis reducer
J2 base
Fig. 4.1 (b) Drive mechanism of J2-axis
- 24 -

B-83495EN/01
J3 housing
J3 axis reducer
J3 axis output pully
4.REPLACING PARTS
Belt
J2 arm
Motor (M3) for J3 axis
J3 axis input pully
J3 housing
Fig. 4.1 (c) Drive mechanism of J3-axis
J4 axis reducer
(Hollow shaft)
J3 arm
Motor (M4) for J4 axis
Pipe
J4 axis input gear
Fig. 4.1 (d) Drive mechanism of J4-axis
- 25 -

4.REPLACING PARTS
J5 axis output pully
J6 axis housing
Belt
B-83495EN/01
J5 axis input pully
Motor (M5) for J5 axis
J5 axis reducer
J6 axis reducer
J3 axis arm
Belt
J6 axis output pully
J6 axis output gear
J6 axis input gear Motor (M6) for J6 axis
J6 axis input pully
Fig. 4.1 (e) Drive mechanism of J5/J6-axis
4.2
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
4
3 2 1
13
12
11
10
8
7
6
9
5
Fig. 4.2 (a) Replacing J1-axis motor
Name
1 BOLT
3 GASKET
4 BOLT
5 MOTOR
6 KEY
8 HOLDER
11 GEAR
Specifications Q’ty LOCTITE Torque N-m (kgf-cm)
9 (20kgfcm)
A290-7142-X204
A290-7142-X205
A6-BA-5X20
A06B-0116-B855#0048
A97L-0118-0402#3X3X12BN
1
1
3
1
1 LT243
A98L-0001-0347#S46
A290-7139-X221
A98L-0040-0223#01001805
A98L-0001-0347#S46
A290-7142-X202 (*1)
A290-7142-X248 (*2)
1
1
1
1
1
A97L-0218-0423#030606
14 SHEET A290-7142-X228
(*1) LR Mate 200 i
D. ARC Mate 50 i
D
(*2) LR Mate 200 i
D/7L. ARC Mate 50 i
D/7L
1
3
1
14
Fig. 4.2 (b) Attachment of the sheet on the J1-axis motor
- 27 -

4.REPLACING PARTS
B-83495EN/01
4.3
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.
- 28 -

B-83495EN/01
15
16
17
4.REPLACING PARTS
6
14
13 12
11 10
5
4
9 8
7
1
2 3
Name
Fig. 4.3 (a) Replacing J1-axis reducer
Specifications Q’ty LOCTITE Torque N-m (kgf-cm)
3 GASKET
4 BOLT
5 BOLT
A97L-0218-0546#030606EN
A290-7142-X319
A290-7142-X317
A6-BA-4X12
A6-BA-4X20
A290-7142-X201
A290-7142-X312
4
1
1
7
9
1
1 7 PIPE
8
WAVE
GENERATOR
9 O RING
10 BOLT
11 REDUCER
(It is attached to the J1 REDUCER)
(It is attached to the J1 REDUCER)
A97L-0218-0546#043016BC
A97L-0218-0951#70 (*1)
A97L-0218-0980#80 (*2)
1
1
12 4.5Nm
1
12 WAVE WASHER (It is attached to the J1 REDUCER)
13 PIPE A290-7142-X311
1
1
14 O RING (It is attached to the J1 REDUCER)
16 J2 BASE COVER A290-7142-X306
1
15 PLATED A97L-0218-0496#M4X10BC 5
1
1 17 GASKET A290-7142-X324
(*1) LR Mate 200 i D. ARC Mate 50 i D
(*2) LR Mate 200 i D/7L. ARC Mate 50 i D/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
- 30 -

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
- 31 -

4.REPLACING PARTS
B-83495EN/01
4.4
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.
- 32 -

B-83495EN/01
10
9
8
4.REPLACING PARTS
20
21
22 24
25
26
23
11
19
17
16
15
K103
14
K102
13 12
7
18
5
6
4
3 2
1
Fig. 4.4 (a) Replacing J2-axis motor
Specifications Q’ty LOCTITE Torque N-m (kgf-cm) Name
A97L-0218-0496#M4X10BC 6
2 J2 BASE COVER ASSY A290-7142-V303 1
3 GASKET
4 BOLT
A290-7142-X324
A6-BA-4X8
1
2
5 CLAMP
9 J2 ARM COVER
A290-7142-X321
A97L-0218-0423#041414
1
7
A290-7142-V302 1
A97L-0218-0496#M4X10BC 6
A290-7142-X307 1
10 GASKET
11 CLAMP
12 SHEET
14 MOTOR
15 SHAFT
16 KEY
18 PIN
19 GASKET
23 WASHER
24 COLLAR
26 GASKET
A290-7142-X325
A290-7142-X322
A290-7142-X330
A97L-0218-0423#051212
A06B-0116-B855#0048
A290-7139-X322
A97L-0118-0402#3X3X12BN
JB-OR1A-G45
A6-PS-4X10S
A290-7142-X315
1 LT243
1
2
1
A97L-0218-0496#M4X22BC 4
A290-7142-X305 1
A97L-0218-0423#031616
A290-7120-X532
A97L-0218-0763#410
(It is attached to the J2
REDUCER)
A290-7142-X316
1
1
1
4
1
1
1
1
1
1
1
- 33 -

4.REPLACING PARTS
A
B-83495EN/01
A
Fig. 4.4 (b) Apply LOCTITE 638 to shaft
Fig. 4.4 (c) Assembled phase of cover S
- 34 -

B-83495EN/01
4.REPLACING PARTS
12
Fig.4.4 (d) Attachment of the sheet (12)
4.5
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
4 reducer in a horizontal state.)
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.
- 35 -

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.
23
22
21
20
24
18
19
17
16
15
14
13
12
11
10
9
8
7
6
4
5
3
2
1
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)
A97L-0218-0496#M4X10BC 5
2 J2 BASE COVER ASSY A290-7142-V303 1
3 GASKET
4 BOLT
A290-7142-X324
A6-BA-4X8
1
2
5 CLAMP A290-7142-X321
A97L-0218-0423#041414
7 SUPPORT ASSY A290-7142-V302
1
7
1
9 MOTOR
11 GASKET
12 PIN
14 REDUCER
17 GASKET
A97L-0218-0423#051212
A06B-0116-B855#0048
JB-OR1A-G45
A290-7142-X315
A6-PS-4X10S
(It is attached to the J2
REDUCER)
A97L-0218-0952#100 (*1)
A97L-0218-0952#120 (*2)
(It is attached to the J2
REDUCER)
A97L-0218-0546#043516BC
A290-7142-X316
(It is attached to the J2
REDUCER)
4
1
1
1
2
1
1
1
12
1
1
19 BOLT
20 SPACER
21 WASHER
A6-BA-4X20
A97L-0218-0794#410
A290-7210-X532
A97L-0218-0423#031616
A290-7142-X305
12
1
1
1
1
A97L-0218-0496#M4X22BC 4
(*1) LR Mate 200 i D. ARC Mate 50 i D
(*2) LR Mate 200 i D/7L. ARC Mate 50 i D/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 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
5 6
7
4.REPLACING PARTS
3 2
1
8
9
10
11
12
13
14 15
K104
K105
Name
Fig. 4.6 (a) Replacing J3-axis motor
Specifications Q’ty LOCTITE
A97L-0218-0496#M4X10BC 6
2
3 GASKET
5
J2 ARM COVER
J2 ARM COVER
6 GASKET
7 BELT
9 MOTOR
A290-7142-X307
A290-7142-X325
1
1
A97L-0218-0496#M4X10BC 6
A290-7142-X307 1
1 A290-7142-X325
A98L-0040-0285#006-095 (*1)
A98L-0040-0285#006-100 (*2)
1
A97L-0218-0504#M5X12
A290-7142-X308
A97L-0218-0423#030606
11 WASHER A290-7142-X203
13 KEY
A290-7142-X309 (*1)
A290-7142-X333 (*2)
A97L-0118-0402#3X3X12BN
3
1
3
1
1
14 MOTOR A06B-0115-B855#0048
15 BOLT A6-BA-5X12
(*1) LR Mate 200 i
D. ARC Mate 50 i
D
(*2) LR Mate 200 i
D/7L. ARC Mate 50 i
D/7L
1 LT243
1
4
Torque N-m (kgf-cm)
- 39 -

4.REPLACING PARTS
B-83495EN/01
Tension adjusting bolt
Fig. 4.6 (b) Adjusting tension of J3 belt
4.7
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.
1
2
3
10
11
5
4
6
7
12
15
13
14
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)
A97L-0218-0496#M4X10BC 5
2 J2 BASE COVER ASSY A290-7142-V303
3 GASKET A290-7142-X324
4 BOLT A6-BA-4X8
A290-7142-X321
A97L-0218-0423#041414
A290-7142-V302
8 PIN
9 GASKET
11 J2 ARM COVER
12 GASKET
13 BOLT
1
1
2
1
7
1
A6-PS-4X10S
A290-7142-X315
2
1
A97L-0218-0496#M4X10BC 6
A290-7142-X307 1
A290-7142-X325
A6-BA-4X14
1
4
16 J2 ARM 2 ASSY
A97L-0218-0496#M4X30BC
2 (*1)
4 (*2)
A97L-0218-0496#M4X45BC 3
A290-7142-V311 (*1)
A290-7142-V314 (*2)
1
5 17 PIN A6-PS-4X10S
(*1) LR Mate 200 i
D. ARC Mate 50 i
D
(*2) LR Mate 200 i D/7L. ARC Mate 50 i D/7L
22
23
24
20
19
18
21
25
Fig. 4.7 (b) Replacing J3-axis reducer (2/3)
- 42 -

B-83495EN/01
Name
20 GASKET
21 CLAMP
23 J3 ARM COVER
24 GASKET
25 CLAMP
29
4.REPLACING PARTS
Specifications Q’ty LOCTITE Torque N-m (kgf-cm)
A97L-0218-0496#M4X10BC 4
A290-7142-X404
A290-7142-X409
A290-7142-X415
A97L-0218-0496#M4X10BC
A290-7142-X405
A290-7142-X410
A290-7142-X416
1
1
1
7
1
1
1
37
30
31 32
33
34
35
36
26 27
28
Fig. 4.7 (c) Replacing J3-axis reducer (3/3)
Name
27 WASHER
Specifications
A97L-0218-0423#030606
A290-7210-X532
A290-7142-X310 (*1)
A290-7142-X334 (*2)
A6-BA-3X16 29 BOLT
30 O RING
31 KEY
(It is attached to the J3 REDUCER)
A97L-0118-0402#3X3X9BN
32 WAVE GENERATOR (It is attached to the J3 REDUCER)
33 BOLT A97L-0218-0546#032204BC
35 O-RING
A97L-0218-0953#80
(It is attached to the J3 REDUCER)
36 WAVE WASHER (It is attached to the J3 REDUCER)
A290-7142-X401
(*1) LR Mate 200 i
D. ARC Mate 50 i
D
(*2) LR Mate 200 i
D/7L. ARC Mate 50 i
D/7L
Q’ty LOCTITE Torque N-m (kgf-cm)
1 1.3Nm
1
1
15
1
1 LT243
1
12 2.0Nm
1
1
1
1
- 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
Fig.4.7 (f) Grease applying area of the J3-axis
4.8
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
3 2
B-83495EN/01
1
13
12
11
10
9 7 6
8
5 4
Fig. 4.8 (a) Replacing J4-axis motor
Specifications Q’ty LOCTITE Torque N-m (kgf-cm) Name
2
J3 COVER
ASSY
3 GASKET
4 BOLT
A290-7142-V404
A290-7142-X409
A6-BA-5X16
5 MOTOR
7 HOLDER
A06B-0114-B855#0048
A98L-0001-0347#S46
A290-7142-X407
A98L-0040-0223#01502505
A98L-0001-0347#S46
A97L-0118-0402#3X3X12BN 10 KEY
12 WASHER
A290-7142-X406
A290-7142-X420
13 SEAL A97L-0218-0423#030606
1
1
3
1
1
1
1
1
1 LT243
1
1
1
- 46 -

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 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).
- 47 -

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
1 BOLT
2 CLAMP
3 BOLT
4 BOLT
7 O RING
8 REDUCER
Specifications
A6-BA-4X8
A290-7142-X415
A6-BA-3X30
A6-BA-3X14
A98L-0040-0049#02503507
A97L-0218-0496#M3X25BC or
A97L-0218-0496#M3X28BC (*)
(It is attached to the J4 REDUCER)
A97L-0218-0954#80
A290-7142-X421
Q’ty
2
1
12
LOCTITE Torque N-m (kgf-cm)
2
1
9
1
1
1
A97L-0218-0423#030606 4
(*) Length of the bolts is different depending on the manufacturing date.
- 48 -

B-83495EN/01
4.REPLACING PARTS
M3X30 (12)
Apply LOCTITE 518 on part
Fig. 4.9 (b) Applying of the sealant
M3X14 (2)
Fig. 4.9 (c) Assembled phase of J4-axis reducer
- 49 -

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
- 50 -

B-83495EN/01
4.REPLACING PARTS
4.10
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-30 i B/R-30 i B 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
9
10
12
4
11
Fig. 4.10 (a) Replacing J5-axis motor
- 51 -

4.REPLACING PARTS
14
Tension adjusting bolt
B-83495EN/01
Fig. 4.10 (b) Replacing J5-axis motor
Name Specifications Q’ty LOCTITE Torque N-m (kgf-cm)
1 PLATED A97L-0218-0496#M4X10BC 7 2.0Nm
2 J3 ARM COVER
3 GASKET
A290-7142-X405
A290-7142-X410
1
1
4 BELT A98L-0040-0286#004-157 1
5 PLATED A97L-0218-0496#M4X10BC 7 2.0Nm
6 J3 ARM COVER A290-7142-X405 1
7 GASKET
8 MOTOR
9 KEY
A290-7142-X410
A06B-0117-B855#0049
A97L-0118-0402#3X3X6BN
A290-7142-X411
1
1
1 LT243
1
11 WASHER
13 BOLT
A290-7142-X420
A97L-0218-0423#030606
A97L-0218-0504#M5X12
A97L-0218-0423#030606
1
1
4
3
4.11
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-30 i B/R-30 i B 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.
- 52 -

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
13
10
8
7
5
4
6
3
2
Fig. 4.11 (a) Replacing J5-axis reducer
- 53 -

4.REPLACING PARTS
B-83495EN/01
Name
1 BELT
Specifications
A98L-0040-0286#004-104
Q’ty LOCTITE Torque N-m (kgf-cm)
1
A97L-0218-0423#030606
3 WASHER A290-7139-X231
5 BOLT
7 KEY
A290-7142-X412
A6-BA-3X8
A98L-0040-0223#01001805
A97L-0118-0402#3X3X6BN
15
16
J3 ARM 2
J3 ARM 1
A97L-0218-0423#041616
A290-7142-X403
A290-7142-X402
3
1
1
12
1
1 LT243
8 O RING (It is attached to the J5 REDUCER) 1
A97L-0218-0496#M3X22BC 9
10 WAVE GENERATOR (It is attached to the J5 REDUCER) 1
11 REDUCER A97L-0218-0955#50 1
12 O-RING
13 WAVE WASHER
(It is attached to the J5 REDUCER) 1
(It is attached to the J5 REDUCER) 1
7
1
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
Note to the selant applying area
LT518
4.REPLACING PARTS
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
Fig.4.11 (d) Grease applying area of the J5-axis
4.12
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-30 i B/R-30 i B 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.
- 56 -

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.
- 57 -

4.REPLACING PARTS
16
17
18
15
B-83495EN/01
1
14
12
11
9
5
13
10 8
7
4
6
3
2
Name
Fig. 4.12 (a) Replacing J5-axis reducer (7L)
Specifications Q’ty LOCTITE Torque N-m (kgf-cm)
1 BELT A98L-0040-0286#004-104
A97L-0218-0423#030606
3 WASHER A290-7139-X231
5 BOLT
A290-7142-X412
A6-BA-3X8
7 KEY
8 O RING
A98L-0040-0223#01001805
A97L-0118-0402#3X3X6BN
1
1 LT243
(It is attached to the J5 REDUCER) 1
A97L-0218-0496#M3X22BC 9
10 WAVE GENERATOR (It is attached to the J5 REDUCER) 1
11 REDUCER A97L-0218-0955#50 1
12 O-RING
13 WAVE WASHER
1
3
1
1
12
17 J3 ARM 2
18 J3 ARM 1
(It is attached to the J5 REDUCER) 1
(It is attached to the J5 EDUCER) 1
A97L-0218-0423#041616
A97L-0218-0546#042516BC
5
4
A97L-0218-0546#041212BC
A290-7142-X403
2
1
A290-7142-X402 1
- 58 -

B-83495EN/01
4.REPLACING PARTS
Fig. 4.12 (b) Spread range of sealant to J5-reducer
- 59 -

4.REPLACING PARTS
A
LT518
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.
A
B-83495EN/01
Apply LOCTITE 518 on part.
Fig.4.12 (c) Applying the sealant on the J3 arm (7L)
- 60 -

B-83495EN/01
4.REPLACING PARTS
4.13
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-30 i B/R-30 i B 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.
- 61 -

4.REPLACING PARTS
B-83495EN/01
1
A
2
8
7
6
5
4
B
3
Fig. 4.13 (a) Replacing J6-axis motor
Tension adjusting bolt
Tension adjusting bolt
9
Fig. 4.13 (b) Replacing J6-axis motor
Name Specifications Q’ty LOCTITE Torque N-m (kgf-cm)
1 BELT
2
FLANGE SOCKET
BOLT
A98L-0040-0286#004-157 1
A97L-0218-0504#M5X12 4
3 BELT
4 MOTOR
A98L-0040-0286#004-157
A06B-0117-B855#0049
1
1
1
5.6Nm (56kgfcm)
LT243 5 KEY A97L-0118-0402#3X3X6BN
6 PULLEY J6-1 A290-7142-X429
7 WASHER A290-7142-X420
A97L-0218-0423#030606
A97L-0218-0423#030606
1
1
1
1
- 62 -

B-83495EN/01
4.REPLACING PARTS
4.14
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-30 i B/R-30 i B 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.
- 63 -

4.REPLACING PARTS
13 14
8
B-83495EN/01
1
9 10 11 12
15
6
7
5
4
3
2
16
Fig. 4.14 Replacing wrist unit (Standard)
Name
1 BELT
Specifications
A98L-0040-0286#004-157
A97L-0218-0423#030606
4 PULLEY J5-2 A290-7142-X412
5 KEY A97L-0118-0402#3X3X6BN
6 BOLT A6-BA-3X8
A98L-0040-0223#01001805
8 BELT
10 WASHER
A98L-0040-0286#004-104
A97L-0218-0423#030606
A290-7142-X420
12 KEY
14
15
J3 ARM 2
O RING
A290-7142-X414
A97L-0118-0402#3X3X6BN
A97L-0218-0423#041616
A290-7142-X403
(It is attached to the J5 REDUCER)
A290-7142-V501
Q’ty LOCTITE Torque N-m (kgf-cm)
1
3
1
1
1
12
LT243
1
1
1
1
1
1
7
1
1
LT243
1
- 64 -

B-83495EN/01
4.REPLACING PARTS
4.15
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-30 i B/R-30 i B 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.
- 65 -

4.REPLACING PARTS
15 16
14
B-83495EN/01
1
8
13
9 10 11
12
7
5
4 3
2
18
6
17
Fig. 4.15 Replacing wrist unit (7L)
Name
1 BELT
Specifications
A98L-0040-0286#004-157
A97L-0218-0423#030606
4 PULLEY J5-2 A290-7142-X412
5 KEY A97L-0118-0402#3X3X6BN
6 BOLT A6-BA-3X8
8 BELT
10 WASHER
12 KEY
A98L-0040-0223#01001805
A98L-0040-0286#004-104
A97L-0218-0423#030606
A290-7142-X420
A290-7142-X414
A97L-0118-0402#3X3X6BN
16
17
J3 ARM 2
O RING
A97L-0218-0423#041616
A97L-0218-0546#042516BC
A97L-0218-0546#041212BC
A290-7142-X434
(It is attached to the J5 REDUCER)
A290-7142-V501
Q’ty LOCTITE Torque N-m (kgf-cm)
1
3
1
1
1
12
LT243
1
1
1
1
1
1 LT243
5
4
2
1
1
1
- 66 -

B-83495EN/01
4.REPLACING PARTS
4.16
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-30 i B/R-30 i B 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.
Name
2 REDUCER
4 WASHER
Fig. 4.16 (a) Replacing J6-axis reducer
Specifications Q’ty LOCTITE Torque N-m (kgf-cm)
A97L-0218-0496#M3X25BC 8
A97L-0218-0956#50 1
A97L-0218-0423#030808
A290-7210-X532
1
1
5 KEY A97L-0118-0402#3X3X6BN
6 WAVE GENERATOR (It is attached to the J6 REDUCER)
7 O RING (It is attached to the J6 REDUCER)
1
1
1
- 67 -

4.REPLACING PARTS
M3X25
B-83495EN/01
Fig. 4.16 (b) Assembling phase of J6-axis reducer
Fig.4.16 (c) Grease applying area of the J6-axis
4.17
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
1
2 3
4
4.REPLACING PARTS
Tension adjusting bolt
Fig. 4.17 Replacing J3 belt
Specifications Q’ty Name LOCTITE Torque N-m (kgf-cm)
2 J2 ARM COVER
3 GASKET
A97L-0218-0496#M4X10BC 6
A290-7142-X307 1
A290-7142-X325 1
A98L-0040-0285#006-095 (*1)
4 BELT
A98L-0040-0293#006-100 (*2)
(*1) LR Mate 200 i
D. ARC Mate 50 i
D
(*2) LR Mate 200 i D/7L. ARC Mate 50 i D/7L
1
4.18
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-30 i B/R-30 i B 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.
- 69 -

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
4
3
2 1
8
Fig. 4.18 Replacing J5/J6 belt
Name
2 J3 ARM COVER
3 GASKET
Specifications Q’ty LOCTITE Torque N-m (kgf-cm)
A97L-0218-0496#M4X10BC 7
A290-7142-X405 1
A290-7142-X410 1
4 BELT
6 J3 ARM COVER
7 GASKET
8 BELT
A98L-0040-0286#004-104 1
A97L-0218-0496#M4X10BC 7
A290-7142-X405
A290-7142-X410
A98L-0040-0286#004-157
1
7
1
4.19
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 ( φ 6mm, φ 4mm) 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
6
5
4
7
Fig. 4.19 Replacing Solenoid valve
Name Specifications Q’ty LOCTITE Torque N-m (kgf-cm)
2 J2 ARM COVER
3 GASKET
4 BOLT
5 BOLT
A97L-0218-0496#M4X10BC 6
A290-7142-X307 1
A290-7142-X325
A6-BA-4X8
A6-BA-4X8
1
2
2
1 A290-7142-X327
A97L-0218-0130#D3B or
A97L-0218-0130#D3R or
A97L-0218-0130#D3 or
A97L-0218-0130#D2 or
A97L-0218-0130#D1
4.20
1
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.
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.
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
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.
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.
Fig. 5 marking label
- 73 -

5.REPLACING CABLES
5.1
Followings are the routing of the robot cables.
K118
(EE)
K204 (OPTION)
(CAMERA/FORCE SENSOR)
K106
(POWER)
K107
(PULSECODER)
K108
(RO, EE)
K202 (OPTION)
(CAMERA)
K203 (OPTION)
(FORCE SENSOR)
K109
(RO)
K116
(J6 AXIS POWER)
K117
(J6 AXIS PULSECODER)
K113
(J5 AXIS POWER)
K114
(J5 AXIS PULSECODER)
K111
(J4 AXIS POWER)
B-83495EN/01
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
K106
(POWER)
K107
(PULSECODER)
K108
(RO, EE)
K202 (OPTION)
(CAMERA)
K203 (OPTION)
(FORCE SENSOR)
K109
(RO)
K118
(EE)
K204 (OPTION)
(CAMERA/FORCE SENSOR)
K116
(J6 AXIS POWER)
K117
(J6 AXIS PULSECODER)
K111
(J4 AXIS POWER)
K113
(J5 AXIS POWER)
K114
(J5 AXIS PULSECODER)
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
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
K102
M2M
K104
M2BK
M3M
M3BK
Relay in the J3 housing
M4M
Ｃｌａmp
J2-1
K111
K106
M4BK
M5M
M1M
K113 M5BK
M6M
M1BK
Cｌａmp
J1-1
Ｃｌａmp
J1-2
BATTERY BACKUP
DON'T
DISCONNECT
コネ ク タ 取 外 不可 K103
Ｃｌａmp
J2-1
BATTERY BACKUP
DON'T
DISCONNECT
R l N ^ Žæ ŠO s Â
K116
M2P M6BK
K101
BATTERY BACKUP
DON'T
DISCONNEC T
コ ネ ク タ 取 外不 可
M1P
BATTERY BACKUP
DON'T
DISCONNECT
コネ ク タ 取 外 不可
BATTERY BACKUP
DON'T
DISCONNECT
コネ ク タ 取 外不 可
K105
K107
K108
Cｌａmp
J2-1
Cｌａmp
J2-1
BATTERY BACKUP
DON'T
DISCONNECT
コ ネ クタ 取 外 不 可
BATTE RY BACKUP
DON'T
DISC ONNECT
コ ネ ク タ 取 外不 可
BATTERY BACKUP
DON'T
DISC ONNECT
コネ ク タ 取 外 不可
BATTERY BACKUP
DON'T
DISC ONNECT
コ ネ クタ 取外 不 可
M3P
M4P
Relay in the J3 housing
BATTERY BACKUP
DON'T
DISCONNECT
コ ネ クタ 取 外 不 可
K114
BATTERY BACKUP
DON'T
DISCONNECT
コ ネ クタ 取 外 不 可
K117
K118
YV2
M5P
M6P
EE
K109
Fig.5.2 Cable externals chart of mechanical unit
5.3
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)
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
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
Specifications Q’ty LOCTITE Torque N-m (kgf-cm) Name
1 PLATED A97L-0218-0496#M4X10BC 5 2.0Nm(20kgfcm)
2 J2 BASE COVER A290-7142-X306 1
3 GASKET A290-7142-X324 1
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5.REPLACING CABLES
B
ClampJ2-1
A290-7142-X321
Match the marking
Pulsecoder line cable K108 cable K109
(blueXwhite)
Power line
(redXwhite)
Nylon band
Joint
A97L-0142-0214#KQ2L0600 (2)
A
Nylon band
Sheet
A290-7142-X328 (1)
(Tie up it with cables
on A290-7142-X320
with a nylon band)
Clamp J1-2
A290-7142-X320 (1)
Bolt
A6-BA-4X8 (2)
Power line
(redXwhite)
Pulsecoder line
(blueXwhite)
AIR 2
( O 6 white)
Nylon band
AIR 1
( O 6 black)
Fig.5.3.1 (b) Replace the cable in J2 base
Match the marking
3 2 1
B-83495EN/01
AIR 2
(φ6 white)
AIR 1
(φ6 black)
J2/J3 Power line
(redXwhite)
J2/J3 Pulsecoder line
(blueXwhite)
Name
Fig.5.3.1 (c) Removing the cover B
Specifications
1 PLATED A97L-0218-0496#M4X10BC
3 GASKET
A290-7142-X204
A290-7142-X205
Q’ty LOCTITE Torque N-m (kgf-cm)
9
1
1
2.0Nm(20kgfcm)
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B-83495EN/01
Pulsecoder line
(blueXwhite)
AIR 2
( O 6 white)
AIR 1
( O 6 black)
+ +
Tie up with nylon bands.
Washer bolt
A97L-0218-0606#M4X6 (2)
Battery box terminal side
Tightening torque
0.40Nm (4.1kgfcm)
Washer bolt
A97L-0218-0606#M4X6
Apply threebond No.1401B
on the connector head of brake and power.
Power line
(redXwhite)
Nylon band
A
Bolt
A6-BA-4X8 (2)
Match the marking
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
2
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 A97L-0218-0496#M4X10BC
2 PLATED A97L-0218-0546#040808BC
3 CON.PLATE A290-7142-X206
4 GASKET A290-7139-X251
(*) Specifications differs depend on the mechanical unit cables.
5
4
1
1
2.0Nm(20kgfcm)
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5.REPLACING CABLES
4 3
1
2
B-83495EN/01
Position of No.1 pin
(Example of mechanical unit
cable A05B-1142-H351)
Name
Fig.5.3.1 (f) Replace the parts of connector plate (bottom connector plate)
Specifications Q’ty LOCTITE Torque N-m (kgf-cm)
1 PLATED A97L-0218-0496#M4X12BC
2 PLATED A97L-0218-0546#040808BC
3 CON.PLATE (*)
4 GASKET
A290-7142-X212
A290-7139-X205
(*) Specifications differs depend on the mechanical unit cables.
9
1
4
1
2.0Nm(20kgfcm)
(
AIR 1
O 6 black)
(
AIR 2
O 6 white)
Power line
(redXwhite)
Pulsecoder line
(blueXwhite)
Plated bolt
A97L-0218-0546#040808BC (4)
Clamp J1-1
A290-7142-X220
Match the marking
(
AIR 1
O 6 black)
(
AIR 2
O 6 white)
CABLE K101
A660-8018-T491
Power line
(redXwhite)
Pulsecoder line
(blueXwhite)
Tie up with nylon bands
Fig.5.3.1 (g) Clamp of J1 base
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B-83495EN/01
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
Power line
(redXwhite)
Pulsecoder line
(blueXwhite)
Air tube
(φ3.2)
Joint
A97L-0118-0108#S23-M5 (1)
Nylon band
B-83495EN/01
Clamp J4-2
A290-7142-X416
Bolt
M4X8 (2)
Fig.5.3.2 (a) Clamp of J3 arm part
3
2 1
Fig.5.3.2 (b) Removing the J3 cover
Name Specifications Q’ty LOCTITE Torque N-m (kgf-cm)
1 PLATED A97L-0218-0496#M4X10BC 4 2.0Nm(20kgfcm)
3 GASKET
A290-7142-X404
A290-7142-X409
1
1
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B-83495EN/01
Pulsecoder line
(blueXwhite)
Power line
(redXwhite)
Air tube
(φ3.2)
Pulsecoder line
(blueXwhite)
Power line
(redXwhite)
Nylon band
Nylon band
Clamp J4
A290-7142-X415
Match the marking
Nylon band
Air tube
(φ3.2)
Match the marking
B
A
Fig.5.3.2 (c) Clamp of J3 housing part
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5.REPLACING CABLES
B
C
B-83495EN/01
A
Pulsecoder line
(blueXwhite)
Power line
(redXwhite)
Joint
A97L-0118-0108#H23-06 (1)
(for AIR 1 black φ3.2→φ6)
B
When H002 - H006,H012 - H016 are specified.
cable K109
(blueXwhite)
Pulsecoder line cable K108 cable K109
(blueXwhite)
Power line
(redXwhite)
AIR 2
(φ6 white)
Clamp J2-2
A290-7142-X322
Detail C
Section B-B
Match the marking.
AIR 1
(φ6 black)
Nylon band
Match the marking.
Clamp J3-1
A290-7142-X323
AIR 1
(φ6 black)
Power line
(redXwhite)
AIR 1
(φ3.18 black)
J2J3 Pulsecoder line
(blueXwhite)
Sheet
A290-7142-X326
Nylon band
Joint
A97L-0142-0214#KQ2L0600 (2)
Pulsecoder line cable K108 cable K109
(blueXwhite)
Power line
(redXwhite)
Nylon band
Match the marking.
AIR 2
(φ6 white)
AIR 2
(φ6 white)
AIR 1
(φ6 black)
J2J3 Power line
(redXwhite)
J2/J3 Pulsecoder line
(blueXwhite)
Cable K109
Detail A
Fig.5.3.2 (d) Clamp of J2 arm/J2 base part
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B-83495EN/01
3 2
1
Name
Fig.5.3.2 (e) Removing the J2 arm cover
Specifications Q’ty LOCTITE Torque N-m (kgf-cm)
2 J2 ARM COVER
3 GASKET
A290-7142-X307
A290-7142-X325
1
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
2
3
1
Fig.5.3.4 (a) Removing the J3 arm cover
Name
1 PLATED
3 J3 ARM COVER
4 GASKET
Specifications Q’ty LOCTITE Torque N-m (kgf-cm)
A97L-0218-0496#M4X10BC(*2) 7
A290-7142-X405
A290-7142-X410
1
1
2.0Nm(20kgfcm)
1
2
3
4
5
Name
Fig.5.3.4 (b) Replacing the cable K118
Specifications Q’ty LOCTITE Torque N-m (kgf-cm)
1 CAP A97L-0118-0757#F
A660-2007-T608
1
1
3 WASHER 2.0Nm(20kgfcm)
4 J3 CON.PLATE S A290-7142-X417
5 GASKET A290-7142-X418
1
1
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B-83495EN/01
5.3.5 Replacing Air Tube
1 See Subsection 5.3.1.
1 See Subsection 5.3.2.
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)
→ J2 connector panel←
Fig.5.3.5 (a) Marking of air tube (connector panel to J2 base)
340
AIR 1
(φ6 black)
50
210 (Standard)
320 (7L) 80
480
AIR 2
(φ6 white)
60
210 (Standard)
320 (7L)
J1← → J3
Fig.5.3.5 (b) Marking of air tube (J2 base to J3 housing)
- 87 -
210

5.REPLACING CABLES
930
150 160 215
135 (Standard)
220 (7L) 270
AIR 1
（φ3.18 black)
J2← → J4
150
Fig.5.3.5 (c) Marking of air tube (J3 housing to J3 arm)
160 215
135 (Standard)
220 (7L) 270
AIR 1
（φ3.18 white)
J2←
Fig.5.3.5 (d) Marking of air tube (when A05B-1142-H001 is specified)
Marking
→ J4
Air tube
( O 3.18mm blue for 1B)
270
135 (Standard)
220 (7L)
215 160
B-83495EN/01
270 215
135 (Standard)
220 (7L)
160
Air tube
( O 3.18mm red for 1A)
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
Marking
(
(
Air tube
O 3.18mm blue for 1B)
Air tube
O 3.18mm green for 2B)
270
135 (Standard)
220 (7L)
215
270
135 (Standard)
220 (7L)
215
160
160
(
Air tube
O 3.18mm yellow for 2A)
270
135 (Standard)
220 (7L)
215 160
(
Air tube
O 3.18mm red for 1A)
270
135 (Standard)
220 (7L)
215 160
(
Fig.5.3.5 (f) Marking of air tube (solenoid valve) (when A05B-1142-H003,H013 are specified)
Marking
Air tube
O 3.18mm blue for 1B)
270
135 (Standard)
220 (7L)
215 160
(
Air tube
O 3.18mm green for 2B)
270
135 (Standard)
220 (7L)
215 160
(
Air tube
O 3.18mm orange for 3B)
270
135 (Standard)
220 (7L) 215 160
(
Air tube
O 3.18mm clear for 3A)
270
135 (Standard)
220 (7L)
215 160
(
Air tube
O 3.18mm yellow for 2A)
270
135 (Standard)
220 (7L)
215 160
(
Air tube
O 3.18mm red for 1A)
270
135 (Standard)
220 (7L)
215 160
Fig.5.3.5 (g) Marking of air tube (solenoid valve)
(when A05B-1142-H004,H005,H006,H014,H015,H016 are specified)
- 89 -

5.REPLACING CABLES
B-83495EN/01
A
Plug
A97L-0218-0019 (1)
Air tube
( O 6mm white)
Air tube
A97L-0218-0010#BFL930R0 (1)
( O 3.18mm white)
Joint
A97L-0118-0108#H23-06 (1)
Half union
A97L-0118-0108#S23-M5 (1)
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
A
Check valve
A97L-0218-0026#04B-M5
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
A290-7142-V005 (for A05B-1142-H005) or
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
A290-7142-V015 (for A05B-1142-H015) or
A290-7142-V016 (for A05B-1142-H016)
Bolt
A6-BA-4X8 (2)
Cable K109
A660-2007-T602
Half union
A97L-0118-0108#S23-M5 (6)
Air tube
( O 6mm white) clear orange
(*1) (*1) yellow
(*2)
Detail A green
(*2) red
(*3) blue
(*3)
(*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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B-83495EN/01
6.ADJUSTMENTS
6
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
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=80 º, J5= ± 90 º )
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
BELT TENSION
MASS
30 – 40N (Standard)
49 – 65N (7L)
0.0367kg (Standard)
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 -

B-83495EN01 APPENDIX
A.SPARE PARTS LIST
A
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
K106 A660-4005-T366
K107 A660-4005-T367
Relay of J4, J5, J6 power
J4 Pulsecoder
Relay of J5, J6 Pulsecoder
Relay of end effector
K108 A660-2007-T601 Relay of EE
K109 A660-2007-T602 YV
K118 A660-2007-T608 EE12P
K131 A660-8016-T944
External battery cable 5m
(When external battery option is selected)
K131 A660-8016-T945
External battery cable 7m
(When external battery option is selected)
K131 A660-8016-T946
External battery cable 14m
(When external battery option is selected)
Table A (b) List of basic cable (7L)
Name Specifications Remarks
K101 A660-8018-T491 RMP
K106
K108
A660-4005-T366#L
A660-2007-T601#L
Relay of J4, J5, J6 power
J4 Pulsecoder
Relay of end effector
Relay of EE
K131 A660-8016-T944
External battery cable 5m
(When external battery option is selected)
K131 A660-8016-T945
External battery cable 7m
(When external battery option is selected)
K131 A660-8016-T946
External battery cable 14m
(When external battery option is selected)
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A.SPARE PARTS LIST
APPENDIX B-83495EN/01
Table A (c) Motor
Name Specifications
β i
SR1/6000(*)
β i SR0.5/6000
β i
SR0.4/4000
β i
SR0.2/4000
Remarks
A06B-0116-B855#0048 J1,J2-axis
A06B-0115-B855#0048 J3-axis
A06B-0114-B855#0048 J4-axis
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
Harmonic drive
Harmonic drive
Harmonic drive
Harmonic drive
Harmonic drive
Harmonic drive
Harmonic drive
A97L-0218-0980#80
A97L-0218-0952#120
A97L-0218-0953#80
A97L-0218-0954#80
A97L-0218-0955#50
A97L-0218-0956#50
J1-axis (7L)
J2-axis (7L)
J3-axis
J4-axis
J5-axis
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
GEAR J1-1
GEAR J1-1
GEAR J4-1
A290-7142-X202
A290-7142-X248
A290-7142-X406
Remarks
J1-axis (Standard)
J1-axis (7L)
J4-axis
Table A (f) Pulley, shaft, key
Pulley J3-1
Pulley J3-2
Name Specifications
A290-7142-X309
A290-7142-X310
Remarks
J3-axis motor (Standard)
J3-axis reducer (Standard)
Pulley J3-1
Pulley J3-2
A290-7142-X333
A290-7142-X334
J3-axis motor (7L)
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
Belt
Table A (g) Belt
Name Specifications
A98L-0040-0285#006-095
Remarks
J3-axis motor (Standard)
- 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
Gasket A290-7142-X316 Cover
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 JB-OR1A-G45
Seal bolt
Seal bolt
Seal bolt
Seal bolt
Seal bolt
Seal bolt
Seal bolt
Seal bolt
Table A (j) Seal bolt
Name Specifications
A97L-0218-0423#030606
Remarks
J4 pipe 4 pcs/1 robot
A97L-0218-0423#030606
A97L-0218-0423#051212
A97L-0218-0546#032204BC
A97L-0218-0546#043016BC
A97L-0218-0546#043516BC
Support 7 pcs/1 robot
J2-axis motor 4 pcs/1 robot
J3-axis reducer 12 pcs/1 robot
J1-axis reducer 12 pcs/1 robot
J2-axis reducer 12 pcs/1 robot
A97L-0318-0405#040606EN
A97L-0318-0406#081010EN
J2 - J6-axis grease inlet 5 pcs/1 robot
J1-axis grease inlet
Table A (k) Spring pin, Stopper, Wrist unit, Sheet, Shaft
Name Specifications Remarks
Spring pin A6-PS-8X20S
Stopper A290-7142-X427
J3 stopper
Wrist unit A290-7142-V501
With J5/J6-axis reducer
Sheet
Air tube
Air tube
Air tube
Air tube
Air tube
Air tube
Table A (l) Air tube
Name Specifications
(H001,H011)
Air tube
(H002,H003,H004,H005,
H006,H012,H013,H014,H0
15,H016)
A97L-0218-0010#AFL3R003
A97L-0218-0114#ABL3R003
A97L-0218-0114#ABL3R003
A97L-0218-0114#BBL3R003
A97L-0218-0114#BBL3R003
A97L-0218-0114#BFL3R003
A97L-0218-0010#BAL3R003
Remarks
3.18mm BLACK AIR1
J2 arm to J3 arm
6mm BLACK AIR1
J2 base to J3 casing
6mm BLACK AIR1
Connector plate to J2 base
6mm WHITE AIR2
6mm WHITE AIR2
Connector plate to J2 base
3.18mm WHITE AIR2
J2 arm to J3 casing
4mm WHITE EXHAUST
J2 arm to J3 casing
- 99 -

A.SPARE PARTS LIST
APPENDIX B-83495EN/01
Air tube
Name Specifications
(H002,H003,H004,H005,
H006,H012,H013,H014,H0
15,H016)
Air tube
(H002,H003,H004,H005,
H006,H012,H013,H014,H0
15,H016)
Air tube
(H003,H004,H005,H006,
H013,H014,H015,H016)
Air tube
(H003,H004,H005,H006,
H013,H014,H015,H016)
Air tube
(H004,H005,H006,H014,
H015,H016)
Air tube
(H004,H005,H006,H014,
H015,H016)
A97L-0218-0010#CFL3R003
A97L-0218-0010#DFL3R003
A97L-0218-0010#EFL3R003
A97L-0218-0010#FFL3R003
A97L-0218-0010#GFL3R003
A97L-0218-0010#HFL3R003
Remarks
3.18mm RED 1A
J2 arm to J3 casing
3.18mm RED 1B
J2 arm to J3 casing
3.18mm YELLOW 2A
J2 arm to J3 casing
3.18mm GREEN 2B
J2 arm to J3 casing
3.18mm CLEAR 3A
J2 arm to J3 casing
3.18mm ORANGE 3B
J2 arm to J3 casing
Table A (m) Solenoid valve (Either the following is installed by the option specification)
(except H001, H011)
Name Specifications Remarks
Solenoid valve
Solenoid valve
Solenoid valve
Solenoid valve
Solenoid valve
A97L-0218-0130#D1
A97L-0218-0130#D2
A97L-0218-0130#D3
A97L-0218-0130#D3R
A97L-0218-0130#D3B
Double solenoidX1 (2 positionX1)
Double solenoidX2 (2 positionX2)
Double solenoidX3 (2 positionX3)
Double solenoidX3
(3 position (exhaust center) X3)
Double solenoidX3
(3 position (closed center) X3)
Table A (n) Battery
Name Specifications Remarks
Battery
Battery
A98L-0031-0027
A98L-0031-0005
C battery/1.5V 4pcs/ per 1 robot
(When battery built-in option is selected)
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
Greasing kit A05B-1142-K021
Harmonic grease 4BNo.2
Grease in tube A05B-1139-K022
- 100 -

B-83495EN01
B.CIRCUIT DIAGRAM, AIR PRESSURE DIAGRAM
B
- 101 -

B.CIRCUIT DIAGRAM, AIR PRESSURE DIAGRAM
APPENDIX
J1 CONNECTOR PANEL
8
9
10
11
12
5
6
7
2
3
4
RMP
1 BK(J1)
J1U1
J1V1
J1W1
J1G1
XROT
RI1
RO1
RI7
PRQJ1
XPRQJ1
20
21
5V(J1,J2) 22
23
24
17
18
19
13
14
15
16
BK(J2)
J2U1
J2V1
J2W1
J2G1
24VF(OT,A1,A2)
RI2
25
26
27
28
29
30
BK(J3)
J3U1
J3V1
J3W1
J3G1
XHBK
31 RI3
RO2
RI8
5V(J3,J4)
PRQJ2
XPRQJ2
32
33
34
35
36
RO3
RO7
5V(J5,J6)
PRQJ3
XPRQJ3
G
47
48
SG
44
45
46
41
42
43
37
38
39
40
BK(J4)
J4U1
J4V1
J4W1
J4G1
RI4
49 BK(J5)
50
51
52
53
54
55
J5U1
J5V1
J5W1
J5G1
RI5
RO4
RO8
0V(J1,J2) 58
PRQJ4
XPRQJ4
56
57
59
60
RO5
0V(J3,J4)
PRQJ5
XPRQJ5
68
69
70
71
72
65
66
67
61
62
63
64
Han 72DD
(2.5SQ 10A)
BK(J6)
BKC(J1-J6)
J6U1
J6V1
J6W1
J6G1
0V(A1,A2,B1-B6)
RI6
RO6
0V(J5,J6)
PRQJ6
XPRQJ6
K101
A660-8018-T491
B-83495EN/01
A63L-0001-0865#1
A63L-0001-0864#CS
A63L-0001-0865#2
A63L-0001-0864#CS
A63L-0001-0848#E10SL1
A63L-0001-0850
J1 MOTOR (βiSR1/6000)
M1M
2 J1V1
3 J1W1
1
4
J1U1
J1G1
M1BK
2
3
BK(J1) 1
4
BKC(J1)
M1P
8
9
10
5V(J1)
0V(J1)
4
5
6V(BT1)
XPRQJ1
6 PRQJ1
7 0V(BT1)
1
2
3
A63L-0002-0066#R06DX
A63L-0002-0066#CRM
( X-KEY
BLACK
)
M2M1
A1 J2U1
A2
A3
BK(J2)
J2W1
B1
B2
B3
J2G1
F06DX
CTM
J2V1
BKC(J2)
K102
A660-4005-T364
A660-4005-T364#L
A63L-0002-0205#6SB
A63L-0002-0205#2428SCFA
(
BLACK
)
M2P1
1
2
6V(BT2)
PRQJ2
3 5V(J2)
4
5
6
6PB
2428PCFA
0V(BT2)
XPRQJ2
0V(J2)
K103
A660-2007-T599
A660-2007-T599#L
A63L-0001-0865#1
A63L-0001-0864#CS
A63L-0001-0865#2
A63L-0001-0864#CS
A63L-0001-0848#E10SL1
A63L-0001-0850
J2 MOTOR (βiSR1/6000)
M2M
2 J2V1
3 J2W1
1
4
J2U1
J2G1
M2BK
2 BK(J2)
3
1
4
BKC(J2)
M2P
8
9 5V(J2)
10 0V(J2)
4
5
6
6V(BT2)
XPRQJ2
PRQJ2
7 0V(BT2)
1
2
3
A63L-0002-0066#R06DYW
A63L-0002-0066#CRM
( Y-KEY
WHITE
)
M3M1
A1 J3U1
A2
A3
BK(J3)
J3W1
B1
B2
B3
F06DYW
CTM
J3G1
J3V1
BKC(J3)
K104
A660-4005-T365
A660-4005-T365#L
A63L-0002-0205#7SW
A63L-0002-0205#2428SCFA
(
WHITE
)
M3P1
5
2
XPRQJ3
7
7PW
2428PCFA
PRQJ3
4
1 6V(BT3)
0V(BT3) 3 5V(J3)
6 0V(J3) K105
A660-2007-T600
A660-2007-T600#L
A63L-0001-0865#1
A63L-0001-0864#CS
A63L-0001-0865#2
A63L-0001-0864#CS
A63L-0001-0848#E10SL1
A63L-0001-0850
J3 MOTOR (βiSR0.5/6000)
M3M
2 J3V1
3 J3W1
1
4
J3U1
J3G1
M3BK
2 BK(J3)
3
1
4
BKC(J3)
M3P
8
9
10
5V(J3)
0V(J3)
4
5
6
7
6V(BT3)
XPRQJ3
PRQJ3
0V(BT3)
1
2
3
A63L-0002-0066#R20DX
A63L-0002-0066#CRM
( X-KEY
BLACK
)
M456M
A1 J4U1
A2
A3
A4
BK(J4)
J4W1
A5
A6
J5G1
J5V1
A7 BKC(J5)
A8
A9
J6U1
BK(J6)
A10 J6W1
B1
B2
B3
B4
J4G1
F20DX
CTM
J4V1
BKC(J4)
B5
B6
B7
J5U1
BK(J5)
B8
B9
J5W1
J6G1
J6V1
B10 BKC(J6)
K106
A660-4005-T366
A660-4005-T366#L
BATTERY
6V
(BT1,BT2,BT3,
BT4,BT5,BT6)
+
( 単二電池
SIZE C
)
-
0V
(BT1,BT2,BT3,
BT4,BT5,BT6)
A63L-0002-0205#13SB
A63L-0002-0205#2428SCFA
(
BLACK
)
M456P
3
7
11
6V(BT4-BT6)
5V(J4)
6
10
13
2 XPRQJ4
0V(BT4-BT6)
0V(J4)
5V(J5,J6)
5
9
12
13PB
2428PCFA
1
XPRQJ5
XPRQJ6
PRQJ4
0V(J5,J6)
4
8
PRQJ5
PRQJ6
K107
A660-4005-T367
A660-4005-T367#L
A63L-0002-0205#13SW
A63L-0002-0205#2428SCFA
(
WHITE
)
EE1
7
11
3 24VF(A1,A2)
RI6
0V(A1,A2)
6
10
RI5
2
XHBK
13 RI8
RI2
5
9
12
RI4
RO8
RI7
1
13PW
2428PCFA
RI1
4
8
RI3
RO7
K108
A660-2007-T601
A660-2007-T601#L
A63L-0002-0205#7SB
A63L-0002-0205#2428SCFA
(
BLACK
)
YV1
5 RO5
7
2 RO2 1
4 RO4
0V(B1-B6) 6
RO1
RO6
3
7PB
2428PCFA
RO3
K109
A660-2007-T602
A660-2007-T602#L
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
B.CIRCUIT DIAGRAM, AIR PRESSURE DIAGRAM
A63L-0002-0066#R08DX
A63L-0002-0066#CRM
( X-KEY
BLACK
)
M4M1
A1 J4U1
A2
A3
A4
BK(J4)
J4W1
B1
B2
B3
B4
J4G1
F08DX
CTM
J4V1
BKC(J4)
K111
A660-4005-T368
A63L-0001-0865#1
A63L-0001-0864#CS
A63L-0001-0865#2
A63L-0001-0864#CS
A63L-0001-0848#E10SL1
A63L-0001-0850
J4 MOTOR (βiSR0.4/6000)
M4M
2 J4V1
3 J4W1
1
4
J4U1
J4G1
M4BK
2
3
BK(J4) 1
4
BKC(J4)
M4P
8
9
10
5V(J4)
0V(J4)
4
5
6
7
6V(BT4)
XPRQJ4
PRQJ4
0V(BT4)
1
2
3
A63L-0002-0066#R06DX
A63L-0002-0066#CRM
( X-KEY
BLACK
)
M5M1
A1
A2
J5U1
BK(J5)
A3 J5W1
B1
B2
J5G1
J5V1
F06DX
CTM
B3 BKC(J5)
K113
A660-4005-T369
A660-4005-T369#L
A63L-0002-0205#6SB
A63L-0002-0205#2428SCFA
(
BLACK
)
M5P1
1 6V(BT5)
2
3
PRQJ5
5V(J5)
4
5
6
6PB
2428PCFA
0V(BT5)
XPRQJ5
0V(J5) K114
A660-2007-T605
A660-2007-T605#L
A63L-0001-0865#1
A63L-0001-0864#CS
A63L-0001-0865#2
A63L-0001-0864#CS
A63L-0001-0848#E10SL1
A63L-0001-0850
J5 MOTOR (βiSR0.2/6000)
M5M
2
3
J5V1
J5W1
1
4
J5U1
J5G1
M5BK
2 BK(J5)
3
1
4
BKC(J5)
M5P
8
9
10
5V(J5)
0V(J5)
6
7
4
5
6V(BT5)
XPRQJ5
PRQJ5
0V(BT5)
1
2
3
A63L-0002-0066#R06DYW
A63L-0002-0066#CRM
( Y-KEY
WHITE
)
M6M1
A1 J6U1
A2
A3
BK(J6)
J6W1
B1
F06DYW
CTM
J6G1
B2
B3
J6V1
BKC(J6)
K116
A660-4005-T370
A660-4005-T370#L
A63L-0002-0205#7SW
A63L-0002-0205#2428SCFA
(
WHITE
)
M6P1
2
5 XPRQJ6
7
PRQJ6
4
6V(BT6)
7PW
2428PCFA
1
0V(BT6)
6
3
0V(J6)
5V(J6)
K117
A660-2007-T607
A660-2007-T607#L
A63L-0001-0865#1
A63L-0001-0864#CS
A63L-0001-0865#2
A63L-0001-0864#CS
A63L-0001-0848#E10SL1
A63L-0001-0850
J6 MOTOR (βiSR0.2/6000)
M6M
2 J6V1
3 J6W1
1
4
J6U1
J6G1
M6BK
2
3
BK(J6) 1
4
BKC(J6)
M6P
8
9
10
5V(J6)
0V(J6)
4
5
6
7
6V(BT6)
XPRQJ6
PRQJ6
0V(BT6)
1
2
3
A63L-0002-0205#13SB
A63L-0002-0205#2428SCFA
(
BLACK
)
EE2
3
7
11
24VF(A1,A2)
RI6
0V(A1,A2)
6
10
RI5
2
(XHBK)
RI2
5
9
13 (RI8)
RI4
RO8
1
12 (RI7)
13PB
2428PCFA
RI1
4
8
RI3
RO7
K118
A660-2007-T608
A660-2007-T608#L
J3 CONNECTOR PANEL
EE
7 RO7
8
6
RO8
12
RI6
5
A63L-0002-0072#12SN
9
0V(A2)
24VF(A1)
10
1 RI1
24VF(A2) 2 RI2
RI5
11 0V(A1)
4 RI4
3 RI3
YV2
4
8
1
RO4
0V(B1)
R01
5
9
12
13SB
2428SCFA
2
RO5
0V(B2)
0V(B5)
RO2
6
10
13
3 R03
RO6
0V(B3)
0V(B6)
7
11 0V(B4)
YV2
3
7
11
A05B-1142-H002,-H012
6
10
13
13PB
2428PCFA
2 RO2
5
9
12
1
0V(B2)
R01
4
8 0V(B1)
SOLENOID VALVE
A97L-0218-0130#D1
A05B-1142-H003,-H013
YV2
7
11
3
0V(B4)
R03
6
10
13
2
0V(B3)
RO2
5
9
12
1
0V(B2)
R01
4
8
13PB
2428PCFA
RO4
0V(B1)
SOLENOID VALVE
A97L-0218-0130#D2
A05B-1142-H004,-H014
YV2
7
11
3
0V(B4)
R03
6
10
2
RO6
0V(B3)
13 0V(B6)
RO2
5
9
12
1
RO5
0V(B2)
R01
4
8
0V(B5)
13PB
2428PCFA
RO4
0V(B1)
SOLENOID VALVE
A97L-0218-0130#D3
A05B-1142-H005
YV2
7
11
3
0V(B4)
R03
6
2
10
13
RO6
0V(B3)
0V(B6)
RO2
5
9
12
RO5
1
0V(B2)
0V(B5)
R01
4
8
13PB
2428PCFA
RO4
0V(B1)
SOLENOID VALVE
A97L-0218-0130#D3B
A05B-1142-H006
YV2
7
11
3
0V(B4)
R03
6
2
10
13
RO6
0V(B3)
0V(B6)
RO2
5
9
12
RO5
1
0V(B2)
0V(B5)
R01
4
8
13PB
2428PCFA
RO4
0V(B1)
SOLENOID VALVE
A97L-0218-0130#D3R
:可動部用
MOVABLE
- 103 -

B.CIRCUIT DIAGRAM, AIR PRESSURE DIAGRAM
APPENDIX
J1 CONNECTOR PANEL
K101
A660-8018-T491
BATTERY
6V
(BT1,BT2,BT3,
BT4,BT5,BT6)
+
( 単一電池
SIZE D
)
-
0V
(BT1,BT2,BT3,
BT4,BT5,BT6)
K131
A660-8016-T498
GB2
A
6V(BT1,BT2,BT3,
BT4,BT5,BT6)
B
0V(BT1,BT2,BT3,
BT4,BT5,BT6)
C
GB2
A
6V(BT1,BT2,BT3,
BT4,BT5,BT6)
B
0V(BT1,BT2,BT3,
BT4,BT5,BT6)
C
K119
A660-8018-T493
TERMINAL
A65L-0001-0337#102P
A63L-0001-0648#610SL3SJ A63L-0001-0648#610SL3SJ
Fig.B (b) Circuit diagram (when remote type battery is specified)
B-83495EN/01
A63L-0002-0205#13SW
A63L-0002-0205#2428SCFA
(
WHITE
)
EE1
7
11
3
RI6
24VF(A1,A2)
6 RI5
2
0V(A1,A2) 10
13
XHBK
RI8
RI2
5
9
12
RI4
1
RO8
RI7
13PW
2428PCFA
RI1
4
8
RI3
RO7
K108
A660-2007-T601
A63L-0002-0205#13SB
A63L-0002-0205#2428SCFA
(
BLACK
)
EE2
7
11
3
RI6
24VF(A1,A2)
6 RI5
2
0V(A1,A2) 10
13
XHBK
(RI8)
RI2
5
9
12
RI4
1
(RO8)
(RI7)
13PB
2428PCFA
RI1
4
8
RI3
(RO7)
J3 CONNECTOR PANEL
EE
1 0V(B1)
2 0V(B2)
3 0V(A1)
4 0V(A2)
5 RO1
6 RO2
7 RO3
8 RO4
9 RO5
10 RO6
11 RI1
12 RI2
A63L-0002-0072#20SN
17 XHBK
13 RI3
14 RI4
15 RI5
16 RI6
18 24VF(A1)
19 24VF(A1)
20 24VF(A2)
A63L-0002-0205#7SB
A63L-0002-0205#2428SCFA
(
BLACK
)
YV1
5 RO5
7
2 RO2
4 RO4
0V(B1-B6)
1
6
7PB
2428PCFA
RO1
RO6
3 RO3 K109
A660-2007-T602
A63L-0002-0205#13SB
A63L-0002-0205#2428SCFA
(
BLACK
)
YV2
7
11
3 R03
6
(0V(B4)) 10
13
RO6
2 RO2
5
(0V(B3))
(0V(B6))
9
12
13PB
2428PCFA
RO5
1 R01
0V(B2)
(0V(B5))
4
8
RO4
0V(B1)
K120
A660-4005-T371
Fig.B (c) Circuit diagram (when EE20P is specified)
J1 CONNECTOR PANEL
CAM1
D LED+
4 GND(VIDEO)
7
C
3
VIDEO
LED-
TRG
6
B
2
12V
GND(VD,TRG)
GND(HD) 5 HD
A
LF13WBR-11P
0V
1 VD
FS1
1
2
0V
TX2
4
3
LF10WBR-4P
24V
TX1
K201
A05B-1142-D001
:可動部用
MOVABLE
A63L-0002-0205#13SB
A63L-0002-0205#2428SCFA
(
BLACK
)
CAM-A
3 LED-
7 LED+ 6
11 GND(VIDEO) 10
13
TRG
2 SHIELD
5
1 12V
GND(TRG) 4
VIDEO
GND(HD)
9
12
GND(VD)
HD
8
13PB
2428PCFA
0V
VD
K202
A660-2007-T609
A63L-0002-0205#5SB
A63L-0002-0205#2428SCFA
(
BLACK
)
FS-A
3 TX1
5
2
DRAIN
TX2
4
5PB
2428PCFA
24V
1 0V
K203
A660-2007-T610
A63L-0002-0205#13SB
A63L-0002-0205#2428SCFA CAM3
7
11
3
LED+
LED-
GND(VIDEO)
6
10
13
TRG
2
VIDEO
SHIELD
GND(HD)
5
9
12
1 12V
GND(TRG)
GND(VD)
HD
4
8
13PB
2428PCFA
0V
VD
K204
A05B-1142-D002
A63L-0002-0205#5SB
A63L-0002-0205#2428SCFA
FS-B
3 TX1
5
2
DRAIN
TX2
4 24V
5PB
2428PCFA
1 0V
J3 CONNECTOR PANEL
CAM2
A 0V
1 VD
5
FS2
6
5
4 24V
HD
B
2
12V C LED-
GND(VD,TRG)
6
3 TRG
GND(HD) 7
D
LF13WBR-11S
LED+
4
VIDEO
GND(VIDEO)
1
2
3
LF07WBR-6S
0V
TX2
TX1
:可動部用
MOVABLE
Fig.B (d) Circuit diagram (camera cable / sensor cable)
- 104 -

B-83495EN01
B.CIRCUIT DIAGRAM, AIR PRESSURE DIAGRAM
J3 CONNECTOR PANEL
CAM2
A
1
0V
VD
5 HD
B
2
12V C (LED-)
GND(VD,TRG)
6
3 TRG
GND(HD) 7
D
LF13WBR-11S
(LED+)
4
VIDEO
GND(VIDEO) K251
A660-2007-T614
CAM3
3
1
2 12V
GND(VIDEO) 11
4 VIDEO
0V
TRG
10
5
HR10-10R-12P(01)
9 TRG
12
8 GND(TRG)
GND(VD)
GND(HD) 6 HD
7 VD
J3 CONNECTOR PANEL
CAM2
A 0V
1 VD
5 HD
B
2
12V C LED-
GND(VD,TRG)
6
3 TRG
GND(HD) 7
D
LF13WBR-11S
LED+
4
VIDEO
GND(VIDEO)
J3 CONNECTOR PANEL
FS2
6
5
4 24V
1
2
3
LF07WBR-6S
0V
TX2
TX1
K252
A660-4005-T400
CAM3
3
1
2 12V
GND(VIDEO)
4
11
VIDEO
0V
TRG
10
5
HR10-10R-12P(01)
9 TRG
12 GND(VD)
GND(HD)
8 GND(TRG)
7 VD
6 HD
LED
1 LED+
2
3
LF07WBR-3P
LED-
Fig.B (e) Circuit diagram (camera cable)
SENSOR CABLE
A660-2007-T615
FORCE SENSOR(6AXES)
FS3
1 0V
2 TX2
4
3
LF10WBR-4P
24V
TX1
J3 CONNECTOR PANEL
FS2
6
5
4 24V
1
2
3
LF07WBR-6S
0V
TX2
TX1
SENSOR CABLE
A660-2007-T691
FORCE SENSOR(3AXES)
FS3
LF10WBR-12P
2
1
11 24V
10
9
12
0V
8
3 7 TX2
4
5 TX1
6
Fig. B (f) Circuit diagram (force sensor cable)
- 105 -

B.CIRCUIT DIAGRAM, AIR PRESSURE DIAGRAM
APPENDIX
J1 connector plate
AIR 1
J1 connector plate
AIR 2
RO1
B-83495EN/01
J3 arm
J2 arm
Exhaust port
J1 connector plate
AIR 1
J1 connector plate
AIR 2
RO2
B1 A1
Fig. B(g) Air pressure diagram
(Double solenoid valve × 1 A05B-1142-H002,H012 is specified)
J3 arm
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
B.CIRCUIT DIAGRAM, AIR PRESSURE DIAGRAM
J1 connector plate
AIR 1
J1 connector plate
AIR 2
J3 arm
J2 arm
Exhaust port
RO5 RO3
RO1
J1 connector plate
AIR 1
J1 connector plate
AIR 2
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)
J3 arm
J2 arm
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
J1 connector plate
AIR 1
J1 connector plate
AIR 2
RO5 RO3 RO1
B-83495EN/01
J3 arm
J2 arm
Exhaust port
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
C.PERIODIC MAINTENANCE TABLE
C
- 109 -

C.PERIODIC MAINTENANCE TABLE
APPENDIX B-83495EN/01
FANUC Robot LR Mate 200 i
D, ARC Mate 50 i
D ,LR Mate 200 i
D/7L,
ARC Mate 50 i
D/7L Periodic Maintenance Table
Working time (H)
Check time
Items
1
Check the exposed connector.(loosening)
0.2H
Grease amount
―
First check
320
3 months months months
960
6
1920
9
2880
○
1 years
2 years
3840 4800 5760 6720 7680 8640 9600 10560
○ ○
2 Tighten the end effector bolt. 0.2H ― ○ ○ ○
3
4
Tighten the cover and main bolt.
Check the mechanical stopper.
2.0H
0.1H
―
―
5 Remove spatter and dust etc. 1.0H ―
○
○
○
○
○
○
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
6
7
Check hand cable and external battery cable (option)
Replacing battery.
(if built-in batteries are specified)
Replacing battery.
(if external batteries are specified)
8 Greasing the reducers.
0.1H
0.1H
0.1H
―
―
―
○ ○
●
●
○
●
0.5H 14ml
9
Replacing cable of mechanical unit *1
10
Check the robot cable, teach pendant cable and robot connecting cable
4.0H ―
0.2H ―
11 Cleaning the ventilator
○ ○ ○
0.2H ― ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
Controller 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
C.PERIODIC MAINTENANCE TABLE
3 4 5 years
11520 12480 13440 14400 years
15360 16320 17280 18240 years
19200 20160 21120 22080
6 years
23040 24000 24960 25920
7 years
26880 27840 28800 29760
8 years
30720
Item
○ ○ ○ ○ ○ 1
○ ○ ○ ○ ○ 2
○ ○ ○ ○ ○ 3
○ ○ ○ ○ ○ 4
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ 5
○ ○ ○ ○ ○ 6
● ● ● ● ●
7
●
○
●
●
○
●
○
●
○ ○
●
8
9
10
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
●
11
12
- 111 -

B-83495EN/01
D.MOUNTING BOLT TORQUE LIST
APPENDIX
D
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/mm
2 or more
Size is M24 or more : Tensile strength 1000N/mm
2 or more
All size of bolt of the plating : Tensile strength 1000N/mm
2 or more
Hexagon bolt, stainless bolt, special shape bolt (button bolt, low-head bolt, flush bolt .etc)
Tensile strength 400N/mm
2 or more
If no tightening torque is specified for a bolt, tighten it according to this table.
Recommended bolt tightening torques Unit: Nm
Nominal diameter
Hexagon socket head bolt
(Steel)
Hexagon socket head bolt (stainless)
Hexagon socket head button bolt
Hexagon socket head flush bolt
Low-head bolt
(steel)
Tightening torque
Hexagon bolt
(steel)
Tightening torque Tightening torque Tightening torque
M3
M4
M6
Upper limit Lower limit Upper limit Lower limit Upper limit Lower limit Upper limit Lower limit
1.8 1.3 0.76
0.53
―――― ―――― ―――― ―――
4.0 2.8 1.8 1.3 1.8
2.5 4.0
2.8 3.2 2.3
14 9.6 5.8 4.1 7.9
5.6 5.5 3.8
M8
M10
M12
(M14)
M16
(M18)
M20
(M22)
M24
(M27)
M30
32
66
110
180
270
380
530
730
930
1400
1800
M36 3200
23
46
78
260
370
510
650
960
1300
2300
14
27
48
160
230
――――
――――
――――
――――
――――
9.8 14 13 9.3
19 32 23
33
―――― ――――
130 76
190 120
53
―――― ――――
82
―――― ――――
110
――――
――――
―――― ――――
160 ―――― ――――
―――― ―――― ――――
―――― ――――
―――― ―――― ――――
―――― ――――
―――― ―――― ――――
26
45
73
98
140
190
――――
――――
――――
――――
――――
19
31
51
69
96
130
――――
――――
――――
――――
――――
- 112 -

B-83495EN/01 E.OPTIONAL CONNECTOR WIRING PROCEDURE
E
Source of information: Hirose Electric Co., Ltd.
NOTE1
NOTE2
NOTE1) Corresponds A05B-1137-J057.
NOTE2) Corresponds A05B-1139-J059.
- 113 -

B-83495EN/01
INDEX
<Number>
1.5-YEAR (5760 HOURS) CHECKS ............................... 6
1-YEAR (3840 HOURS) CHECKS .................................. 6
3-MONTH (960 HOURS) CHECKS ................................ 6
4-YEAR (15360 HOURS) CHECKS ................................ 6
<A>
ADJUSTING TENSION OF BELT ................................ 92
ADJUSTMENTS ............................................................ 92
<B>
BACKLASH MEASUREMENT .................................... 19
<C>
CABLE AND AIR TUBE REPLACEMENT ................. 76
CABLE FORMING ........................................................ 75
CABLE WIRING............................................................ 74
CHECKS AND MAINTENANCE ................................... 1
CIRCUIT DIAGRAM, AIR PRESSURE DIAGRAM.. 101
<D>
DAILY CHECKS.............................................................. 1
<F>
FAILURES, CAUSES AND MEASURES ..................... 13
FIGURE OF DRIVE MECHANISM .............................. 24
FIRST 1-MONTH (320 HOURS) CHECK....................... 3
FIRST 3-MONTH (960 HOURS) CHECKS .................... 3
<M>
MAINTENANCE ............................................................. 7
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
REPLACING J2-AXIS REDUCER................................ 35
REPLACING J3 BELT................................................... 68
REPLACING J3-AXIS MOTOR .................................... 38
REPLACING J3-AXIS REDUCER................................ 40
REPLACING J4-AXIS MOTOR .................................... 45
REPLACING J4-AXIS REDUCER................................ 47
REPLACING J5/J6 BELT .............................................. 69
REPLACING J5-AXIS MOTOR .................................... 51
REPLACING J5-AXIS REDUCER (7L)........................ 56
REPLACING J5-AXIS REDUCER (Standard) .............. 52
REPLACING J6-AXIS MOTOR .................................... 61
REPLACING J6-AXIS REDUCER................................ 67
REPLACING PARTS ..................................................... 23
REPLACING SOLENOID VALVE ............................... 70
REPLACING THE BATTERIES (1-YEAR
PERIODIC INSPECTION IF BUILT-IN
BATTERIES ARE SPECIFIED) (1.5-YEAR
PERIODIC INSPECTION IF EXTERNAL
BATTERIES ARE SPECIFIED)................................... 9
REPLACING WRIST UNIT (7L) .................................. 65
REPLACING WRIST UNIT (Standard)......................... 63
REPLENISH THE GREASE OF THE DRIVE
MECHANISM (4 YEARS (15360 HOURS)
CHECKS).................................................................... 11
<S>
SAFETY PRECAUTIONS ............................................ s-1
SEALANT APPLICATION ........................................... 71
SPARE PARTS LIST ..................................................... 97
<T>
TROUBLESHOOTING .................................................. 13

B-83495EN/01
Edition Date Contents
REVISION RECORD r-1

B-83495EN/01
* B 8 3 4 9 5 E N / 0 1 *