< Robot
CRX-10+A, CRX-10+A/L, CRX-20+A/L
MECHANICAL UNIT
MAINTENANCE MANUAL
B-84195EN/02
© FANUC CORPORATION, 2021
•
Original Instructions
Thank you very much for purchasing FANUC Collaborative Robot.
Before using the Robot, be sure to read the "SAFETY PRECAUTIONS" in this manual and
understand the content.
• No part of this manual may be reproduced in any form.
• The appearance and specifications of this product 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 endeavor to include all pertinent matters. There are, however, a very
large number of operations that must not or cannot be performed, and if the manual
contained them all, it would be enormous in volume. It is, therefore, requested to assume
that any operations that are not explicitly described as being possible are "not possible".
SAFETY PRECAUTIONS
B-84195EN/02
SAFETY PRECAUTIONS
This chapter explains cautions for safety usage of FANUC collaborative robot.
Robot cannot work without the end effector or peripheral equipment. By combined with the end effector
and peripheral equipment and assembling the system, robot can demonstrate works. In other words the
robot is one part of the system.
FANUC 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 workplace. 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 best be determined by safety system
professionals.
FANUC therefore, recommends that each customer consult with such professionals in order to provide a
safe application.
Additionally, robot system owner, 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 robot to be aware of the
recommended operating procedures. Because FANUC prepare for the professional training course of the
robot, please use it.
It is recognized that the operational characteristics of robots can be significantly different from those of
other machines and equipment.
Robots are capable of high energy movements through a large volume beyond the base of robots.
Although, robot is substitution for work at dangerous zone or harmful zone, but it may cause work-related
accident by mistake. So perfect safety precautions for usage is required when installing it.
In order to prevent work-related accident by robot, as indicators of the steps that an employer should take
each safe standard (JIS, ISO, IEC) are provided, these shows the contents for during installation and
usage.
This chapter provides some hints and guidelines for the robot system safety design.
Before using the FANUC collaborative robot, be sure to read this manual to become familiar with those
contents.
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SAFETY PRECAUTIONS
1
B-84195EN/02
DEFINITION OF WARNING AND CAUTION
To ensure the safety of users 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". Please read each "WARNING", "CAUTION" and "NOTE" before using the
robots.
Symbol
Definitions
WARNING
Used if hazard resulting in the death or serious injury of the user will be expected to
occur if he or she fails to follow the approved procedure.
Used if a hazard resulting in the minor or moderate injury of the user, or equipment
damage may be expected to occur if he or she fails to follow the approved procedure.
Used if a supplementary explanation not related to any of WARNING and CAUTION is
to be indicated.
CAUTION
NOTE
•
2
2.1
Check this manual thoroughly, and keep it handy for the future reference.
FANUC COLLABORATIVE ROBOT
SYSTEM
OVERVIEW
The collaborative robot means the robot that work with workers.
The robot system that is designed with following this manual, can admit the safety work of person near the
moving robot.
Stop
System example：
Robot hands parts to person
If the robot contacts to person,
The robot stops.
This chapter explains cautions for safety usage of collaborative robot. So unless otherwise specified, in this
manual, “robot” means “collaborative robot”.
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SAFETY PRECAUTIONS
B-84195EN/02
2.2
PURPOSE OF ROBOT
FANUC Robot series can be used for the following applications.
Arc welding
Handling
Assembling
Required functionality for these applications is implemented by selecting an appropriate TOOL software.
Please consult your FANUC sales representative if you want to use the robot for any application other than
listed above.
Even when you use the robot for the purpose of any of the applications listed above, the robot must not be
under any of the conditions listed below. Inappropriate usage of robots may cause not only damage to the
robot system, but also serious injury or even death of the user in the premises.
•
•
•
•
•
•
•
•
Flammable atmosphere
Explosive atmosphere
Radioactive environment
In water or any kind of liquid
Use of robot for the purpose of transferring human or animals
Use of robot as a step (climbing upon the robot)
Outdoor
Use of robot under conditions not in accordance with FANUC recommended installation or usage
FANUC is not responsible for any damage caused by misuse of the robots.
Before using the robot, check the specifications of the robot, and then take adequate safety measures to
prevent hazardous conditions.
2.3
CONFIGURATION OF ROBOT SYSTEM
The following elements has been verified their safety.
•
Robot
•
Robot controller
•
Robot teach pendant
•
End effector
•
Other peripheral devices (machine)
•
Workpiece
Users conduct risk assessment of robot system, and the following elements must be prepared by the user
according to system configuration as the need arises.
•
Safeguard
•
Interlocked gate
•
Interlocking device
Except the robot, the robot controller and the robot teach pendant depend on the system, so please them by
users. FANUC Robot has an interface to connect interlocking devices. So confirm the specifications and
design the interlock system.
Security is already confirmed against following components.
•
Robot
•
Robot controller and teach pendant
FANUC can not guarantee safety for end effector, other peripheral equipment and workpiece.
System designer must design the system in consideration of security according to safety standard.
Robot system designer must design the robot system to secure the security according to EN ISO 10218
(ANSI RIA ISO 10218) and Annex I of Machinery Directive.
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SAFETY PRECAUTIONS
2.4
B-84195EN/02
DEFNITION OF THE USER
The user can be classified as follows.
Collaborative worker
•
•
•
Enter collaborative workspace, work with the robot
Change the robot attitude by forcing robot directly, example push to escape function
Restart the program with operator button set for collaborative worker.
Operator:
•
•
Turns robot controller power ON/OFF
Starts robot program from operator’s panel
Programmer:
•
•
Operates the robot and performs the teaching using a teach pendant.
Operates the robot and performs the teaching using the direct teach.
Maintenance engineer:
•
•
•
Operates the robot
Teaches robot inside the safety fence
Maintenance (repair, adjustment, replacement)
Programmer and maintenance engineer must be trained specialized training for the robot.
Collaborative worker that may contact to robot must be informed regularly about the
risks ,emergencies and necessary safety measures.
Table 2.4 (a) shows the workings to the collaborative robot. In this table, the symbol “” means the
working allowed to be carried out by the personnel.
Table 2.4 (a) List of workings to the collaborative robot
Programmer
Collaborative
Operator
or Teaching
worker
operator
Power ON/OFF for Robot controller
Select operating mode (AUTO, T1, T2)
Select Remote/Local mode
Select robot program with teach pendant
Select robot program with external device
Start robot program with operator’s panel
Start robot program with teach pendant
Reset alarm with operator’s panel
Reset alarm with teach pendant
Set data on the teach pendant
Teaching with teach pendant
Teaching with direct teach
Emergency stop with operator’s panel
Emergency stop with teach pendant
Maintenance for operator’s panel
Maintenance for teach pendant
Enter collaborative workspace,
work with the robot
Restart the program with operator button
which is set for collaborative worker

Maintenance
technician



























s-4
















SAFETY PRECAUTIONS
B-84195EN/02
The collaborative worker, programmer and maintenance engineer take care of their safety using the
following safety protectors as the need arises, for example.
•
•
•
•
Adequate clothes, uniform, overall for operation
Safety shoes
Helmet
Protective glasses
In addition, a user in this manual means collaborative worker, programmer, teaching operator and
maintenance engineer
2.4.1
Robot Training
When people access the robot, the collaborative robot may move not stop. All people that may enter the
area where the collaborative robots are placed, must be trained following training
-
The worker must be trained for the characteristic of the collaborative robot. The characteristic of the
collaborative robot is described in the whole this manual. Especially, refer to Section 3.6 in SAFETY
PRECAUTIONS in particular.
-
Collaborative worker, operator work with collaborative robot may contact with the collaborative robot.
The workers must periodically trained for its danger and method to secure safety in emergency.
The programmer, teaching operator and maintenance engineer must be trained for the robot operating and
maintenance.
The required items are:
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
Robot basic knowledge,
Robot safety (laws, ordinances labor security hygiene rule, safety precautions)
Practice of jog feed,
Practice of robot manual operation and teaching
Programming practice, teaching and playback practice,
Practice of automatic operation,
Explanation of configuration and function of robot,
Explanation and practice of setting up frame,
Explanation of interface between robot and peripheral device,
Explanation and practice of initial setting,
Explanation and practice of troubleshooting
Explanation and practice of periodic checks and periodic replacement
Explanation and practice of file input/output
Explanation and practice of mastering, and
Explanation and practice of disassemble and assemble of robots.
Some training courses for these items for the maintenance engineer or system engineer are provided in the
robot school and each technical service center. Contact your local FANUC representative
WARNING
Robot operating personnel such as programmers, teaching operators or
maintenance engineers must be properly trained. Without appropriate training,
any operation inside the safety fence may cause very severe injury or even
death of personnel due to the multiple and various hazards caused by the robot
arm.
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SAFETY PRECAUTIONS
2.4.2
B-84195EN/02
Safety of the working person
Working person safety is the primary safety consideration. As it is very dangerous to enter the operating
area of the robot during its automatic operation, adequate safety precautions must be observed.
The following lists the general safety precautions.
person safety.
Careful consideration must be made to ensure working
(1) We obligate the Working person to take a FANUC training courses.
FANUC provides various training courses.
Contact your local FANUC representative for details.
(2) Even when the robot is stationary during operation, 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) Implement the Risk assessment, if necessary, 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 is received, the controller stops the robot (Please refer to "STOP TYPE OF ROBOT" in SAFETY
PRECAUTIONS for detail of stop type). For connection, refer to below Fig. 2.4.2 (b).
(4) Provide the peripheral devices with appropriate grounding (Class A, Class B, Class C, and Class D).
(5) Recommend to install the peripheral device outside of 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) Implement the Risk assessment, if necessary, install a mat switch or photoelectric switch on the floor
with an interlock to a visual or aural alarm that issues alarm with light, buzzer, or 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 the power
on the robot controller.
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, make sure to turn the power off the robot
controller.
(10) Operators must take the gloves off while manipulating the operator’s panel or teach pendant.
Operation with gloved fingers may 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. (Refer to Controller
maintenance manual.)
(12) The robot must be transported and installed by accurate procedure 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 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.
(16) In preparing the trestle, please secure the maintenance worker safety at high place in reference to Fig.
2.4.2 (c). Design with the Scaffolding and Safety-belt with circumspection.
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SAFETY PRECAUTIONS
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RP1
Pulsecoder
RI/RO,XHBK,XROT
RM1
Motor power/brake
EARTH
Safety fence
Interlocking device and safety plug that are activated if the
gate is opened.
Fig. 2.4.2 (a) Safety fence and safety gate
WARNING
1 When you close a fence, make sure that no one is around the robot in closing
the safety fence.
2 After the door interlock switch is actuated, robot slows down and stops within 2
seconds, and then servo power is cut off. Before cutting off the servo power,
never enter the safeguarded area (inside of safety fence, etc.).
For the R-30iB Mini Plus
Main board
EAS1, 24V-2, EAS2, 0V are on the main board.
EAS1
Refer to the 3. ELECTRICAL CONNCETIONS of II. CONNECTION
in
R-30iB Mini Plus CONTROLLER
MAINTENANCE MANUAL (B-84175EN) for details.
24V-2
EAS2
0V
Fig. 2.4.2 (b) Connection diagram for the signal of the safety fence
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SAFETY PRECAUTIONS
B-84195EN/02
Hook for safety belt
Fence
Steps
Trestle
Footstep
for maintenance
Fig. 2.4.2 (c) Footstep for maintenance
2.4.3
Safety of the Collaborative Worker
A collaborative worker indicates the personnel who work with collaborative robot, and if necessary,
perform the start operation of the program with operator button for collaborative worker. Because they may
contact with the collaborative robot, they must periodically be trained about its danger and securing safety
method at emergency.
2.4.4
Safety of the Operator
An “Operator” indicates a person who turns on and off the power to the robot system, and starts a robot
the program with operator’s panel (in a daily operation.). Prohibit operators from working inside the safety
fence.
(1) If you don’t need to operate the robot, turn the power off the robot controller, or press the
“EMERGENCY STOP” button, and then proceed your work.
(2) Install a safety fence with a safety gate to prevent any worker other than the operator from entering
the work area unexpectedly and the worker from entering a hazardous area.
(3) Install one or more necessary quantity of EMERGENCY STOP button(s) within the operator’s reach
in appropriate location(s) based on the system layout.
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.
Emergency
stop button
外部非常停止ボタン
(Note)
Connect EES1 and 24V-2, EES2 and 0V.
Main board
For the R-30iB Mini Plus
EES1, 24V-2, EES2, 0V are on the main board.
EES1
Refer to the 3. ELECTRICAL CONNCETIONS of II.
CONNECTION in
R-30iB Mini Plus CONTROLLER
MAINTENANCE MANUAL (B-84175EN) for details.
24V-2
EES2
0V
Fig. 2.4.4 (a) Connection diagram for external emergency stop button
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SAFETY PRECAUTIONS
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2.4.5
Safety of the Programmer
While teaching the robot, the operator must enter the work area of the robot. Especially the teach pendant
operator must secure own safety.
(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 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 Enabling device
(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 must be done outside of the safety fence as far as possible. If programming needs to be
done in the area of the safety fence, the programmer must take the following precautions:
Before entering the safety fence area, ensure that there is no risk of hazardous situation in the
area.
Be ready to press the emergency stop button whenever it is necessary.
Operate the Robot at low speed.
Before starting programming, check the entire system status to ensure that no remote instruction
to the peripheral equipment or motion would harm working person .
(6) Operator must work under the condition of Contact Stop function activates.
(7) Required to deactivate the Contact Stop temporally, take measure to disseminate Contact Stop function
deactivates.
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.
Our teach pendant is provided with an enabling device (DEADMAN switch) as well as an emergency stop button.
These button and switch function as follows:
(1) Emergency stop button: Causes the stop of the robot (Please refer to "STOP TYPE OF ROBOT" in SAFETY
PRECAUTIONS for detail of stop type) when pressed.
(2) Enabling device (DEADMAN switch) : Functions differently depending on the teach pendant enable/disable
switch setting status.
(a) Enable: Servo power is turned off when the operator releases the enabling device (DEADMAN switch)
or when the operator presses the switch strongly.
(b) Disable: The enabling device (DEADMAN switch) is disabled.
Note) The DEADMAN switch is provided to stop the robot when the operator releases the teach pendant or
presses the pendant strongly in case of emergency. The R-30iB employs a 3-position enabling device
(DEADMAN switch), which allows the robot to operate when the 3-position enabling device (DEADMAN
switch) is pressed to its intermediate point. When the operator releases the enabling device
(DEADMAN switch) or presses the switch strongly, the robot stops immediately.
The programmer 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 enabling device (DEADMAN
switch). The programmer 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 enabling device (DEADMAN switch) should not
exceed about 10000 times per year.
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SAFETY PRECAUTIONS
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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.
In case of operating the robot as a collaborative robot without safety fence, there may be a possibility that robot will
not stop even personnel approach. In that case, the robot will suspend when personnel contact.
Mode
AUTO
mode
T1, T2
mode
Teach pendant
enable switch
On
Off
On
Off
Software remote
condition
Teach pendant
Operator panel
Peripheral
device
Local
Remote
Local
Remote
Local
Remote
Local
Remote
Not allowed
Not allowed
Not allowed
Not allowed
Allowed to start
Allowed to start
Not allowed
Not allowed
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: Enabling device (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 the test operation according to the following
procedure.
(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 must leave
the robot work area.
2.4.6
Safety of the Maintenance Engineer
For the safety of maintenance engineer personnel, pay utmost attention to the following.
(1) Must never be in the area during its operation.
(2) A hazardous situation may occur 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 must 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 poweron state, the emergency stop button must be pressed.
(3) If it becomes necessary to enter the robot operation area while the power is on, press the emergency
stop button on the operator panel, or the teach pendant before entering the area. 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 that there is no dangerous situation around. 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.
(6) Before teaching, check the robot and its peripheral devices are all in the normal condition.
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SAFETY PRECAUTIONS
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(7) Do not operate the robot in the automatic mode while anybody is in the robot work area.
(8) Make certain that their escape path is not obstructed inside the safety fence, or the robot operation
area. Provided, however, that the robot secure the operation as a collaborative robot.
(9) When a tool is mounted on the robot, or any moving device other than the robot is installed, such as
belt conveyor, careful attention required for those motion.
(10) Assign an expert near the operator panel who can press the EMERGENCY STOP button whenever he
sees the potential danger.
(11) In case of replacing a part, please contact your local FANUC representative. Wrong procedure may
cause the serious damage to the robot and the worker.
(12) Make sure that no impurity into the system in while (in) replacing or reinstalling components.
(13) Turn off the circuit breaker to protect again electric shock in handling each unit or printed circuit board
in the controller during inspection. 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) In case of remove the motor or brake, suspend the arm by crane or other equipment beforehand to
avoid falling.
(17) Whenever grease is spilled on the floor, remove them as soon as possible to prevent from falling.
(18) The following parts are heated. If a maintenance worker needs to touch such a part in the heated state,
the worker should wear heat-resistant gloves or use other protective tools.
•
Servo motor
•
Inside of the controller
•
Reducer
•
Gearbox
•
Wrist unit
(19) Maintenance must be done with appropriate lightning. Be careful that those lightning will not cause
any further 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) Must never climb or step on the robot even in the maintenance. If it is attempted, the robot would be
adversely affected. In addition, a misstep can cause injury to the worker.
(22) Secure footstep and wear the safety belt in performing the maintenance work in high place.
(23) Remove all the spilled oil or water and metal chips around the robot in the safety fence after
completing the maintenance.
(24) All the related bolts and components must return to the original place in replacing the parts. If some
parts are missing or left (remained), repeat the replacement work until complete the installation.
(25) In case robot motion is required during maintenance, the following precautions should be taken :
•
Secure 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.
•
Keep vigilant attention for the potential danger. and to press the emergency stop button whenever
it is necessary.
(26) Periodic inspection required. (Refer to the robot mechanical manual and controller maintenance
manual.) A failure to do the periodical inspection can may adversely affect the performance or service
life of the robot and may cause an accident
(27) After replacing some parts, a test run required by the predetermined method. (See TESTING section
of “Controller operator’s manual”. During the test run, the maintenance staff must work outside the
safety fence as the need arises.
(28) Make certain that their escape path is not obstructed inside the safety fence, or the robot operation
area. Provided, however, that the robot secure the operation as a collaborative robot.
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2.5
B-84195EN/02
RELEVANT STANDARDS
FANUC robot series meets following standards.
[For CE marking : Machinery/Low voltage Directives]
EN ISO 10218-1
EN 60204-1
EN/ISO 13849-1
[For NRTL]
UL 1740
CAN/CSA Z434
CSA C22.2 No.73
NOTE
For ISO 13849-1 the following safety categories have been applied.
Controller model
R-30iB Mini Plus
Controller model
R-30iB Mini Plus
Emergency
stop
[7DF5 or later]
Cat.4
PL e
SIL 3
Dual Check Safety (optional functions)
Position/
Safe I/O
Safety
Speed check
connect
Network
[7DF5 or later]
Cat.3
PL d
SIL 2
Cat.3
PL d
EN ISO
13849-1:2015
[7DF5 or later]
Cat.4
PL e
SIL 3
Collaborative robot function
(Collaborative robot safety function)
Applied
standard
Applied
standard
EN ISO 13849-1:2015
[CE marking : For EMC Directive]
EN 55011 (Group 1, Class A)
EN 61000-6-2
For the above standards, FANUC robot systems have been certified by the following third parties.
CE marking : TÜV Rheinland Japan, TÜV SÜD Japan
NRTL :
TÜV SÜD America
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3
ROBOT SYSTEM DESIGN
In this chapter, requirements for robot system design are described.
Placement of Equipment
Power Supply and Protective Earth Connection
Other Precautions
In addition, the basic requirements for end effector, workpiece, and peripheral equipment are outlined in
3.5 in SAFETY PRECAUTIONS. The characteristic of collaborative robot are outlined in 3.6 in SAFETY
PRECAUTIONS.
About the safety fence, safety gate and other protection devices, refer to Section 4.5 to 4.7 in SAFETY
PRECAUTIONS.
Collaborative robot applications are different from traditional robot systems because of the capability of
the robot to operate in close proximity to a person in the robot’s operating space without an enabling device.
Guidance in ISO 10218-2 (ANSI/RIA R15.06-2012) should be followed in the construction of the robot
system using collaborative robots.
In ISO10218-2, carrying out risk assessment (a dangerous evaluation) for the whole robot system is
demanded. Depending on a result of the risk assessment (a dangerous evaluation), please carry out
appropriate safe protection plan to reduce the risk that a person injures.
3.1
GENERAL
The robot system must be designed, constructed, and implemented so that in case of a foreseeable failure
of any single component, whether electrical, electronic, mechanical, pneumatic, or hydraulic, safety
functions are not affected or when they are, the robot system is left in a safe condition (“Failure to safety”).
Under the intended conditions of use, the discomfort, fatigue and psychological stress faced by the operator
must be reduced to the minimum possible, taking into account ergonomic principles such as:
allowing for the variability of the collaborative worker and operator’s physical dimensions, strength
and stamina,
providing enough space for movements of the parts of the collaborative worker and operator’s body,
avoiding a machine-determined work rate,
avoiding monitoring that requires lengthy concentration,
adapting the man/machinery interface to the foreseeable characteristics of the collaborative worker
and operators.
The application of the electrical equipment of the robot system must be accordance with IEC/ EN60204-1
or NFPA70/NFPA79.
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3.2
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PLACEMENT OF EQUIPMENT
Please make sure the following requirements are all satisfied for each component of a robot system.
•
Be sure to perform the risk assessment and be sure to design the appropriate safeguarding measures.
•
An appropriate safety fence/guard must be placed according to the safety standards. Please refer to
section 3.5 and 3.6 in SAFETY PRECAUTIONS for the basic requirement of the safety fence/guard
and protection devices.
•
As the need arises, the additional space are required beyond the restricted space to define the
safeguarded space.
•
The operator panel must be located at a safe place:
outside the safety fence, and cannot be reached from inside the safety fence, if the robot system
has safety fence.
where it can be easily seen, and easily operated by the operator,
where the operator can operate it without hesitation or loss of time and without ambiguity,
where collaborative worker or operator can confirm the emergency stop button easily and can
operate it easily, and
where no dangerous situation is created by operating it.
•
If the robot controller is placed inside or near the robot operating space, the distance between the
maintenance space of robot controller and robot operating space should be sufficient( over 1.22m from
the opening section of robot controller, or opening section of robot controller is placed to opposite
direction of robot operating space.
•
The operating position must be designed and constructed in such a way as to avoid any risk due to
exhaust gases and/or lack of oxygen.
•
If the robot system is intended to be used in a hazardous environment presenting risks to the health
and safety of the collaborative worked and operator or if the robot system itself gives rise to a
hazardous environment, adequate means must be provided to ensure that the operator has good
working conditions and is protected against any foreseeable hazards.
•
Where appropriate, the operating position must be fitted with an adequate cabin designed, constructed
and/or equipped to fulfill the above requirements. The exit must allow rapid evacuation. Moreover,
when applicable, an emergency exit must be provided in a direction which is different from the usual
exit.
•
A large space must be secured around each component enough for the maintenance and inspection of
the robot system.
•
The robot system must be designed and constructed in such a way as to allow access in safety to all
areas where intervention is necessary during operation, adjustment and maintenance.
•
The space inside or near the robot operating space for maintenance and inspection, must be designed
to protect the user from falling off or slipping off the step, and where appropriate, handholds that are
fixed relative to the operator and that enable them to maintain their stability should be prepared.
•
The robot system must be secured on a stable floor. Especially the robot mechanical unit must be
attached to the stable place according to the instructions in the maintenance manual or operator’s
manual.
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•
The robot system must be designed to avoid trapping and collision between the moving parts of the
robot and other fixed or moving objects.
•
The layouts must be designed in such a way that between moving parts of the robot and objects in the
environment (e.g. pillars of the structure, ceiling joists, fences, supply leads) sufficient clearance is
available.
•
When T2 mode is used, the following clearance is required for robot system installation.
0.5m or more from readily accessible areas of buildings, structures, utilities, other machines and
equipment not specifically supporting the robot function that may create trapping or a pinch point
Where this minimum clearance is not provided, additional safeguarding devices is required.
Stop robot motion while personnel are within 0.5m of the trapping or pinch hazard
If these actions are not applied, it may cause injury of the users.
•
When a limitation of the restricted space, by limiting the range of motion of the primary axes (J1, J2,
J3-axes), is required by the plan, limiting devices must be provided. They should not injury to a person
and must comply with one of the following.
Mechanical stopper which are capable of stopping the robot at any adjusted position when it is
carrying its rated load at maximum velocity.
Alternative methods of limiting the range of motion may be provided only if they are designed,
constructed, and installed to achieve the same level of safety as the mechanical stoppers.
This may include using the robot controller and limit switches according to IEC/EN 60204-1 or
NFPA70/NFPA79.
Note that the limiting devices must be correctly adjusted and secured.
•
When it is intended that collaborative worker or operators will perform manual operations associated
with the robot, such as loading and unloading of parts, this must be taken into account in the
arrangement of the robot system, either by providing part loading devices so that the operator cannot
access the hazardous area, or by providing appropriate safeguards for the manual activity.
•
Where appropriate and where the working conditions so permit, work stations constituting an integral
part of the robot system must be designed for the installation of seats.
•
The operator’s seat must enable him or her to maintain a stable position. Furthermore, the seat and its
distance from the operator's panel must be capable of being adapted to the operator.
•
If the robot system is subject to vibrations, the seat must be designed and constructed in such a way
as to reduce the vibrations transmitted to the operator to the lowest level that is reasonably possible.
The seat mountings must withstand all stresses to which they can be subjected, where there is no floor
beneath the feet of the operator, footrests covered with a slip-resistant material must be provided.
•
On transportation of robot mechanical unit or controller, proper transportation procedure described on
operator’s or maintenance manual for each models has to be followed.
WARNING
Follow the procedure specified by FANUC when transporting the robot
mechanical unit or controller. Otherwise, it may fall over due to the loss of the
mechanical stability (balance), resulting in serious injury or death of personnel.
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3.3
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POWER SUPPLY AND PROTECTIVE EARTH
CONNECTION
•
The power supply and the grounding must be connected according to the maintenance manual.
•
Unsafe conditions must be avoided in the event of a power down, power recovery after a power down
or supply voltage fluctuations. Unsafe conditions to be avoided are;
Dropping workpiece or any material,
Safety equipment not functioning, etc.
WARNING
Dropping workpiece or any material may result in personal injury.
•
The robot system must have means to isolate its power sources. These means must be located in such
a way that no person will be exposed to any hazard, as well as must have a lockout/tagout capability.
WARNING
The robot mechanical unit and controller have to be properly connected by PE
(Protective Earth). Without PE connection, electric shock can occur.
3.4
OTHER PRECAUTIONS
•
Shutdown (removal of power) to the robot system or any peripheral equipment must not result in a
hazardous condition.
•
All environmental conditions must be evaluated to ensure compatibility of the robot and the robot
system with the anticipated operational conditions. These conditions include, by are not limited to,
explosive mixtures, corrosive conditions, humidity, dust, temperature, electromagnetic interference
(EMI), radio frequency interference (RFI), and vibration.
•
The control position where the operator stands must be predetermined.
The control position must satisfy the following conditions.
The operator can easily operate the operator panel or the teach pendant.
The operator can easily make sure that nobody is inside or near the robot operating space or
inside the safety fence (if safety fence is placed).
The operator can easily verify the operation of the system.
The operator can immediately stop the entire or partial system in the event a malfunction of the
system or any dangerous condition.
•
The following safety measure must be used if the operator cannot easily verify nobody is inside the
safety fence, or as required by the risk-assessment result.
A visible/audible warning (complying EN/ISO/IEC standards or OSHA) is used before robot
starts moving.
A measure for the collaborative worker inside or near the robot operating space to stop the robot
system or a measure for the person to evacuate outside the robot operating space.
The control system is designed and constructed in such a way that starting is prevented while
someone is in the danger zone.
•
If necessary, means must be provided to ensure that the robot system can be controlled only from
control positions located in one or more predetermined zones or locations.
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•
Where there is a more than one control position, the control system must be designed in such a way
that the use of one of them precludes the use of the others, except for stop controls and emergency
stops.
•
When the robot system has two or more operating positions, each position must be provided with all
the required control devices without the operators hindering or putting each other into a hazardous
situation.
•
The manual intervention and reset procedure to restart the robot system after an emergency stop must
take place outside the restricted space.
•
A warning device must be such that the operator and people in dangerous area can easily recognize it.
•
For UL standard compliance, “a yellow or amber visual indicator” specified by CL 36.1 of UL 1740
was to be installed by the end-user or system manufacturer. SYSRDY or PROGRUN output signals
are available for installing such a visual indicator.
•
The area must be appropriately lighted, especially for maintenance and inspection.
The lighting must not create a new dangerous situation (e.g. dazzled).
CAUTION
Operation inside of the safety fence (teaching, maintenance, etc.) without
suitable ambient lighting can cause hazards of collision (with some obstacles
inside of the safety fence) or slipping/falling down of personnel.
•
It is recommended that adjustment, greasing or oiling, and other maintenance work can be performed
from outside the dangerous area while the system is stopping.
If it is not feasible, a method to perform these operations safely must be established.
•
If the robot and the peripheral equipment synchronously move in the robot system, an appropriate
measure must be provided to avoid unsafe condition by stopping the entire system in the event any of
the equipment stops due to malfunction.
•
Any robot that can be controlled from a remote location must be provided with an effective means that
must prevent hazardous conditions of the robot being initiated from any other location.
•
It is recognized that for certain phases of the robot system life (e.g. commissioning, process
changeover, cleaning, and maintenance) it may not be possible to design completely adequate
safeguards to protect against every hazard or that contain safeguards may be suspended.
Under these conditions, appropriate safe working procedures must be used.
•
A robot system manufacturer must provide an operation manual according to EN ISO 10218 etc.
•
Requirements of each safety standard (EN ISO, IEC, JIS etc.) and labor security hygiene rule must be
considered when a robot application system is designed.
•
Keep the component cells of the robot system clean, operate the robot where insulated from the
influence of grease, water, and dust.
•
Don’t use unconfirmed liquid for cutting fluid and cleaning fluid.
•
Adopt limit switches or mechanical stoppers to limit the robot motion, and avoid the robot from
collisions against peripheral devices or tools.
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•
Observe the following precautions about the mechanical unit cables. Failure to follow precautions may
cause mechanical troubles.
Use mechanical unit cable that have required user interface.
Do not 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.
•
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 and power-off of the robot
is executed.
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 operates routinely and power-off stop
is executed for the robot.
Power-off stop is regularly incurred due to an inappropriate setting for Dual Check Safety
(DCS).
•
Power-off stop of Robot is executed 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.
•
Operating the robot in the jog mode, set it at an appropriate speed so that the operator can manage the
robot in any eventuality.
•
Before pressing the jog key, be sure to comprehend the robot movement by the key in advance.
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3.5
END EFFECTOR, WORKPIECE AND PERIPHERAL
EQUIPMENT
It is the responsibility of the robot system manufacturer to perform the risk assessment of the end effector,
workpiece and peripheral equipment.
This section outlines the basic requirement for the risk assessment of these components.
End Effector
•
End effectors must be designed and constructed, or safeguarded, so that
power failure does not cause release of the load (workpiece) or result in a hazardous condition.
The static and dynamic forces created by the load (workpiece) and the end effector together are
within the load capacity and dynamic response of the robot.
Shape or motion of the end effector does not harm the personnel.
•
We recommend to protect the hard part with sponges, and relax the force when the personnel contact
it.
•
If it is equipped with a tool that can function with several different conditions (speed, etc.), the
selection of the condition must be safely and securely done.
Workpiece
•
The material and its shape must not be dangerous and if unsafe, safety measures must be provided.
•
If the workpiece is in extreme high or low temperature, safety measures must be provided to avoid
personnel from touching or getting too close to it.
WARNING
Dropping workpiece or any material may result in personal injury.
Peripheral Equipment (including end effector)
•
The material and shape must not be dangerous.
•
If any component could break down during operation, it must be placed so that it will not scatter if it
breaks down.
•
Pipes (for liquid/gas) must have enough strength for its internal / external pressure.
•
Pipes must be secured and protected from the external pressure or tension.
•
Be sure to provide measures to avoid a dangerous situation if a pipe is broken causing sudden
movement of the pipe or the high speed flow of material.
•
If a pneumatic device is used, be sure to install an air valve which shuts off the air supply to the robot.
•
If a power source other than the electricity (e.g. pneumatic, water, heat) is used in the system, be sure
to perform appropriate risk-assessment, and be sure to provide appropriate safety measures.
•
Be sure to provide safety measures to avoid swapping of components that cause unsafe conditions, by
design to avoid mount mistakes,
indication of necessary information on the parts.
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•
Be sure to provide safety measures to avoid inferior contacts, by
design,
displaying the information on the connectors, pipes and cables.
•
Be sure to provide safety measures to avoid an unsafe condition by touching an extremely high/low
temperature parts (if any).
•
Be sure to provide safety measures to avoid fire or explosion through sufficient amount of
investigation.
•
Vibration and sound noise must be kept to a minimum.
•
For place where personnel may contact, get rid of sharp points and rough surfaces, because those may
harm personnel by contact.
•
If a laser equipment is used, the following must be considered.
avoid unexpected emission of laser light
direct/indirect emission of light must give no harm to the health
laser light must give no harm to health during maintenance / adjustment.
3.6
THE CHARACTERISTIC OF COLLABORATIVE ROBOT
AND LIMITATIONS AND USAGE NOTES
This section describes that the characteristic of collaborative robot and limitations and usage notes.
Refer to Collaborative Robot Function OPERATOR’S MANUAL (B-83744EN) about the detail of each
function.
CONTACT STOP FUNCTION
•
When the external force exceeds the external force limit, the robot stops. Example, when a person
contacts to robot and big external force add to robot, the robot stops. This function does not guarantee
safety in the all situation. The notice must be followed and additional appropriate safeguarding
measures must be placed as the need arises.
* External force：Force to act on the robot at the time of contact by the robot motion.
•
The external force is calculated by the torque acting on each axis. Therefore, when the robot contacts
at the point near the each axis, the robot may not stop even if the external force is more than the
external force limit. On the other hand, when the robot contacts at the point far from the each axis, the
robot may stop even if the external force is smaller than the external force limit.
•
A default value of external force limit is 150N. The sensitivity of contact stop can be increased by
decreasing the external force limit. But in case of increasing sensitivity, the robot may stop by
misdetecting the contact depending on the motion of the robot. The external force limit can’t increase
more than 150N.
•
There is a function which resume the program automatically after contact stop. If this function is
effective, Even if the robot stops, program is restarted automatically when required condition is met.
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WARNING
Motion groups other than Collaborative robot are outside of the scope of the
contact stop function. If a person comes into contact with the motion group other
than Collaborative robot, a serious personal injury could result. If the robot
system is designed to include the motion group other than Collaborative robot,
adequate risk assessment for the whole robot system is necessary to verify that
the motion group other than Collaborative robot are outside of the scope of the
contact stop function.
ACCEPTABLE MOTION SPEED FOR BODY REGIONS
•
Be sure to set motion speed in order to prevent injury caused by the force of contact to a sensitive area
as determined by the risk assessment. Please note that a default value of collaborative motion speed is
250mm/s, and the maximum setting value is 1000mm/s. For reference, acceptable motion speed for
body regions are shown below.
Acceptable motion speed for body regions
Body region
Acceptable motion speed (mm/s)
Face, Neck
Arm, Hand, Fingers
Thigh, knee
Lower legs
Body region excluding the above region
Not applicable
1000
250
Not applicable
300
RESTART AFTER CONTACT STOP
•
Restart by the switch installed near the robot is possible. In that case, be sure to install the emergency
stop button near the restart switch.
PUSH TO ESCAPE
•
When a person pushes the robot, the robot escapes. Only J1 axis, J2 axis and J3 axis can respectively
escape by pushing. The robot stops after certain distance escape. In this case, release your hand for a
moment and push again. When the robot escapes, the attitude of TCP changes.
RETREAT AFTER CONTACT STOP
•
When the robot was stopped by the contact stop and if strong force to robot remains, the robot will
retreat slightly.
NOTE TO DESIGN THE COLLABORATIVE WORKSPACE
When the designer of a robot application system design the workspace where person work near robot, the
designer must follow the following notes.
WARNING
When person is pinched between the robot and the other object (wall, floor, etc.),
and the robot arm, it may result in personal injury.
•
The space where a person escapes at contacting to robot must be placed between collaborative
workspace and wall, floor, etc. If the space can’t be placed, the robot system must be designed to use
additional appropriate safeguarding measures. Example, when a person access to dangerous space, the
robot stops.
•
The following countermeasure is effective as a measure to reduce the generation force when pinching
between the robot and the other object.
Reduce the robot's motion speed near the place where pinching is occurred.
Cover the object or the table with a soft material because the lower the rigidity of the contact
point, the smaller the generated force.
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•
The collaborative workspace shall be marked appropriately. (floor marking, signs, etc.)
Access or admittance restrictions shall be marked be placement of appropriate signs, such as “Active
Robotic Collaborative workspace; authorized persons only”, “Caution, robot can move at any time”.
•
Untrained (according to Subsection 2.4.1) people must not enter collaborative workspace.
•
The ambient working space in which people may collide with the collaborative robot shall be arranged
so they can move safely.
WARNING
Inappropriate collaborative workspace may result in personal injury.
WORKING NOTE INSIDE THE COLLABORATIVE WORKSPACE
•
Please don't put any objects on the robot. Foreign objects may cause an improper detection of the
external contact seen by the robot.
•
When people enter the collaborative workspace, please take care of their safety using the personal
protective equipment (helmet, safety shoes, protective glasses etc.), as the need arises.
INDICATION OF COLLABORATION MODE
•
The visual indication, for example lamp, indicating that the robot is in collaborative operation is
necessary. The LED installed on the robot is set for this purpose. The LED color differs depending on
the robot status according to the following table.
LED color
Robot status
Green
Flash green
Yellow
Red
Collaborative mode
Direct teaching
High speed mode
Alarm occurrence
Fig. 3.6 (b) LED on the robot
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PROTECT OF HEAD, NECK
WARNING
An impact force to the head or neck from contact with the robot may cause death
or heavy injury of the users.
•
The robot system must be designed not to contact robot to head or neck of person with frequency.
WARNING
If a part of body is pinched, it might cause heavy injury.
•
When wrist unit or J3 arm approaches J1 base or J2 base, a part of your body may be pinched.
EXTERNAL FORCE AGAINST THE ROBOT
•
If force generated from the end effector, force of pushing direction or pulling direction generated from
the cables and hoses connected to the end effector exceeds the restriction value of the external force
Design a system during considering to avoid force mentioned above is applied to the robot.
For information of the external force and load monitoring method, refer to Subsection 4.2.2 “Payload
Monitor” of the OPERATOR’S MANUAL (Collaborative Robot Function) (B-83744EN).
HIGH SPEED MODE
•
By default, the collaborative robots can also be used as a no-collaborative robot (in a nocollaborativemode) in a high speed mode. The maximum speed of each model for both collaborative
and no-collaborative mode is shown in the table. If the robots are operated in the high speed mode,
risk assessment for traditional robot (no-collaborative) is required and additional appropriate
safeguarding measures is required as the need arises. The basic safeguarding measures is safeguarding
fence, but other safeguarding measures that is result of risk assessment may be admitted.
Model
Maximum speed in
collaborative mode (mm/s)
Maximum speed in
high speed mode (mm/s)
1000
1000
2000
1000
CRX-10iA, CRX-10iA/L
CRX-20iA/L
•
Contact stop function is not available with this mode.
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4
SAFETY DEVICES
4.1
STOP TYPE OF ROBOT
There are following three types of Stop Category.
Stop Category 0 following IEC 60204-1 (Power-off Stop)
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.
“Stop Category 0” performs following processing.
•
An alarm is generated, and then the servo power turns off. Instantly the robot stops.
•
Execution of the program is paused.
Frequent Category 0 Stop of the robot during operation can cause mechanical problems of the robot.
Avoid system designs that require routine or frequent Category 0 Stop conditions.
Stop Category 1 following IEC 60204-1 (Controlled Stop, Smooth Stop)
The robot is decelerated until it stops, and servo power is turned off.
“Stop Category 1” performs following processing.
•
The alarm "SRVO-199 Controlled stop" or "SRVO-289 Smooth Stop" occurs along with a
decelerated stop. The program execution is paused.
•
An alarm is generated, and then the servo power turns off.
In Smooth stop, the robot decelerates until it stops with the deceleration time shorter than Controlled stop.
The stop type of Stop Category 1 is different according to the robot model or option configuration. Please
refer to the operator's manual of a particular robot model.
Stop Category 2 following IEC 60204-1 (Hold)
The robot is decelerated until it stops, and servo power remains on.
“Stop Category 2” performs following processing.
•
The robot operation is decelerated until it stops. Execution of the program is paused.
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WARNING
1 The stopping distance and time of Stop Category 1 are longer than those of Stop
Category 0. A risk assessment for the whole robot system which takes into
consideration the increased stopping distance and stopping time is necessary
when Stop Category 1 is used. Please refer to the operator's manual of a
particular robot model for the data of stopping distance and time.
2 In multi arm system, the longest stopping distance and time of Stop Category 1
among each robot are adopted as those for the system. A risk assessment for
the whole robot system which takes into consideration a possibility that the
stopping distance and time increase, is necessary on the multi arm system.
3 In the system which has extended axis, the longer stopping distance and time of
Stop Category 1 among robot and extended axis are adopted as those for the
system. A risk assessment for the whole robot system which takes into
consideration a possibility that the stopping distance and time increase, is
necessary on the system which has extended axis. Please refer to the extended
axis setup procedure of the controller operator’s manual for considering the
stopping distance and time of the extended axis.
4 When Stop Category 1 occurs during deceleration by Stop Category 2, the stop
type of robot is changed to Stop Category 0.
5 In case of Stop Category 1, motor power shutdown is delayed for a maximum of
2 seconds. In this case, a risk assessment for the whole robot system is
necessary, including the 2 seconds delay.
When the emergency stop button is pressed or the FENCE is open, the stop type of robot is Stop Category
0 or Stop Category 1. The configuration of stop type for each situation is called stop pattern. The stop
pattern is different according to the option configuration.
In case of CRX-10iA, CRX-10iA/L, CRX-20iA/L, there is the following 1 Stop pattern.
Stop
pattern
Mode
Emergency
stop
button
External
Emergency
stop
FENCE open
SVOFF
input
Enabling device
(Deadman
switch) (*)
D
AUTO
T1
T2
Category 1
Category 1
Category 1
Category 1
Category 1
Category 1
Category 1
-
Category 1
Category 1
Category 1
Category 1
Category 1
Category 0: Stop Category 0
Category 1: Stop Category 1
-:
Disable
(*) The stop pattern of NTED input is same as enabling device (Deadman switch).
The following table indicates the Stop pattern according to the controller type or option configuration.
R-30iB Mini Plus
Option
Standard
D(**)
(**) R-30iB Mini Plus 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.
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EMERGENCY STOP
This robot has following emergency stop devices.
•
•
emergency stop button (They are on the operator panel and teach pendant.)
external emergency stop (input signal)
When emergency stop button is pushed, the robot stops immediately (refer to Section 3.1).
The external emergency stop input signal is input from peripheral devices.
The signal terminal is inside of the robot controller.
4.3
MODE SELECT SWITCH
The MODE SELECT SWITCH is installed on the robot controller. (This is an option for some controllers.)
You can select one of the operation modes using this switch. The selected operation mode can be locked
by removing its key.
When the mode is changed by this switch, the robot system stops and a message is shown in teach pendant
LCD.
AUTO
T1
T2
Fig. 4.3 (a) Example of mode select switch
4.3.1
Operating Modes
There are two or three operating modes.
CAUTION
When high speed mode (contact stop function is disabled) is applied, contact
stop function, push to escape function, retreat function after contact stop are set
to disabled.
AUTO: Automatic Mode
•
•
•
•
•
•
The robot program can be started by the operator panel start button or peripheral device I/O.
If the robot system has safety fence, safety fence is enabled.
The robot can be operated at the specified maximum speed.
The contact stop function is enabled.
The push to escape function is enabled
The retreat function after contact stop is enabled
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T1: Test Mode 1
•
•
•
•
•
•
Program can be activated from the teach pendant only.
The robot cannot be operated at speeds higher than 250mm/s at both of tool center point (tool
coordinate origin) or wrist flange center.
If the robot system has safety fence, safety fence is disabled. (Robot does not stop when fence is
opened.)
The contact stop function is enabled.
The push to escape function is disabled
The retreat function after contact stop is disabled at jogging
T2: Test Mode 2(Optional)
•
•
•
•
•
•
Program can be activated from the teach pendant only.
The robot can be operated at the specified maximum speed.
If the robot system has safety fence, safety fence is disabled. (Robot does not stop when fence is
opened.)
The contact stop function is enabled.
The push to escape function is disabled
The retreat function after contact stop is disabled at jogging
Please refer to the operator’s manual of robot controller for detail.
4.4
ENABLING DEVICE (DEADMAN SWITCH)
The enabling device (deadman switch) is used as an “enabling device”.
When the teach pendant is enabled, robot motion is allowed only while at least one of enabling devices
(deadman switches) is gripped. If you release or hard grip switches, the robot stops immediately.
In case of the tablet TP, if you release or hard push the enabling device (deadman switch), the robot stops
immediately.
Enabling device
デットマンスイッチ
(Deadman
switch)
Fig. 4.4 (a) Enabling device (Deadman switch) (Tablet TP)
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Enabling device
(Deadman switch)
Fig. 4.4 (b) Enabling device (Deadman switch) (iPendant)
Based on the risk assessment by FANUC, number of operation of enabling device (DEADMAN switch)
must not exceed about 10000 times per year.
4.5
SAFEGUARDS
The safeguards consists of:
•
safety fence (fixed guard),
•
safety gate (with interlocking devices),
•
safety plug and socket, and
•
other protection devices.
These safety devices must be complied with EN ISO, IEC and so on In addition, system designers must
install these devices according to the risk assessment.
This section describes the basic requirements for these devices. Please refer to EN ISO 10218 and so on for
detail. Note that these safety devices must be fitted to the robot system by the system house, etc.
WARNING
Suitable safety guards are installed around robot system as the need arises.
Robot operation without safety guards required from the result of risk
assessment can cause serious injury or death of personnel.
4.5.1
Safety Fence
The basic requirements for Safety Fence are as follows.
•
The fence is constructed to withstand foreseeable operational and environmental forces.
•
The fence is free of sharp edges and projection and is not themselves a hazard.
•
The fence prevents access to the safeguarded space except through openings associated with
interlocking devices.
•
The fence is permanently fixed in position and is removable only with the aid of tools.
•
Fixing system of the safety fence must remain attached to the safety fence or to the robot system when
they are removed.
•
Where possible, safety fence must be incapable of remaining in place without their fixings.
•
The fence cause minimum obstruction to the view of the production process. (wire mesh, lattice, panel
etc.)
•
The fence is located at an adequate distance from the maximum space.
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•
•
The fence should be connected to PE (Protective Earth) to prevent the electric shock with accident.
Please refer to the following and their related standards for detail of safety fence aperture size,
minimum size of grids and so on.
-
4.5.2
EN ISO 13855
EN ISO 13857
ANSI B11.19
Safety Gate and Plugs
The basic requirements for Safety Gate are as follows.
•
•
•
The gate prevents the robot system from automatic operation until the gate is closed.
The closure of the gate is not the control to restart automatic operation. This must be a deliberate
action at a control station.
The gate has plug and socket for interlock. The plug and socket must be selected appropriate things
for safety.
This gate must be the one either it remains locked closed until the risk of injury from the hazard has passed
(interlocking guard with guard locking) or opening the guard while the robot system is working gives a stop
or emergency stop instruction (interlocking guard).
Please refer to EN ISO 14119 or ANSI B11.19 for detail of interlocking system.
If a personnel whole body can enter the safeguard space via the interlocking door, installing a device that
the door does not close without intending.
Care should be taken to ensure that actuation of an interlock installed to protect against on hazard (e.g.
stopping hazardous motion of the robot system) does not create a different hazard (e.g. the release of
hazardous substances into the work zone).
4.5.3
Other Protection Devices
Protection devices must be designed and incorporated into the control system so that:
•
they can be adjusted only by means of an intentional action, such as the use of a tool, key, etc.,
•
the absence or failure of one of their components prevents starting or stops the moving parts.
As the need arises, the robot system must be designed so that
•
moving parts cannot start up while they are within the operator’s reach,
•
the exposed person cannot reach moving parts once they have started up.
If some presence sensing devices are used for safety purposes, they must comply with the following.
•
A presence sensing device must be installed and arranged so that persons cannot enter and reach into
a hazardous area without activating the device.
•
A presence sensing device must be installed and arranged so that persons cannot reach the restricted
space before the hazardous conditions have ceased.
•
Barriers used in conjunction with the presence-sensing device may be required to prevent persons
from bypassing the device.
•
Their operation must not be adversely affected by any of the environmental conditions for which the
system was intended.
•
When a presence-sensing device has been activated, it may be possible to restart the robot system from
the stopped position provided that this does not create other hazards.
•
As the need arises, resumption of robot motion must require the removal of the sensing field
interruption. The result of risk assessment may require that this must not be the control to restart
automatic operation.
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SAFETY PRECAUTIONS
4.6
B-84195EN/02
OPERATION INSIDE OF THE SAFETY FENCE
When some workers (programmer, maintenance engineer) have to enter the safety fence, the following care
has to be taken into account.
•
•
•
•
•
•
•
•
•
•
•
•
•
Make sure that the robot system has been completely stopped before entering the safety fence. Never
enter the safety fence during the robot moving. If the robot is moving, stop the robot by hold button
(or input signal), and after "controlled stop" it (servo power off), then you can enter the safety fence.
(In case a safety fence is installed.)
Make sure that an indicator lamp for stop condition (to be suitably installed by the end user) shows
the stopped status of the robot, and enter the safety fence from the safety gate.
To inform you are working in the safety fence, display “working”. During robot teaching or test
operation, robot may move to an unexpected direction. So exercise special care, and perform teaching
in the position where you can escape from the robot in case of dangerous situation.
Set "Safe speed" signal enabled.
When more than one worker collaborates for their operation, a user in charge should be equipped with
teach pendant, and other users have to follow his order.
Any operations from the external interface and robot controller operation panel without his order have
to be prohibited.
All users inside of the safety fence always have to secure the escape zone to avoid hazards from
unintended movement of the robot.
Care should be taken by all workers not to close off the escape routes for each other.
Do not operate the robot resting against the wall, apparatus installed inside of the safety fence, etc.
those take away escape zone from the operator.
Keep watching the robot during operation in jogging, program verification, etc.
Stop the robot immediately by E-stop SW when somebody recognizes dangerous situation.
Whenever possible, other user who is readily accessible to the E-stop SW keeps watch from the outside
of the safety fence.
Make sure that deadman switches on teach pendant are operated only by hand.
Make sure that nobody still exists inside of the safety fence when the safety gate is going to be closed.
Do not leave tools etc. inside of the operating space of robot or peripheral devices, when operation
inside of the safety fence has been finished.
WARNING
1 Safety procedures of entering the safety fence have to be established and
observed. Improper procedure of entering the safety fence can cause serious
injury or death of personnel who enter the safety fence.
2 During teaching or maintenance of robot system with safety fence opened,
special care shall be take not to enter any other personnel who is not work for
these operations. Unauthorized entry to inside of safety fence can cause serious
injury or death of personnel who enter the safety fence.
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4.7
THE SAFETY SEQUENCE FOR FENCE ENTRY
This section describes the safety procedure of entering the safety fence.
Note that only a programmer or a maintenance person can enter the safety fence. A general person
CANNOT enter the safety fence.
Entering into the SAFETY FENCE
0.
The robot is moving automatically (in AUTO mode).
1.
Stop the robot by pressing HOLD buttons or HOLD input signal.
2.
Change the operating mode to T1 or T2 from AUTO.
3.
Remove the operating mode key switch for mode lock to prevent other persons change the operating
mode.
4.
Remove the plug2 from socket 2.
5.
Open the gate of the safety fence, and put the plug2 to socket4.
6.
Remove the plug1 from socket1
7.
Enter inside of the safety fence, and put the plug 1 to socket 3.
Please refer to Fig. 4.7 (a) for details of safety fence and safety plug configurations.
The key of operating mode key switch and the safety plug1 must be carried into the safety fence.
The safety plug1 must be put to the socket3 inside fence.
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Safety Fence
Maximum space
ControllerOperator’s
(operator panel)
box
and and
Mode
switch
key key
Mode
switch
Restriction space
Teach pendant
Safety gate
Safeguard distance
Safety Fence
Safety gate
Safety Fence
Plug 1
Safety gate
Socket 3 (inside of safety fence)
Socket 1
Socket 2
Socket 4
Plug 2
Socket 1
Socket 2
«Inside of safety fence»
Safety fence
Socket 3
Safety gate
(CLOSED)
Plug 1
Plug 2
FENCE1
FENCE2
Socket 3
Safety fence
Socket 4
«Outside of safety fence»
EMGIN1 EMGIN2
Socket 1
Plug 1
FENCE1
Socket 4
Saf
(OP ety ga
E N te
ED
)
Socket 1
Socket 2
FENCE2
Plug 2
EMGIN1 EMGIN2
Socket 1
Socket 3
Plug 1
Socket 3
Plug 1
Socket 4
Socket 4
Plug 2
Plug 2
Socket 2
Socket 2
When the safety gate is CLOSED
When the safety gate is OPENED
Fig. 4.7 (a) SAFETY FENCE and SAFETY GATE example
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5
GENERAL CAUTIONS
In this chapter, the requirements for safety during the following situations are described:
•
Installation (5.1)
•
Commissioning and functional testing (5.2)
•
Programming (5.3)
•
Program verification (5.4)
•
Troubleshooting (5.5)
•
Saving programmed data (5.6)
•
Automatic operation (5.7)
•
Maintenance (5.8)
•
Dismantling / scrapping (5.9)
•
Procedure to move arm without drive power in emergency or abnormal situations (5.10)
•
Warning & Caution label (5.11)
The user must ensure that the safeguarding methods are provided, utilized, and maintained for each
operation associated with the robot system and in particular for personnel other than those utilizing the
teach pendant or enabling device.
The user must ensure that a teach pendant not connected to the robot controller must be inaccessible.
WARNING
1 Safety procedures of entering the safety fence have to be established and
observed. Improper procedure of entering the safety fence can cause serious
injury or death of personnel who enter the safety fence.
2 During teaching or maintenance of robot system, special care shall be take not
to access any other personnel who is not work for these operations.
Unauthorized entry to inside of safety fence can cause serious injury or death of
personnel who enter the safety fence.
3 The servo motors, the regenerative resistor units and the isolated transformers
on the AC power supply may be hot even after robot operation. Touching the
surface of these components should be therefore avoided as much as possible.
When touching any of these components is nonetheless required (ex.: for
maintenance purposes), special care must be applied in order to avoid burn
injury.
5.1
INSTALLATION
Be sure to install the robot system in accordance with FANUC’s requirements. The safeguarding methods
must be identified by the hazard analysis and the risk assessment. The user must review the safety
requirements to ensure that the appropriate safeguards are applied and operational prior to use in production.
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SAFETY PRECAUTIONS
5.2
B-84195EN/02
COMMISSIONING AND FUNCTIONAL TESTING
During the testing of robots or robot systems after installation or relocation, be sure to follow the following
procedures. These procedures are also applied to robots or robot systems after modifications (e.g. changes
in hardware or software, replacement of parts, adjustments) and after maintenance or repairs that can
adversely affect their operation.
5.2.1
Designation of the Restricted Space and Restriction of User
During the commissioning and functional testing, if the contact stop function is enabled, it is admitted that
people they are trained about collaborative robot access the robot
During the commissioning and functional testing, if the contact stop function is disabled or untrained people
may access the robot, and the safeguarding methods are not in place, interim means of designating the
restricted space must be in place before proceeding. And users must not be allowed in the safeguarded space
until the safeguards are functional.
5.2.2
Safety and Operational Verification
For commissioning and testing of the robot or the robot system, follow the instruction by the manufacturer
(FANUC). At the initial start-up, be sure to include the following procedure (but not limited to).
Before applying power, verify that
•
the robot has been properly mechanically mounted and is stable,
•
the electrical connections are correct and the power (i.e. voltage, frequency, interference levels) is
within specified limits,
•
the other utilities (e.g. water, air, gas) are properly connected and within specified limits,
•
the peripheral equipment is properly connected,
•
the limiting devices that establish the restricted space (when utilized) are installed,
•
the safeguarding means are applied, and
•
the physical environment is as specified (e.g. lighting and noise levels, temperature, humidity,
atmospheric contaminants).
After applying power, verify that
•
the start, stop, and mode selection (including key lock switches) control devices function as intended,
•
each axis moves and is restricted as intended,
•
emergency stop circuits and devices are functional,
•
the safeguards and interlocks function as intended (when installing the controller),
•
Contact stop function correctly,
•
it is possible to shut out the outer power source,
•
Teaching and restarting function correctly,
•
other safeguarding is in place (e.g. barriers, warning devices),
•
in reduced speed, the robot operates properly and has the capability to handle the product or workpiece,
and
•
in automatic (normal) operation, the robot operates properly and has the capability to perform the
intended task at the rated speed and load.
5.2.3
Robot System Restart Procedures
A procedure for the restart of the robot system after hardware, software or task program modification, repair,
or maintenance must include but not necessarily be limited to the following:
•
check any changes or additions to the hardware prior to applying power;
•
functionally test the robot system for proper operation.
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5.3
PROGRAMMING
Whenever possible, programming must be performed with all persons outside the safeguarded space or the
robot operating space and neighborhood. When it is necessary to perform programming with personnel
inside the safeguarded space, the following safety procedures are necessary.
WARNING
No other personnel than programmer or teaching operator enter inside of safety
fence during teaching. Unauthorized entry to inside of safety fence can cause
serious injury or death of personnel who enter the safety fence.
5.3.1
Prior to Programming
The following conditions must be met before making taught program.
•
The programmer must be trained on the type of robot used in the actual robot system and must be
familiar with the recommended programming procedures including all of the safeguarding methods.
•
The programmer must visually check the robot system and safeguarded space to ensure that extraneous
conditions which can cause hazardous do not exist.
•
When using the teach pendant to make taught program, the teach pendant must be tested to ensure
proper operation.
•
Any faults or failures of the robot system must be corrected prior to teaching the robot.
•
Before entering the safeguarded space or robot operating space and neighborhood, the programmer
must ensure that all necessary safeguards are in place and functioning.
•
The programmer must set the operating mode to taught mode prior to entering the safeguarded space
or robot operating space and neighborhood. Take measure to prevent the third person starting auto
operation.
•
The results of risk assessment may admit that people they are not programmer but trained about
collaborative robot access to the robot operating space and neighborhood easily, during programming.
In this case, confirm that the contact stop function is enabled.
5.3.2
During Programming
During programming, only the programmer must be allowed in the safeguarded space and the following
conditions must be met.
•
•
•
•
The robot system must be under the sole control of the programmer within the safeguarded space or
robot operating space or neighborhood.
The controls of the teach pendant must be used as intended.
The robot system must not respond to any remote commands or conditions that would cause hazardous
conditions.
All robot system emergency stop devices must remain functional. If it is impossible, take measures to
secure security of users in safeguard space or robot operating space or neighborhood.
The results of risk assessment may admit that people they are not programmer but trained about
collaborative robot access to the robot operating space and neighborhood easily, during programming. In
this case, confirm that the contact stop function is enabled. If the programmer changes the contact stop
function to disable temporary, indicate to the surrounding people
5.3.3
Returning to Automatic Operation
The programmer must return the suspended safeguards to their original effectiveness prior to initiating
automatic operation of the robot system.
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SAFETY PRECAUTIONS
5.3.4
•
•
•
•
•
•
•
•
5.4
B-84195EN/02
Other Cautions for Programming
Adopt a limit switch or other sensor to detect a dangerous state and, if necessary, design the program
to stop the robot when the sensor signal is received.
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.
For a system in which the robot and its peripheral devices are in synchronous motion, particular care
must be taken in programming in order not to interfere with each other.
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.
Design to arrange avoiding mutual interfere when various robot’s operation space crossover
significantly.
Be sure to specify the predetermined work origin in a motion program so that the robot starts from the
origin and terminates at the origin. Make it possible for the operator to distinguish easily that the robot
motion has terminated at a glance.
Circumspect program with sufficient delay required for the program after executing some control
command in adopting actuators (pneumatic, hydraulic, and electric)
Adopt limit switches for the end effector, and control the robot system by monitoring the state.
PROGRAM VERIFICATION
When visual examination of the robot system response to the task program is necessary as part of the
verification procedure, it should be made with all persons outside the safeguarded space and its
neighborhood. When it is necessary to perform program verification with personnel inside the safeguarded
space or the robot operating space and neighborhood, apply the following contents.
•
Program verification must initially be performed at reduced speed.
Special care is required when override is specified in the program.
•
When it is necessary to examine the movement of the robot at full (operational) speed, apply the
following contents:
Only the programmer can change safety operation mode to normal operation mode by means
which requires careful operation;
Workers in safeguard space or robot operating space and its neighborhood always can use enable
device or other devices with an equivalent safety level if necessary;
safe working procedures are established to minimize the exposure of personnel to hazards within
the safeguarded space or robot operating space and its neighborhood.
5.5
TROUBLESHOOTING
When troubleshooting is performed from within the safeguarded space or the robot operating space and
neighborhood, be sure to follow the following contents.
•
•
•
5.6
personnel responsible for trouble shooting are specifically authorized and trained for these activities;
personnel entering the safeguarded space or robot operating space must operate the robot with the
enable machine;
safe working procedures are established to minimize the exposure of personnel to hazards within the
safeguarded space or robot operating space and its neighborhoood.
SAVING PROGRAMMED DATA
A record of the task programs together with any modifications must be maintained. The programmed date
which is saved in portable media must be stored in a suitably protected environment when not in use.
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5.7
AUTOMATIC OPERATION
Automatic operation must only be permissible when
•
the intended safeguards are in place and functioning,
•
proper safe working procedures are followed.
The results of risk assessment may require to check following items before automatic operation
•
no personnel are present within the safeguarded space,
WARINIG
Please make sure that nobody remained inside of the safety fence before
starting up automatic operation of robot systems. If somebody remained inside
of the safety fence exists, trapped personnel inside of the safety fence might
meet serious situation, which can lead them to serious injury or death.
5.8
MAINTENANCE
The robot and robot system must have an inspection and maintenance program to ensure continued safe
operation of the robot system.
The inspection and maintenance program must take into account the robot and robot system manufacturer’s
recommendations.
Personnel who perform maintenance or repair on robots or a robot system must be trained in the procedures
necessary to perform safely the required tasks.
Personnel who maintain and repair robot systems must be safeguarded from hazards.
Where possible, maintenance must be performed from outside the safeguarded space or robot operating
space or neighborhood by placing the robot arm in a predetermined position.
The results of risk assessment may admit that people they don’t maintain or repair but trained about
collaborative robot access to the robot operating space and neighborhood easily, during maintenance. In
this case, confirm that the contact stop function is enabled.
The following is the safety procedure of entering safeguarded space for maintenance.
WARNING
Make sure the Main breaker must be shut down in the robot maintenance with
the exception of following.
-
Replacing batteries of the Robot
Demand of operating the peripheral equipment in maintenance operation
Safety maintenance disturbance
Maintenance without disconnecting the electric power supply may cause the
serious electric shock.
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SAFETY PRECAUTIONS
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Entering safeguarded space for maintenance
1
Stop the robot system.
2
Shut off the power of the robot system, and lock the main breaker to prevent powering on during
maintenance, by mistake.
If you have to enter the safeguarded space while power is available to the robot system, you must do
the following things prior to entering the safeguarded space:
check the robot system to determine if any conditions exist that are likely to cause malfunctions,
check if the teach pendant works correctly, and
if any damage or malfunction is found, complete the required corrections and perform retest
before personnel enter the safeguarded space.
3
Enter the safeguarded space (see Section 4.7 “The Safety Sequence for Fence Entry”).
4
After the maintenance working, check if the safeguard system is effective. If it has been suspended to
perform the maintenance working, return their original effectiveness.
5.9
DISMANTLING / SCRAPPING
Do not start dismantling the robot before contacting such as FANUC Europe Corporation , FANUC
America Corporation, SHANGHAI-FANUC Robotics CO., LTD. or FANUC Corporation in Japan.
Please contact us when you have to dismantle/scrap FANUC robot systems.
WARNING
When dismantling and/or scrapping robot mechanical units equipped with spring
balancers, the robot arm may move unexpectedly due to the stored elastic
energy of the springs inside the balancer(s), and subsequently lose its balance.
Dismantling and scrapping of such robot system must be done only after
releasing the stored energy and according to the instructions provided by
FANUC. Very severe injury or death of personnel may occur in case any of
these instructions is not followed
CAUTION
Robot batteries used for memory and/or encoder backup must be disposed of
appropriately. Failure to do so may cause short circuit during
dismantling/scrapping, which potentially can cause ignition or explosion.
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5.10
PROCEDURE TO MOVE ARM WITHOUT DRIVE POWER
IN EMERGENCY OR ABNORMAL SITUATIONS
(1) For emergency or abnormal situations (e.g. persons trapped in or pinched by the robot), brake release
unit can be used to move the robot axes without drive power.
Please order following unit and cable.
Name
Brake release unit
Robot connection
cable
Power cable
Specification
A05B-2695-J350
A05B-2695-J360 (5m)
A05B-2695-J361(10m)
A05B-2695-J362 (5m)
A05B-2695-J363 (10m)
A05B-2690-J101 (5 m)
A05B-2690-J102(10m)
A05B-2695-J101 ( 5m)
A05B-2695-J102(10m)
(CRX-5iA, CRX-10iA, CRX-10iA/L, CRX-20iA/L)
(CRX-5iA, CRX-10iA, CRX-10iA/L, CRX-20iA/L)
(CRX-25iA)
(CRX-25iA)
(AC200-240V single phase, right angle, round terminal M5)
(AC200-240V single phase, right angle, round terminal M5)
(AC100-120V single phase, right angle, Power plug)
(AC100-120V single phase, right angle, Power plug)
(2) Prepare and store adequate numbers of brake release units which are ready and readily accessible for
robot system before installation.
(3) Regarding how to use brake release unit, please refer to “Robot controller maintenance manual”.
WARNING
Robot arm would fall down by releasing its brake because of the gravity.
Therefore, it is strongly recommended to take adequate measures such as
hanging Robot arm by a crane before releasing a brake.
CAUTION
Robot systems installed without adequate number of brake release units or
similar means are neither in compliance with EN ISO 10218-1 nor with the
Machinery Directive and therefore cannot bear the CE marking.
5.11
WARNING & CAUTION LABEL
(1) Operation space and payload label
Fig. 5.10 (a) Operating space and payload label
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6
DAILY MAINTENANCE
6.1
MECHANICAL UNIT
To keep the robot system safe, please perform periodic maintenance those are specified in operator’s
manual or maintenance manual.
In addition, please clean each part of the system and visually check them for any damage or cracks.
Daily check items are as follows (but not limited to).
•
•
•
•
•
•
•
•
•
•
•
6.2
Input power voltage
Pneumatic pressure
Damage of connection cables
Looseness of connectors
Lubrication
Emergency stop functions
Effectiveness of deadman switch on teach pendant
Safety gate interlocks (in case the robot system has safety gate interlocks)
Vibration, noise by the robot movement
Functions of peripheral devices
Fixtures of robot and peripheral devices
CONTROL UNIT
Before operating the system each day, clean each part of the system and check the system parts for any
damage or cracks.
Also, check the following:
(a) Before service operation
Check the cable connected to the teach pendant for excessive twisting.
Check the controller and peripheral devices for abnormalities.
Check the safety function.
(b) After service operation
At the end of service operation, return the robot to the proper position, then turned off the controller.
Clean each part, and check for any damage or cracks.
If the ventilation port and the fan motor of the controller are dusty, wipe off the dust.
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PREFACE
B-84195EN/02
PREFACE
This manual explains maintenance procedures for the following mechanical units:
Model name
Mechanical unit specification No.
Maximum load
A05B-1702-B201
A05B-1702-B203
A05B-1702-B202
A05B-1702-B204
A05B-1702-B212
FANUC Robot CRX-10iA
FANUC Robot CRX-10iA/L
FANUC Robot CRX-20iA/L
10kg
10kg
20kg
The label stating the mechanical unit and force sensor specification number is affixed in the following
position. Before reading this manual, verify the specification number of the mechanical unit.
(1)
TYPE
NO.
DATE
(2)
(3)
(4)
WEIGHT
(5)
Kg
Position of label indicating mechanical unit and force sensor specification number
TABLE 1 (a) Mechanical unit
CONTENTS
LETTERS
(1) Model name
(2) TYPE
FANUC Robot
CRX-10iA
A05B-1702-B201
A05B-1702-B203
FANUC Robot
CRX-10iA/L
A05B-1702-B202
A05B-1702-B204
FANUC Robot
CRX-20iA/L
A05B-1702-B212
(3) No.
SERIAL NO. IS
PRINTED
p-1
(4) DATE
PRODUCTION
YEAR AND
MONTH ARE
PRINTED
(5) WEIGHT kg
(Without controller)
40
40
41
PREFACE
B-84195EN/02
RELATED MANUALS
For the FANUC Robot series, the following manuals are available:
R-30iB Mini Plus
controller
Mechanical unit
FANUC Robot
CRX series
OPERATOR’S MANUAL
(Basic Operation)
B-83284EN
OPERATOR’S MANUAL
(Alarm Code List)
B-83284EN-1
OPERATOR’S MANUAL
(Optional Function)
B-83284EN-2
ARC Welding Function
OPERATOR’S MANUAL
B-83284EN-3
Dispense Function
OPERATOR’S MANUAL
B-83284EN-5
Collaborative Robot Function
OPERATOR’S MANUAL
B-83744EN
MAINTENANCE MANUAL
B-84175EN
Intended readers :
Operator, programmer, Teaching operator,
Maintenance technician, System designer
Topics :
Robot functions, Operations, Programming, Setup,
Interfaces, Alarms
Use :
Robot operation, Teaching, System design
Intended readers :
Maintenance technician, System designer
Topics :
Installation, Start-up, Connection, Maintenance
Use :
Installation, Start-up, Connection, Maintenance
Intended readers:
System designer, Maintenance engineer
Topics:
Installation, connection to controller, maintenance
Use:
Installation, start-up, connection, maintenance
OPERATOR’S MANUAL
B-84194EN
This manual uses following terms.
Name
Terms in this manual
Connection cable between robot and controller
Robot mechanical unit
Robot connection cable
Mechanical unit
p-2
TABLE OF CONTENTS
B-84195EN/02
TABLE OF CONTENTS
SAFETY PRECAUTIONS ............................................................................ s-1
1
DEFINITION OF WARNING AND CAUTION ....................................... s-2
2
FANUC COLLABORATIVE ROBOT SYSTEM.................................... s-2
2.1
2.2
2.3
2.4
2.5
3
4
2.4.1
2.4.2
2.4.3
2.4.4
2.4.5
2.4.6
Robot Training ...................................................................................................... s-5
Safety of the working person................................................................................. s-6
Safety of the Collaborative Worker ....................................................................... s-8
Safety of the Operator ........................................................................................... s-8
Safety of the Programmer...................................................................................... s-9
Safety of the Maintenance Engineer.................................................................... s-10
RELEVANT STANDARDS ........................................................................ s-12
ROBOT SYSTEM DESIGN ................................................................ s-13
3.1
3.2
3.3
3.4
3.5
3.6
GENERAL ................................................................................................ s-13
PLACEMENT OF EQUIPMENT................................................................ s-14
POWER SUPPLY AND PROTECTIVE EARTH CONNECTION............... s-16
OTHER PRECAUTIONS .......................................................................... s-16
END EFFECTOR, WORKPIECE AND PERIPHERAL EQUIPMENT........ s-19
THE CHARACTERISTIC OF COLLABORATIVE ROBOT AND
LIMITATIONS AND USAGE NOTES ........................................................ s-20
SAFETY DEVICES ............................................................................. s-24
4.1
4.2
4.3
STOP TYPE OF ROBOT .......................................................................... s-24
EMERGENCY STOP ................................................................................ s-26
MODE SELECT SWITCH ......................................................................... s-26
4.4
4.5
ENABLING DEVICE (DEADMAN SWITCH) ............................................. s-27
SAFEGUARDS ......................................................................................... s-28
4.6
4.7
5
OVERVIEW ................................................................................................ s-2
PURPOSE OF ROBOT .............................................................................. s-3
CONFIGURATION OF ROBOT SYSTEM .................................................. s-3
DEFNITION OF THE USER ....................................................................... s-4
4.3.1
Operating Modes ................................................................................................. s-26
4.5.1
4.5.2
4.5.3
Safety Fence ........................................................................................................ s-28
Safety Gate and Plugs.......................................................................................... s-29
Other Protection Devices..................................................................................... s-29
OPERATION INSIDE OF THE SAFETY FENCE...................................... s-30
THE SAFETY SEQUENCE FOR FENCE ENTRY .................................... s-31
GENERAL CAUTIONS ...................................................................... s-33
5.1
5.2
5.3
INSTALLATION ........................................................................................ s-33
COMMISSIONING AND FUNCTIONAL TESTING ................................... s-34
5.2.1
5.2.2
5.2.3
Designation of the Restricted Space and Restriction of User .............................. s-34
Safety and Operational Verification .................................................................... s-34
Robot System Restart Procedures ....................................................................... s-34
5.3.1
5.3.2
Prior to Programming .......................................................................................... s-35
During Programming ........................................................................................... s-35
PROGRAMMING ...................................................................................... s-35
c-1
TABLE OF CONTENTS
5.4
5.5
5.6
5.7
5.8
5.9
5.10
5.11
6
5.3.3
5.3.4
B-84195EN/02
Returning to Automatic Operation ...................................................................... s-35
Other Cautions for Programming ........................................................................ s-36
PROGRAM VERIFICATION ..................................................................... s-36
TROUBLESHOOTING.............................................................................. s-36
SAVING PROGRAMMED DATA .............................................................. s-36
AUTOMATIC OPERATION ...................................................................... s-37
MAINTENANCE........................................................................................ s-37
DISMANTLING / SCRAPPING ................................................................. s-38
PROCEDURE TO MOVE ARM WITHOUT DRIVE POWER IN
EMERGENCY OR ABNORMAL SITUATIONS ......................................... s-39
WARNING & CAUTION LABEL ................................................................ s-39
DAILY MAINTENANCE ..................................................................... s-40
6.1
6.2
MECHANICAL UNIT ................................................................................. s-40
CONTROL UNIT ....................................................................................... s-40
PREFACE ....................................................................................................p-1
1
CHECKS AND MAINTENANCE ............................................................. 1
1.1
1.2
1.3
2
3
4
PERIODIC MAINTENANCE .......................................................................... 1
1.1.1
1.1.2
Daily Checks ............................................................................................................ 1
Periodic Check and Maintenance ............................................................................. 2
1.2.1
1.2.2
Confirmation of Oil Seepage .................................................................................... 4
Check the Mechanical Unit Connectors ................................................................... 5
CHECK POINTS ............................................................................................ 4
STORAGE ..................................................................................................... 6
MAINTENANCE ...................................................................................... 9
2.1
REPLACING THE BATTERIES ..................................................................... 9
TROUBLESHOOTING .......................................................................... 10
3.1
3.2
3.3
TROUBLESHOOTING DUE TO MECHANICAL UNIT ................................ 10
TROUBLESHOOTING DUE TO FUSE ........................................................ 17
BACKLASH MEASUREMENT ..................................................................... 18
REPLACING PARTS ............................................................................ 25
4.1
4.2
4.3
4.4
4.5
4.6
4.7
4.8
4.9
4.10
4.11
DRIVE MECHANISM ................................................................................... 26
REPLACING J1-AXIS MOTOR (M1) ........................................................... 29
REPLACING J1-AXIS REDUCER ............................................................... 31
REPLACING J1-AXIS SENSOR .................................................................. 39
REPLACING J2-AXIS MOTOR (M2) ........................................................... 44
REPLACING J2-AXIS REDUCER ............................................................... 46
REPLACING J2-AXIS SENSOR .................................................................. 50
REPLACING J3-AXIS MOTOR (M3) ........................................................... 54
REPLACING J3-AXIS REDUCER ............................................................... 56
REPLACING J3-AXIS SENSOR .................................................................. 61
REPLACING J4-AXIS MOTOR (M4) ........................................................... 66
c-2
TABLE OF CONTENTS
B-84195EN/02
4.12
4.13
4.14
4.15
4.16
4.17
4.18
4.19
4.20
4.21
4.22
5
REPLACING J4-AXIS REDUCER ............................................................... 69
REPLACING J4-AXIS SENSOR .................................................................. 78
REPLACING J5-AXIS MOTOR (M5) ........................................................... 84
REPLACING J5-AXIS REDUCER ............................................................... 89
REPLACING J5-AXIS SENSOR .................................................................. 92
REPLACING J6-AXIS MOTOR (M6) ........................................................... 97
REPLACING J6-AXIS REDUCER ............................................................... 99
REPLACING J6-AXIS SENSOR ................................................................ 103
REPLACING LED UNIT ............................................................................. 107
REPLACING TOOL I/F BOARD ................................................................ 107
SEALANT APPLICATION .......................................................................... 108
REPLACING CABLES ........................................................................ 109
5.1
5.2
5.3
CABLE WIRING......................................................................................... 110
CABLE FORMING ..................................................................................... 112
CABLE AND AIR TUBE REPLACEMENT ................................................. 114
5.3.1
5.3.2
5.3.3
5.3.4
5.3.5
5.3.6
5.3.7
6
Replacing Cable K001,K002,K201,K301,K309 (connector panel to J2 base) .... 114
Replacing Cable K115,K121,K122,K123,K221,K303,K310
(J2 base to J2 arm lower side) .............................................................................. 121
Replacing Cable K131,K132,K13,K134,K231,K304,K311
(J2 arm lower side to J3 casing) ........................................................................... 125
Replacing Cable K141,K142,K241,K306,K312 (J3 casing to J3 arm) ................ 130
Replacing cable K152, K154, K251, K307, K313 (J3 arm part to J6 casing part)134
Replacing Cable K161,K261,K308,K314 (J6 casing to wrist flange) .................. 136
Replacing cable K133,K151,K153 (J3-axis, J5-axis motor cable) ....................... 140
MASTERING ....................................................................................... 142
6.1
6.2
6.3
6.4
6.5
OVERVIEW ............................................................................................... 142
RESETTING ALARMS AND PREPARING FOR MASTERING ................. 143
ALL-AXES VISION MASTERING .............................................................. 144
6.3.1
6.3.2
6.3.3
6.3.4
6.3.5
6.3.6
6.3.7
Bracket Assembling ............................................................................................. 145
Cable assembling .................................................................................................. 146
Setting and Adjustment of Camera....................................................................... 146
Base plate installation ........................................................................................... 148
Execute All-Axis Vision Mastering ..................................................................... 148
Removal of the fixture .......................................................................................... 151
Payload value for wrist camera installation.......................................................... 151
SINGLE AXIS MASTERING (FOR PARTS REPLACING) ......................... 151
VERFYING MASTERING .......................................................................... 155
APPENDIX
A
MAINTENANCE PARTS ..................................................................... 159
B
MECHANICAL UNIT CIRCUIT DIAGRAM.......................................... 163
C
PERIODIC MAINTENANCE TABLE ................................................... 172
D
STRENGTH OF BOLT AND BOLT TORQUE LIST............................ 174
c-3
1. CHECKS AND MAINTENANCE
B-84195EN/02
1
CHECKS AND MAINTENANCE
Optimum performance of the robot can be maintained by performing the periodic maintenance procedures
presented in this chapter. (See APPENDIX C 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 cases where robot use
exceeds 3840 hours/year, adjust the given maintenance frequencies
accordingly. The ratio of actual operation time/year vs. the 3840 hours/year
should be used to calculate the new (higher) frequencies. For example, when
using the robot 7680 hours a year with a recommended maintenance interval of
3 years or 11520 hours, use the following calculation to determine the
maintenance frequency: 3 years / 2 = perform maintenance every 1.5 years.
1.1
PERIODIC MAINTENANCE
1.1.1
Daily Checks
Check the following items when necessary before daily system operation.
Check items
Oil seepage
Vibration, abnormal
noises
Positioning
accuracy
Peripheral devices
for proper operation
Brakes for each
axis
Warnings
Check points and management
Check to see if there is oil on the sealed part of each joint. If there is an oil seepage, clean it.
⇒”1.2.1 Confirmation of Oil Seepage”
Check whether vibration or abnormal noises occur.
When vibration or abnormal noises occur, perform measures referring to the following
section:
⇒”3.1 TROUBLESHOOTING” (symptom：Vibration, Noise)
Check that the taught positions of the robot have not deviated from the previously taught
positions. If displacement occurs, perform the measures as described in the following
section:
⇒”3.1 TROUBLESHOOTING” (symptom：Displacement)
Check whether the peripheral devices operate properly according to commands from the
robot and the peripheral devices.
Check that the droppage of the end effector is within 5 mm when the servo power turned off.
If the end effector (hand) drops, perform the measures as described in the following section:
⇒”3.1 TROUBLESHOOTING” (symptom：Dropping axis)
Check whether unexpected warnings occur in the alarm screen on the teach pendant. If
unexpected warnings occur, perform the measures as described in the following manual:
⇒”CONTROLLER OPERATOR’S MANUAL (Alarm Code List)(B-83284EN-1)”
-1-
1. CHECKS AND MAINTENANCE
1.1.2
B-84195EN/02
Periodic Check and Maintenance
Check the following items at the intervals recommended below based on the total operating time or the
accumulated operating time, whichever comes first. (○ : Item needs to be performed.)
Check and maintenance
intervals
(Operating time, Accumulated
operating time)
1
3
1
month months year
320h
960h
3840h
○
○
1st
check
○
○
Check for water
○
Only
1st
check
○
○
Only
1st
Check
○
○
Only
Check for damages
to the teach pendant
cable, the operation
box connection cable
or the robot connection
cable
Check for damage
to the end effector
(hand)
connection cable
Check the exposed
connectors
1st
check
○
Only
1st
○
Check points, management and
maintenance method
3
4
8
years
years
years
11520h 15360h 30720h
Cleaning the
controller
ventilation
system
Check for external
damage
Only
○
2
years
7680h
Check and
maintenance item
Retightening the
end effector
mounting bolts
check
-2-
Confirm the controller ventilation system
is not dusty. If dust has accumulated,
remove it.
Check whether the robot has external
damage due to the interference with the
peripheral devices. If an interference
occurs, eliminate the cause. Also, if the
external damage is serious and causes a
problem in which the robot cannot be
used, replace the damaged parts.
(Perform diary checks for green covers.)
Check whether the robot is subjected to
water or cutting oils. If water is found,
remove the cause and wipe off the liquid.
Check whether the cable connected to
the teach pendant, operation box and
robot are unevenly twisted or damaged.
If damage is found, replace the damaged
cables.
Check whether the end effector
connection cables are unevenly twisted
or damaged. If damage is found, replace
the damaged cables.
Check the connection of exposed
connectors.
⇒”1.2.2 Check the Mechanical Unit
Connectors”
Retighten the end effector mounting
bolts.
Refer to the following section for
tightening torque information:
⇒”4.1 END EFFECTOR
INSTALLATION TO WRIST” of the
Mechanical unit operator’s manual (B84194EN)
Periodic
maintenance
table No.
9
1
2
8
3
4
5
1. CHECKS AND MAINTENANCE
B-84195EN/02
Check and maintenance
intervals
(Operating time, Accumulated
operating time)
1
3
1
month months year
320h
960h
3840h
○
○
Only
2
years
7680h
Check and
maintenance item
Check points, management and
maintenance method
Retightening the
external main bolts
Retighten the robot installation bolts
(according to procedure in Section 1.2),
bolts to be removed for inspection, and
bolts exposed to the outside. Refer to
the recommended bolt tightening torque
guidelines at the end of the manual. An
adhesive to prevent bolts from loosening
is applied to some bolts. If the bolts are
tightened with greater than the
recommended torque, the adhesive
might be removed. Therefore, follow the
recommended bolt tightening torque
guidelines when retightening the bolts.
Check that spatters, sawdust, or dust
does not exist on the robot main body. If
dust has accumulated, remove it.
Especially, clean the robot movable parts
well (each joint, surroundings of the wrist
flange, conduit part, wrist axis hollow
part).
3
4
8
years
years
years
11520h 15360h 30720h
1st
check
○
Only
○
Clean spatters,
sawdust and dust
1st
check
-3-
Periodic
maintenance
table No.
6
7
1. CHECKS AND MAINTENANCE
B-84195EN/02
1.2
CHECK POINTS
1.2.1
Confirmation of Oil Seepage
Check items
Check there is oil on sealed part of each joint parts. If there is oil seepage, clean them.
Fig. 1.2.1 (a) Check parts of oil seepage
Management

Oil might accumulate on the outside of the seal lip depending on the movement condition or
environment of the axis. If the oil changes to a state of liquid, the oil might fall depending on the axis
movement. To prevent oil spots, be sure to wipe away any accumulated oil under the axis components
as shown in Fig. 1.2.1 (a) before you operate the robot.
If you must wipe oil frequently, and opening the grease outlet does not stop the seepage, perform the
measures below.
⇒”3.1 TROUBLESHOOTING DUE TO MECHANICAL UNIT” (symptom : Grease leakage )
-4-
1. CHECKS AND MAINTENANCE
B-84195EN/02
1.2.2
Check the Mechanical Unit Connectors
Inspection points of the connectors

Robot connection cables, earth terminal and user cables
Check items


Circular connector: Check the connector for tightness by turning it manually.
Earth terminal:
Check the connector for tightness.
Fig. 1.2.2 (a) Connector Inspection points
-5-
1. CHECKS AND MAINTENANCE
1.3
B-84195EN/02
STORAGE
The following tools and instruments are required for the maintenance procedures.
(a) Measuring instruments
Instruments
Accuracy/Tolerance
Dial gauge
1/100 mm
Slide calipers
150 mm
Applications
Measurement of positioning accuracy and
backlash
(b) Tools
Parts name
Cross-head screwdrivers
Straight-head screwdrivers
Nut driver
Hexagon wrench set
Torque wrench
L shaped torque wrench
Torque driver
Long T wrench
Cutting pliers
Cutting nippers
Monkey wrench
Grease gun
Guide pin for J1-axis motor
Guide pin for J2 sensor
Spacer for J2 sensor
J5-axis motor unit replacing
Fixture
Flashlight
Antistatic safety shoes
Antistatic gloves
Wrist strap
LOCTITE
Remarks
Large, medium, small
Large, medium, small
width across flats (mm) 4, 5, 5.5, 6, 10
width across flats (mm) 2, 2.5, 3, 4, 5, 6
Torque (Nm) 0.86, 2.0, 3.4, 4.5, 5.6, 7.7, 7.9, 9.0, 15.3, 20.0
Hexagon bit : width across flats (mm) 2, 2.5, 3, 4, 5
For J3 arm unit assembling
Torque (Nm) 2.0
width across flats (mm) 2.5
We recommend the following or the equivalent device.
MAKER : BESTOOL-KANON
Parts name : head replaceable pre-set ratchet torque wrench
Model number : N6QSPK
Parts name : Hex drive head for pre-set ratchet torque wrench
Model number : 25HCK 2.5
Torque (Nm) 0.11, 0.9, 1.5
Plus bit : #0, #1
Box bit : width across flats (mm) 4, 5, 5.5, 6, 10
width across flats (mm) 2, 2.5, 3, 4, 5
A290-7702-X953 (Fig. 1.3 (a))
A290-7702-X954 (Fig. 1.3 (b))
A290-7702-X955 (Fig.1.3 (c))
A290-7702-X951, A290-7702-X952 (Fig.1.3 (d))
For tool I/F board replacement
For tool I/F board replacement
For tool I/F board replacement
We recommend the following or the equivalent device.
Maker：HOZAN CO.JP
Parts name：WRIST STRAP
Model number：F-153
243, 518
-6-
1. CHECKS AND MAINTENANCE
B-84195EN/02
160
O 5
O 4
10
A290-7702-X953
Fig. 1.3 (a) Guide pin for J1-axis motor
O 6.5
67
11.5
M6
A290-7702-X954
R
95
Fig. 1.3 (b) Guide pin for J2-axis sensor
R
72
.5
3
A290-7702-X955
Fig. 1.3 (c) Spacer for J2-axis sensor
-7-
1. CHECKS AND MAINTENANCE
55
B-84195EN/02
Bolt
ボルト
A6-BA-3X12(2)
A6-BA-3X12
(2)
J5 unit
fixture A
J5ユニット冶具A
A290-7702-X951
A290-7702-X951
57
J5J5ユニット冶具B
unit fixture B
A290-7702-X952
A290-7702-X952
197
The following
bolts are required
別途、以下のボルトが必要
A6-BA-3X12
(4)
A6-BA-3X12(4)
Fig.1.3 (d) J5-axis moor unit replacing fixture
-8-
2. MAINTENANCE
B-84195EN/02
2
MAINTENANCE
2.1
REPLACING THE BATTERIES
The position data of each axis is preserved by the backup batteries. Please use the following procedure to
replace when the backup battery voltage drop alarm occurs.
Procedure of replacing the battery
1
Press the EMERGENCY STOP button to prohibit the robot motion.
CAUTION
Be sure to keep the power 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
3
4
5
6
Remove the bolts and the J2 arm root side cover.
Remove the cable connector of the batteries.
Remove bolt s and cover plate of the battery.
Take out the old batteries (2 pcs) from the battery case. Then replace the batteries (2 pcs).
Assemble them by reversing the sequence. The gasket is reusable.
Gaseket
ガスケット
Cover
カバー
Bolt ボルト
M4 xM4X12
12 (6(6個)
pcs)
締結トルク：4.5Ｎｍ
Tightening
torque: 4.5Nm
Battery clip
Lithium battery (2 pcs)
バッテリクリップ
FANUC spec. :
A98L-0031-0040#A
リチウムバッテリ (2本）
Note)
When replacing the battries,
ファナック仕様:A98L-0031-0011#D
replace two batteries together.
Batteries
cable
バッテリケーブル
Cover
plate of battery
バッテリカバー板金
Bolt ボルト
(4個)
(4 pcs)
M3 x 8M3X8
Fig. 2.1 (a) Replacing the battery
-9-
Cable connector of
バッテリケーブルコネクタ
the batteries
3. TROUBLESHOOTING
3
B-84195EN/02
TROUBLESHOOTING
The source of mechanical unit problems may be difficult to locate because of overlapping causes. Problems
may become further complicated, if they are not corrected properly. Therefore, you must keep an accurate
record of problems and take proper corrective actions.
3.1
TROUBLESHOOTING DUE TO MECHANICAL UNIT
Table 3.1 (a) shows the major troubleshooting that may occur in the mechanical unit and their probable
causes. If you cannot pinpoint a failure cause or which measures to take, contact your local FANUC
representative. For troubleshooting except the mechanical unit, refer to “CONTROLLER
MAINTENANCE MANUAL (B-84175EN etc.)” and Alarm Code List (B-83284EN-1).
Symptom
Vibration
Noise
Description
-
-
-
-
-
-
-
-
Table 3.1 (a) TROUBLESHOOTING
Cause
The J1 base lifts off the
base plate as the robot
operates.
There is a gap between
the J1 base and base
plate.
The J1 base retaining bolt
is loose.
The rack or floor plate
vibrates during operation
of the robot.
Vibration becomes more
serious when the robot is
in 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.
[J1 base fastening]
It is likely that the robot J1
base is not securely
fastened to the base plate.
Probable causes are a
loose bolt, an insufficient
degree of surface flatness,
or contamination caught
between the base plate
and floor plate.
If the robot is not securely
fastened to the floor plate,
the J1 base lift from the
ground. Thus may cause
the collision, and lead to
vibration.
[Rack or floor]
It is likely that the rack or
floor is not rigid enough.
If they are not rigid
enough, counterforce
deforms the rack or floor,
and responsible for the
vibration.
[Overload]
It is likely that the load on
the robot is heavier than
the maximum rating.
It is likely that the robot
control program is too
demanding for the robot
hardware.
- 10 -
Measure
-
-
-
-
-
-
-
If a bolt is loose, apply
LOCTITE and tighten it
with the appropriate
torque.
Adjust the base plate
surface flatness to within
the specified tolerance.
If there is any
contamination, eliminate
them.
Apply adhesive between
the J1 base and base
plate.
Reinforce the rack or floor
to make it more rigid.
If reinforcing the rack or
floor is impossible, modify
the robot control program;
doing so will reduce the
vibration.
Check the maximum load
that the robot can handle
or not. If the robot is
overloaded, reduce the
load, or modify the robot
control program.
Vibration can be reduced
by re-modifying the robot
control program; reducing
speed or acceleration with
minimizing the influence on
the entire cycle time.
3. TROUBLESHOOTING
B-84195EN/02
Symptom
Vibration
Noise
(Continued)
Description
-
-
-
Vibration was first noticed
after the robot collided with
an object or the robot was
overloaded for a long
period.
Periodic vibration and
noise occur.
There is some relationship
between the vibration of
the robot and the operation
of a machine near the
robot.
Cause
[Gear, bearing, or reducer]
It is likely that collision or
overload applied an
excessive force on the
drive mechanism, thus
damaging the tooth
surface or rolling contact
surface of a bearing, or
reducer.
It is likely that prolonged
use of the robot while
overloaded caused fretting
of the tooth surface or
rolling contact surface of a
bearing, or reducer due to
resulting metal fatigue.
It is likely that foreign
matter caught in a gear,
bearing, or within a
reducer caused damage
on the tooth surface or
rolling contact surface of
the bearing, or reducer.
It is likely that foreign
matter caught in a gear,
bearing, or within a
reducer cause vibration.
[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.
- 11 -
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.
Connect the grounding
wire firmly to ensure a
reliable ground potential
and prevent extraneous
electrical noise.
3. TROUBLESHOOTING
Symptom
Vibration
Noise
(Continued)
Rattling
B-84195EN/02
Description
-
-
-
The cause of problem
cannot be identified from
examination of the floor,
rack, or mechanical unit.
While the robot is not
supplied with power,
pushing it with the hand
causes tottering part of the
mechanical unit.
There is a gap on the
mounting face of the
mechanical unit.
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.
Pulsecoder defect may be
the cause of the vibration
as the motor cannot
propagate the accurate
position to the controller.
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 unit 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 unit has an
intermittent break, vibration
might occur because
commands cannot be sent
to the motor accurately.
If a connection cable
between the mechanical
unit and the controller has
an intermittent break,
vibration might occur.
If the power supply cable is
about to be snapped,
vibration might occur.
If the power source voltage
drops below the rating,
vibration might occur.
It may vibrate when the
invalid value parameter
was set.
[Mechanical unit coupling bolt]
It is likely that overloading
or a collision has loosened
a mounting bolt in the
robot mechanical unit.
- 12 -
Measure
-
-
-
-
-
-
-
-
Refer to the Controller
Maintenance Manual for
troubleshooting related to
the controller and amplifier.
Replace the motor of the
axis that is vibrating, and
check whether vibration
still occurs. To replace the
motor, Contact your local
FANUC representative.
If vibration occurs only
when the robot assumes a
specific posture, it is likely
that a cable in the
mechanical unit is broken.
Check whether the jacket
of the cable connecting the
mechanical unit and
controller is damaged. If
so, replace the connection
cable, and check whether
vibration still occurs.
Check whether the jacket
of the power cable is
damaged. If so, replace
the power cable, and
check whether vibration
still occurs.
Check that the robot is
supplied with the rated
voltage.
Check that the robot
control parameter is set to
a valid value. If it is set to
an invalid value, correct
them. Contact your local
FANUC representative for
further information if
necessary.
Check the following
retaining bolts tightness for
each axis. If any of these
bolts is loose, apply
LOCTITE and bolt down
with appropriate torque.
Motor
Reducer
Reducer shaft
Sensor
Sensor flange
J3 arm
End effector
3. TROUBLESHOOTING
B-84195EN/02
Symptom
Rattling
Motor
overheating
Description
-
-
-
Backlash is greater than
the allowance stated in the
applicable maintenance
manual.
(See Section 3.3.)
The ambient temperature
of the installation location
increases, causing the
motor to overheat.
After the robot control
program or the load was
changed, the motor
overheated.
Cause
[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.
-
[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.
-
-
-
-
-
-
-
-
-
After a robot control
parameter (load setting
etc.) was changed, the
motor overheated.
[Parameter]
If data input for a
workpiece is invalid, the
robot cannot be accelerate
or decelerate normally, so
the average current
increases, leading to the
motor overheating.
- 13 -
-
Measure
Operate one axis
individually 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 damaged. If
there are no damaged
gears, replace the reducer.
Using the robot within its
maximum rating prevents
problems with the drive
mechanism.
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 motor well ventilated
enables the motor to
release heat efficiently,
thus preventing
overheating. Using a fan to
direct air at the motor is
also effective.
If there is a source of heat
near the motor, it is
advisable to install
shielding to protect the
motor from heat radiation.
As for load setting, Input
an appropriate parameter
referring to Section 4.2 of
the operator’s manual (B84194EN).
3. TROUBLESHOOTING
Symptom
Motor
overheating
Grease
leakage
Oil leakage
Dropping axis
B-84195EN/02
Description
-
-
-
Symptom other than stated
above
Grease or oil is leaking
from the mechanical unit.
An axis falls because the
brake went out.
An axis falls in standstill.
Cause
Measure
[Mechanical unit 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 motor brake
failure locked on the break,
and cause the motor
overloaded.
It is likely that a failure of
the motor prevented it from
delivering its rated
performance, thus causing
an excessive current to
flow into the motor.
[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 reassembling.
An oil seal might be
damaged if extraneous
dust scratches the lip of
the oil seal.
-
[Brake drive relay and motor]
It is likely that brake drive
relay contacts are stuck to
each other and keep the
brake current flowing, thus
preventing the brake from
operating when the motor
is reenergized.
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
soak through the motor,
causing the brake to slip.
-
- 14 -
-
-
-
-
-
-
Repair the mechanical unit
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.
Judgment is possible if the
average current decreased
after replacing the motor,
the former motor had been
defected.
If a crack develops in the
casting, sealant can be
used as a quick-fix to
prevent further grease or
oil leakage. However, the
component should be
replaced as soon as
possible, because the
crack might extend.
O-rings are used in the
locations listed below.
Motor coupling section
Reducer (case and
shaft) coupling section
J3/J4/J5 gear unit
Oil seals are used in the
locations stated below.
Inside the reducer
J6 brake
Check whether the brake
drive relay contacts stuck
each other or not. If they
are found to be stuck,
replace the relay.
Replace the motor
confirmed following
symptoms.
Brake shoe is worn out
brake main body is
damaged
Oil soak through the
motor
3. TROUBLESHOOTING
B-84195EN/02
Symptom
Displacement
Description
-
-
-
-
The robot operates at a
point other than the taught
position.
The repeatability is not
within the tolerance.
Displacement occurs only
in specific peripheral
equipment.
Displacement occurred
after a parameter was
changed.
BZAL alarm
Displayed.
-
BZAL is displayed on the
teach pendant screen.
CLALM alarm
occurred.
Move error
excess alarm
occurred.
-
Ambient temperature of
the robot installation
location is low, CLALM
alarm is displayed on the
teach pendant screen.
Ambient temperature of
the robot installation
position is low,
“Move error excess” alarm
is displayed on the teach
pendant screen.
-
Cause
[Mechanical unit problems]
If the repeatability is
unstable, probable causes
are a failure in the drive
mechanism or a loose bolt,
and so on.
If the repeatability is
stable, it is likely that
collision by an excessive
load caused slip on the
fasting surface of each
axis arm, and reducer.
It is likely that the
Pulsecoder is faulty.
[Peripheral equipment
displacement]
It is likely that an external
force was applied to the
peripheral equipment, thus
shifting its position relative
to the robot.
[Parameter]
It is likely that the
mastering data was
overwritten, and the origin
had misaligned.
It is likely that the voltage
of the memory backup
battery is low.
It is likely that the
Pulsecoder cable is
defective.
[Peripheral temperature]
When the robot is used in
a low temperature
environment that is near to
0ºC, or the robot is not
operated for a long time in
an environment that is less
than 0ºC, there will be a
large viscous resistance of
the drive train immediately
after starting which will
cause the alarm.
- 15 -
Measure
-
-
-
-
-
-
-
-
If the repeatability is
unstable, repair the
mechanical unit by
referring to the above
descriptions of vibration,
noise, and rattling.
If the repeatability is
stable, correct the taught
program. The problem will
not occur unless another
collision occurs.
If the Pulsecoder is faulty,
replace the motor or the
Pulsecoder.
Correct the setting of the
peripheral equipment
position.
Correct the taught
program.
Re-enter the previous
optimal mastering data.
If optimal mastering data is
unavailable, perform
mastering again.
Replace the battery.
Replace the cable.
Perform a warm up
operation or a low speed
operation for several
minutes.
3. TROUBLESHOOTING
Symptom
CLALM alarm
occurred.
Move error
excess alarm
occurred.
B-84195EN/02
Description
-
-
-
After changing the motion
program or the load
condition, the CLALM
alarm is displayed.
After changing the motion
program or the load
condition, the “Move error
excess” alarm is displayed.
None of the symptoms
stated above are the
problem.
Cause
-
[Overload]
It is likely that load
exceeded the permissible
value.
It is likely that the motion
program is too severe for
the robot.

Tight motion such as
reverse motion using
“CNT”.

Linear motion occurs
near singularity point
where axes revolve in
high speed.
It is likely the vibration
occurred.
-
Though a
person does
not touch the
robot, a
contact stop or
payload error
occurs and
stops the robot
Cross check
alarm
displayed.
-
Though a person does not
touch the robot, robot
stops due to contact stop.
Robot stops due to
payload error
-
-
Cross check alarm is
displayed on the teach
pendant screen.
It is likely that a robot
collision occurred.
-
-
It is likely that rated voltage
is not supplied due to the
voltage drop.
Angle of robot mounting
surface is not set correctly.
Unintended contact
occurred.
Incorrect robot installation
is performed.
The end effector or the
workpiece does not match
the load setting.
Vibration of the floor or the
hand is applied to the
robot.
Refer to “Though a person
does not touch the robot, a
contact stop or payload
error occurs and stops the
robot” contents
It is likely that the sensor is
broken.
- 16 -
Measure
-
-
-
-
-
-
-
-
-
-
If a robot collision has
occurred, press the
[RESET] key while
pressing the [SHIFT] key.
Then, jog the robot in the
opposite direction while
pressing the [SHIFT] key.
Check the motion program.
Check the permissible
value of the robot payload.
If the load exceeds the
permissible value, reduce
the load or change the
motion program.
Consider minimizing the
influence on cycle time by
reducing the speed or
acceleration, and changing
the motion program.
Check that the load setting
is performed correctly.
Refer to the Symptoms:
Vibration, Noise section of
this troubleshooting for
more information.
Check that the robot is
supplied with the proper
rated voltage.
Set the angle of robot
mounting surface correctly.
Get rid of the matter which
contact with the robot.
Install the robot according
to Section 1.2.
Match the end effector and
the workpiece to the load
setting.
Make sure that vibration of
the floor or the hand is not
applied to the robot.
Refer to “Though a person
does not touch the robot, a
contact stop or payload
error occurs and stops the
robot” contents
Replace the unit.
3. TROUBLESHOOTING
B-84195EN/02
3.2
TROUBLESHOOTING DUE TO FUSE
The following describes alarms, symptoms and countermeasures when the fuse blows out installed to the
tool I/F board.
FUSE13: RS485+ / For protection of analog input 1ch circuit
FUSE14: RS485- / For protection of analog input 2 ch circuit
Name
FUSE13
FUSE14
Symptom when fusing
If RS485 communication is
performed with the end effector,
Host-425 displayed.
If analog communication is
performed with the end effector,
analog values becomes 0.
If RS485 communication is
performed with the end effector,
Host-425 displayed.
If analog communication is
performed with the end effector,
analog values becomes 0.
FUSE14
(0.5A)
Countermeasure
(1) Check there is no short circuit on the wiring between the End
effector –EE interface. Remove the cause if necessary.
(2) Replace the mechanical unit cable between the EE interface
and the tool I/F board.
(3) Replace the tool I/F board referring to 4.21.
(1) Check there is no short circuit on the wiring between the End
effector –EE interface. Remove the cause if necessary.
(2) Replace the mechanical unit cable between the EE interface
and the tool I/F board.
(3) Replace the tool I/F board referring to 4.21.
FUSE13
(0.5A)
Fig. 3.2 (a) Fuses on the tool I/F board
- 17 -
3. TROUBLESHOOTING
3.3
B-84195EN/02
BACKLASH MEASUREMENT
Measurement method
1
2
3
Put the robot in a specified posture. (See Fig 3.3 (b) to (m).)
Apply positive and negative loads to each axis as shown in Fig. 3.3 (a).
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
停止位置
0
+3kgf
-3kgf
+3kgf
0kgf
L1
-3kgf
0kgf
L2
+3kgf
L3
-3kgf
0kgf
0kgf
First step
(Do1回目(測定しない)
not measure)
Second step
2回目(B
2=L1+ L 2)
(B2=L
1+L2)
Third step
3回目(B =L + L )
(B3=L3+L4)3 3 4
L4
Fig. 3.3 (a) Backlash measurement method
Backlash B is calculated using the following expression:
B=
B2 + B3
2
- 18 -
3. TROUBLESHOOTING
B-84195EN/02
Loading position
負荷をかける位置
1328
Measuring
測定位置
position
J1 Arbitrary
J1
任意
J2
90º
J2
90°
J3
0º
J4
0º
J3
0°
J5
0º
J6
-90º
J4
0°
J5 0°
J6 -90°
Fig. 3.3 (b) Backlash measurement posture of J1-axis (CRX-10iA)
Loading position
負荷をかける位置
1498
Measuring
測定位置
position
J1 Arbitrary
J1 任意
J2
90º
J3
0º
J2 90°
J4
0º
J3 0°
J5
0º
J6
-90º
J4 0°
J5 0°
J6 -90°
Fig. 3.3 (c) Backlash measurement posture of J1-axis (CRX-10iA/L, CRX-20iA/L)
- 19 -
3. TROUBLESHOOTING
B-84195EN/02
Measuring
測定位置
position
785
540
Loading position
負荷をかける位置
J1 Arbitrary
J2 J1 任意
0º
J3 J2 90º
0°
J4
0º
J5 J3 90°
0º
J6 J4 -90º
0°
J5 0°
J6 -90°
Fig. 3.3 (d) Backlash measurement posture of J2-axis (CRX-10iA)
Measuring
測定位置
position
J1
J2
J3
J4
J5
J6
955
710
Loading position
負荷をかける位置
Arbitrary
0º
任意
90º
0°
0º
90°
0º
0°
-90º
J1
J2
J3
J4
J5
J6
0°
-90°
Fig. 3.3 (e) Backlash measurement posture of J2-axis (CRX-10iA/L, CRX-20iA/L)
- 20 -
3. TROUBLESHOOTING
788
B-84195EN/02
Loading position
負荷をかける位置
J1
J1
J2
J2
J3
J4
J3
J5
J6
J4
J5
J6
任意
45°
-90°
-90°
0°
-90°
Arbitrary
45º
-90º
-90º
0º
-90º
Measuring
測定位置
position
788
Fig. 3.3 (f) Backlash measurement posture of J3-axis (CRX-10iA)
Loading position
負荷をかける位置
J1
J1
J2
J2
J3
J4
J3
J5
J6
J4
J5
J6
任意
45°
-90°
-90°
0°
-90°
Arbitrary
45º
-90º
-90º
0º
-90º
Measuring
測定位置
position
Fig. 3.3 (g) Backlash measurement posture of J3-axis (CRX-10iA/L, CRX-20iA/L)
- 21 -
3. TROUBLESHOOTING
B-84195EN/02
J1J1 Arbitrary
任意
J2
45º
J2
45°
J3
-90º
J4J3 -90°
0º
J5
90º
0°
J6J4 -90º
Measuring
測定位置
position
J5 90°
J6 -90°
248
Loading position
負荷をかける位置
Fig. 3.3 (h) Backlash measurement posture of J4-axis (CRX-10iA)
J1 J1Arbitrary
任意
J2
45º
J2
45°
J3
-90º
J4 J3 -90°
0º
J5 J4 90º
0°
J6
-90º
Measuring
測定位置
position
J5 90°
J6 -90°
248
Loading position
負荷をかける位置
Fig. 3.3 (i) Backlash measurement posture of J4-axis (CRX-10iA/L, CRX-20iA/L)
70
160
Loading position
負荷をかける位置
測定位置
Measuring position
DETAIL A
J1J1Arbitrary
任意
J2
90º
J3J2 90°
0º
J4J3
90º
0°
J5
-90º
90°
J6J4 -90º
A
Fig. 3.3 (j) Backlash measurement posture of J5-axis (CRX-10iA)
- 22 -
J5 -90°
J6 -90°
3. TROUBLESHOOTING
B-84195EN/02
70
160
Loading position
負荷をかける位置
Measuring
測定位置
position
DETAIL A
J1
J2
J3
J4
J5
J6
A
J1Arbitrary
任意
90º
J2 90°
0º
J3 90º
0°
J4 -90º
90°
-90º
J5 -90°
J6 -90°
Fig. 3.3 (k) Backlash measurement posture of J5-axis (CRX-10iA/L, CRX-20iA/L)
任意
J1J1Arbitrary
J2J2 41°
41º
J3
-90º
J4J3 -90°
0º
J5J4
0º
0°
J6
0º
J5
J6
Measuring
測定位置
position
125
Loading position
負荷をかける位置
Fig. 3.3 (l) Backlash measurement posture of J6-axis (CRX-10iA)
- 23 -
0°
0°
3. TROUBLESHOOTING
B-84195EN/02
J1
J2
J3
J4
J5
J6
Measuring
測定位置
position
Arbitrary
J1 任意
30º
J2 -90º
30°
0º
J3 -90°
0º
J4 0°
0º
J5 0°
J6 0°
125
Loading position
負荷をかける位置
Fig. 3.3 (m) Backlash measurement posture of J6-axis (CRX-10iA/L, CRX-20iA/L)
Table 3.3 (a) Permissible backlash value (CRX-10iA)
Angle conversion (arc-min)
Displacement conversion (mm)
Distance between the rotation
center and dial gauge (mm)
J1
J2
J3
J4
J5
J6
2.28
0.88
2.28
0.36
2.43
0.56
3.29
0.24
3.00
0.14
3.61
0.13
1328
540
788
248
160
125
Table 3.3 (b) Permissible backlash value (CRX-10iA/L)
Angle conversion (arc-min)
Displacement conversion (mm)
Distance between the rotation
center and dial gauge (mm)
J1
J2
J3
J4
J5
J6
2.28
1.00
2.28
0.47
2.43
0.56
3.29
0.24
3.00
0.14
3.61
0.13
1498
710
788
248
160
125
Table 3.3 (c) Permissible backlash value (CRX-20iA/L)
Angle conversion (arc-min)
Displacement conversion (mm)
Distance between the rotation
center and dial gauge (mm)
J1
J2
J3
J4
J5
J6
2.19
0.95
2.19
0.45
2.29
0.52
2.81
0.20
2.32
0.17
3.01
0.11
1498
710
788
248
160
125
NOTE
When measuring backlash under circumstances where the distance between the
rotation center and the dial gauge is different from those in the above table, use
the table to make angle and displacement conversions.
- 24 -
4. REPLACING PARTS
B-84195EN/02
4
•
•
•
•
REPLACING PARTS
When replacing a part, adjustment is required.
When removing or mounting a motor, apply force only in the shaft direction. 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 are not aligned properly, assembly might prove
impossible. Carefully check the state of the parts before removing them.
To secure the performance of the seal, replace seal bolts (A97L-0218-0496#M4X12BC) with new
ones after replacing parts, if possible. If impossible, reuse them applying LOCTITE 243 after peeling
off the old sealant.
NOTE
1 When applying LOCTITE to a part, spread the LOCTITE on the entire length of
the engaging part of the female thread. If applied to the male threads, poor
adhesion can occur potentially loosening the bolt. Clean the bolts and the
threaded holes and wipe off any oil on the engaging section. Make sure that
there is no solvent left in the threaded holes. Remove all the excess LOCTITE
when you are finished screwing the bolts into the threaded holes.
2 Description of [LT243] means LOCTITE 243.
•
•
•
•
•
Observe the specified tightening torque strictly if it’s specified. If not specified, refer to the tightening
torque specified in the APPENDIX.
Assemble the reducer to the vertical direction as much as possible when you assemble it.
When applying LOCTITE 518 to the reducer, be careful that the LOCTITE does not get into the
reducer.
Stir and soften the grease well, before spreading on the reducer.
Before remove the J3 casing cover, wear the antistatic gloves and the antistatic safety shoes and the
wrist strap (Refer to Section 1.3), then connect it to the earth.
CAUTION
Be sure to take measures against static electricity before removing the J3 casing
cover. If you touch the tool I/F board without measures, the tool I/F might break.
Wrist
strap
リストストラップ
Antistatic
gloves
静電気対策用手袋
Earth
アース
Antistatic
safety shoes
静電気対策用安全靴
Fig.4 (a) Countermeasure against static electricity
- 25 -
4. REPLACING PARTS
B-84195EN/02
WARNING
Be sure to assemble parts to original positions after maintenance works. If parts
are not attached, safety function may lost, and it may cause injury of the
personnel.
CAUTION
When removing and attaching parts, do so slowly and carefully. If impact torques
are applied to the sensor, it may cause failure of the sensor.
4.1
DRIVE MECHANISM
The drive mechanisms of each axis are shown in the Fig. 4.1 (a) to (e).
Indicator
インジケータ
J2
base
J2ベース
J1-axis
motor (M1)
J1軸モータ(M1)
Pipe
パイプ
Gear
インプットギヤ
J1-axis
reducer
Ｊ１軸減速機
(Hollow
shaft)
(中空シャフト)
J1
base
J1ベース
Fig. 4.1 (a) Drive mechanism of J1-axis
- 26 -
4. REPLACING PARTS
B-84195EN/02
J2
arm
J2アーム
J2-axis
reducer
J2軸減速機
(中空シャフト)
(Hollow
shaft)
インプットギヤ
Gear
J2-axis
motor (M2)
J2軸モータ(M2)
J2ベース
J2
base
Pipe
パイプ
Fig. 4.1 (b) Drive mechanism of J2-axis
J3-axis
reducer
J3軸減速機
(Hollow
shaft)
(中空シャフト)
Pipe
パイプ
J3ケーシング
J3 casing
ドライブシャフト
Drive shaft
J2 arm
J2アーム
Fig. 4.1 (c) Drive mechanism of J3-axis
- 27 -
Gear
インプットギヤ
J3-axis
motor
J3モータ(M3)
(M3)
4. REPLACING PARTS
B-84195EN/02
J3
arm
J3アーム
J4-axis
motor
J4軸モータ
(M4) (M4)
Gear
インプットギヤ
J4軸減速機
J4-axis
reducer
(中空シャフト)
(Hollow
shaft)
Drive
ドライブシャフト
shaft
J3
casing
J3ケーシング
Pipe
パイプ
J2アーム
J2
arm
Fig. 4.1 (d) Drive mechanism of J4-axis
J5-axis
motor(M5)
(M5)
J5軸モータ
Spline
スプライン
Gear
ギヤ
Gear
ギヤ
Pipe
パイプ
J5-axis
reducer
J5軸減速機
(Hollow
shaft)
(中空シャフト)
Gear
インプットギヤ
Pipe
パイプ
J3 arm
J3アーム
J6
flange
J6フランジ
J6 casing
J6ケーシング
J6-axis
motor (M6)
J6軸モータ
(M6)
Gear
ギヤ
J6-axis
brake
J6軸ブレーキ
Fig. 4.1 (e) Drive mechanism of J5/J6-axis
- 28 -
J6-axis
reducer
J6軸減速機
(Hollow
shaft)
(中空シャフト)
4. REPLACING PARTS
B-84195EN/02
4.2
REPLACING J1-AXIS MOTOR (M1)
CAUTION
If J1-axis may rotate in case of except floor mount, take measures such putting
the robot on a stand to prevent the robot from rotating.
Replacing procedure
1
To remove the J1 -axis motor, set a dial gauge at the J1 -axis, and prepare for single axis mastering
after replacement. Refer to Section 6.4.
Move the robot so that the J2 base cover can be removed. Then turn off controller power.
Remove the bolts (1). Then remove the J2 base cover (2) and the gasket (3).
2
3
2
3
1
Fig. 4.2 (a) Replacing the J1-axis motor (1/2)
Parts name
1
2
3
4
5
6
7
8
9
10
GEOMET BOLT
J2 BASE COVER
GASKET
Specifications
A97L-0318-0426#4X12
A290-7702-V303
A290-7702-X312
Q’ty
6
1
1
Locking
Torque N-m
(kgf-cm)
4.5Nm (46kgfcm)
Remove the relay connector (IND1) of the LED unit (5).
Remove bolts (4). Then remove the LED unit (5).
Remove all connectors (M1M, M1P, M1BK) connected to the motor from the J1-axis motor.
Remove bolts (6). Then remove the J1-axis motor (7) and the O-ring (10). In this time, be careful to
the following.

The tooth muscle of the gear (8) is diagonal. Therefore, when pulling out the motor, straightly
pull it during rotating the whole of the motor to axis rotation direction. If the motor is lay down
or removed without rotation, it might damage the gear teeth.

Grease will drop. So be careful the to prevent grease does not adhere to the motor connectors or
relay connector.
Wipe off grease on the (8). In this time, be careful not to damage the gear.
Remove the bolt (9). Then pull out the gear (8) from the motor shaft.
Replace the J1-axis motor (7) by new one, then attach the bolt (9) and the gear (8).
- 29 -
4. REPLACING PARTS
B-84195EN/02
6
7
8
9
10
5
4
Fig. 4.2 (b) Replacing the J1-axis motor (2/2)
Parts name
4
5
6
7
8
9
10
11
12
13
14
15
16
17
BOLT
LED UNIT
BOLT
J1-AXIS MOTOR
GEAR
BOLT
O RING
Specifications
A6-BA-4X10
A97L-0318-0704
A6-BA-5X16
A06B-2127-B303
A290-7702-X204
A6-BA-5X20
A98L-0001-0347#S46
Q’ty
2
1
4
1
1
1
1
Locking
Torque N-m
(kgf-cm)
5.6Nm (57kgfcm)
LT243
7.9Nm (80kgfcm)
Sufficiently degrease the motor and the J2 base’s tightening surface, using a cloth dampened with
solvent. Do not spray solvent directly onto the surface. (Refer to Fig. 4.2 (c))
Confirm dirt is not attached on the gear (8). If dirt is seen, remove it with air.
According to Fig.4.2 (c), apply 2ml grease to the gear inserting position.
Attach the J1-axis motor (7) with bolts (6). In this time, be careful to the following.

Be sure to insert the O-ring (10).

When inserting the motor, be careful the motor does not tilt and the cable in the J2 base contact
the motor.

The tooth muscle of the gear (8) is diagonal. Therefore, when inserting the motor, straightly insert
it during rotating the whole of the motor to axis rotation direction. If the motor is lay down or
inserted without rotation, it might damage the gear teeth.

After inserting the motor, insert the J1 guide pin (spec.:A290-7702-X953 refer to Section 1.3)
into the tap hole to align the motor hole position.
Connect the J1-axis motor connectors (M1M,M1P,M1BK) to the J1-axis motor (7).
According to the reversed sequence of the removal, attach the LED unit (5) and the J2 base cover (2).
In this time, be careful to the following.

When assembling the LED unit, be careful that the cables do not ride on the LED.

When assembling the J2 base cover, do not sandwich the cables.
Perform single axis mastering for J1-axis referring to Section 6.4.
- 30 -
4. REPLACING PARTS
B-84195EN/02
Grease
2ml
グリース
2ml
J2
base side
J2ベース側
J1-axis
motor side
J1モータ側
Degreasing
：脱脂範囲
area
Greasing area
：塗布範囲
Fig. 4.2 (c) Grease removing area and applying area when replacing the J1-axis motor
4.3
REPLACING J1-AXIS REDUCER
NOTE
If the robot is not positioned by positioning pins or locating surfaces,
misalignment will occur when removing the robot from the floor plate and
attaching it again. As a result single axis mastering cannot be performed
correctly.
REPLACING PROCEDURE
1
2
3
To remove the J1, J2-axis motor, set a dial gauge at the J1,J2-axis, and prepare for single axis
mastering after replacement. Refer to Section 6.4.
Set the Quick Master Reference Position. Refer to the QUICK MASTERING section of the
mechanical unit operator’s manual (B-84194EN). (All the axes are set to 0º before shipment.
Move the robot to J1=0°. Then change the robot posture so that the J2 base cover and the connector
panel can be removed when the robot is lay down. (recommended posture: J1=0°,J2=0°J3=249°, other
axes angles are arbitrary) (Refer to Fig.4.3 (a))
- 31 -
4. REPLACING PARTS
B-84195EN/02
推奨姿勢
倒す方向
倒す方向
J1=0°
J2=0°
J3=249°
J4=任意
J5=任意
J6=任意
CRX-10iA/L, CRX-20iA/L
CRX-10iA
Fig.4.3 (a) Recommended posture
4
5
6
7
8
9
10
11
12
13
Turn off controller power, then remove the robot connection cable from the controller.
Remove the J2 base cover referring to Fig.4.2 (a) in Section 4.2.
Remove the relay connector (IND1) of the LED unit.
Remove the LED unit referring to Fig.4.2 (b) in Section 4.2.
Remove all connectors (M1M,M1P,M1BK,M2M,M2P,M2BK) connected to theJ1,J2-axismotor.
Remove the J1-axis motor and the J2-axis motor. Refer to procedure 7 in Section 4.2 (Fig.4.2 (b)) and
procedure 8 in Section 4.5 (Fig.4.5 (a)). (Removing the gear from the motor is not required)
Cut the cable ties (1-A),(1-B),(1-D) which fix the C braided tube (1-A).Then remove the braided tube
(1-A). Refer to Fig. 5.3.1 (a) in Subsection 5.3.1.
Remove the all relay connectors (M12BK1, M3M1, M456M1, M3456P1, TS2, CAM-A or FS-A)
referring to Fig. 5.3.1 (a) in Subsection 5.3.1.
Cut the cable tie (1-E) which fix the cable on the clamp J1-2 referring to Fig.5.3.1 (a) in Subsection
5.3.1.
Remove the bolts (1), then remove the clamp J1-2 (2).
1
2
Fig. 4.3 (b) Replacing the J1-axis reducer (1/4)
- 32 -
4. REPLACING PARTS
B-84195EN/02
Parts name
1
2
14
Specifications
BOLT
CLAMP J1-2
A6-BA-4X10
A290-7702-X321
Q’ty
Locking
Torque N-m (kgf-cm)
2
1
Remove the J1-axis cover (3) as shown in Fig. 4.3 (c).
3
Fig. 4.3 (c) Replacing the J1-axis reducer (2/4)
Parts name
3
15
J1-AXIS COVER
Specifications
A290-7702-X310
Q’ty
Locking
Torque N-m (kgf-cm)
2
Remove the robot from the floor plate. Then lay it down referring to Fig.4.3 (a).
WARNING
When removing the robot floor plate and turning it sideways, be sure to perform
these work with two or more people. If it was done by one people, it may cause
injury.
16
17
18
19
Remove the J1 base cover referring to Fig.4.4 (a),(b) in Section 4.4.
Pull out the relay connectors in the J2 base to the J1 base side. Do not pull out cables forcibly during
the relay connectors are caught in hollow hole.
Remove bolts (4) and (5). Then remove the washers (6) and (7).
Remove the J1 base unit (8) with using the removal taps. (Refer to Fig.4.3 (e)) In this time, grease
drops. Be careful grease does not splash on the motor connectors and the relay connectors.
- 33 -
4. REPLACING PARTS
B-84195EN/02
8
7
4
4
6
5
Fig. 4.3 (d) Replacing the J1-axis reducer (3/4)
4
5
6
7
Parts name
BOLT
BOLT
WASHER A
WASHER B
8
J1 BASE UNIT
Specifications
A6-BA-5X30
A6-BA-5X20
A290-7702-X323
A290-7702-X324
A290-7702-V202,
10iA, 10iA/L
A290-7702-X201 etc.
A290-7702-V212,
20iA/L
A290-7702-X201 etc.
Q’ty
14
5
6
1
Locking
Torque N-m (kgf-cm)
9.0Nm(92kgfcm)
9.0Nm(92kgfcm)
1
Removal
taps (M5)
抜きタップ（M5）
J2 arm
side
J2アーム側
Fig. 4.3 (e) Position of the removal taps for the J2 base (J1 base side)
20
21
22
Remove bolts (12). Then remove the J1-axis reducer (13).
Prepare the new J1-axis reducer (13). Apply 8ml grease to the sensor flange mounting part (part A)
referring to Fig. 4.3 (g).
Attach the new J1-axis reducer (13) with bolts (12). In this time, be careful to the following.

According to Fig. 4.3 (h) match the temporary fixing bolts of the J1-axis reducer (13) and counter
bore for temporary fixing bolt of the J1 sensor flange (15).

Be sure to replace the O-ring (11),(14) and the wave washer (10) by new articles and install them.

When tightening bolts (12), tighten the opposing side bolts evenly to 4.5Nm(46kgfcm). Then
tighten them to the regulated torque 9.0Nm(92kgfcm).
- 34 -
4. REPLACING PARTS
B-84195EN/02
9
10
11
12
13
14
15
Fig.4.3 (f) Replacing the J1-axis reducer (4/4)
Parts name
9
10
11
12
WAVE GENERATOR
WAVE WASHER
O RING
BOLT
13
J1-AXIS REDUCER
14
15
O RING
J1 SENSOR FLANGE
Specifications
Q’ty
(Reducer appendix)
(Reducer appendix)
(Reducer appendix)
A6-BA-5X35
10iA, 10iA/L A97L-0318-0292#80
20iA/L
A97L-0318-0292#120
(Reducer appendix)
A290-7702-X205
1
1
1
12
- 35 -
1
1
1
Locking
Torque N-m
(kgf-cm)
9.0Nm(92kgfcm)
4. REPLACING PARTS
B-84195EN/02
Wave generator
ウェーブジェネレータ
Reducer
減速機
A
B
Sensor
flange
センサフランジ
After 減速機
assembling
the
reducer
組み付け後
Before減速機
assembling
the組み付け前
reducer
Grease applying area
：塗布範囲
Fig. 4.3 (g) Applying grease to the reducer
Reducer
減速機
Bolt減速機のボルト頭
head of the reducer
(4 locations)
(４か所)
Sensor flange
センサフランジ
Counter bore for bolt relief
センサフランジの
of the sensor flange
ボルト逃げ用ざぐり
(4 locations)
(４か所)
Fig. 4.3 (h) Phase of the reducer installation
23
Before assembling the new wave generator (9), apply 34ml grease to the reducer inside, the bearing
(part B) of the wave generator. Refer to Fig. 4.3. (g).
- 36 -
4. REPLACING PARTS
B-84195EN/02
24
25
26
Attach the new wave generator (9).
Match the phase of the J1-axis reducer (13) during rotating the wave generator (9). Refer to Fig. 4.3
(i).
Clean the seal surface and apply sealant on the J2 base referring to Fig.4.3 (j) and Section 4.22.
Tap
of the bolt 1 (M5X30)
図4.3(k)の
in ボルト1(M5x30)用のタップ
Fig 4.3. (k)
Match
the bolt of
part phase
of the J1 base
部
J1ベースと減速機の
部のボルトの位相を
上図のように合わせること。
and the reducer
as aboved figure.
Fig.4.3 (i) Phase of the J1-axis reducer
J2
arm side
J2アーム側
Apply
LOCITE 518 on the dotted line
部にロックタイト518を塗布のこと。
Fig.4.3 (j) Applying the LOCTITE
- 37 -
4. REPLACING PARTS
27
28
B-84195EN/02
According to Fig. 4.3 (i), (k), match the phase of the J1-axis reducer (13) and the J2 base. Then attach
the washers (6), (7) and the J1 base unit (8) with bolts (4), (5) referring to Fig.4.3 (k).
Pass the cable pulled out at procedure 17 from the J1 base side to the J2 base side. Do not pass the
cables forcibly during the relay connectors are caught in the hollow hole.
11
9
2
5
15
M5X20
M5X20
17
13
12
M5X20
3
18
7
M5X20
J2 arm side
J2アーム側
19
10
8
4
M5X20
16
14
1
6
Tightening
締結手順 procedure
11.Tighten
of 1 to 19 to 4.5Nm (46kgfcm).
1 から in
19order
の順に4.5Nm(46kgfcm)で締めます。
22.Tighten
of 1 o 19 to 9.0Nm (92kgfcm).
1 から in
19order
の順に規定トルク9.0Nm(92kgfcm)で締めます。
Fig. 4.3 (k) Tightening of the bolts and the bolt positon
29
Install the robot on the floor plate.
WARNING
When removing the robot floor plate and turning it sideways, be sure to perform
these work with two or more people. If it was done by one people, it may cause
injury.
30
31
According to the reversed sequence of procedure 5 to 14, attach the LED unit. Wire the cables in the
J2 base. Then attach t the J2 base cover. In this time, be careful to the following.

When mounting the J1, J2-axis motors, refer to procedure 14 in Section 4.2 and procedure 15 in
Section 4.5. In addition, apply 16ml grease to the motor inserted portion referring to Fig. 4.2 (c)
in Section 4.2.

(If the camera cable is specified) After connecting the camera cable connector, wind insulation
tape 2 round or motor to cover the connector whole referring to Fig. 5.3.1 (l) in Subsection 5.3.1.

When assembling the LED unit, be care the cables is located on the LED.

When assembling the J2 base cover, be careful not to sandwich the protection sheet and cables.
Perform quick mastering and perform single axis mastering of J1, J2-axis. Refer to the QUICK
MASTERING section of the mechanical unit operator’s Manual (B-84194EN) and Section 6.4 of this
manual.
- 38 -
4. REPLACING PARTS
B-84195EN/02
4.4
REPLACING J1-AXIS SENSOR
NOTE
If the robot positioning is not performed by way of the positioning pins or locating
surfaces, the robot may slip when it is removed from the floor plate and
reinstalled. So single axis mastering cannot be performed correctly.
Replacing procedure
1
2
3
4
5
6
7
8
9
10
11
To remove the J1-axis sensor from the J1-axis reducer, set a dial gauge at the J1-axis, and prepare for
single axis mastering after replacement. Refer to Section 6.4.
Set the Quick Master Reference Position. Refer to the QUICK MASTERING sections of the
mechanical unit Operator’s Manual (B-84194EN). (All the axes are set to 0º before shipment.)
Move the robot to J1=0°. Then change the robot posture so that the J2 base cover and the connector
panel can be removed when the robot is lay down. (recommended posture: J1=0°,J2=0°,J3=249°, other
axes angles are arbitrary) (See Fig. 4.3 (a) in Section 4.3.)
Turn off controller power. Then remove the robot connection cable from the controller.
Remove the J2 base cover referring to Fig.4.2 (a) in Section 4.2.
Remove the relay connector (IND1) of the LED unit.
Remove the LED unit referring to Fig.4.2 (b) in Section 4.2.
Remove the all connectors (M1M, M1P, M1BK, M2M, M2P, M2BK) connected to J1, J2-axis motors.
Cut the cable ties (1-A), (1-B) and (1-D) which fix the braided tubes, and remove the braided tubes
(1-A) referring to Fig.5.3.1 (a) in Section 5.3.1.
Remove the all relay connectors (M12BK1, M3M1, M456M1, M3456P1, TS2, and CAM-A or FS-A)
referring to Fig.5.3.1 (a) in Section 5.3.1.
Remove the robot from floor plate. Then turn it sideways. Refer to Fig. 4.3 (a) in Section 4.3.
WARNING
When removing the robot floor plate and turning it sideways, be sure to perform
these work with two or more people. If it was done by one people, it may cause
injury.
12
Remove the bolts (1), then remove the J1 base cover (2), the pins (3) and the gasket (4).
4
3
2
1
Fig 4.4 (a) Replacing J1-axis sensor (1/2) (back side connector)
- 39 -
4. REPLACING PARTS
Parts name
1
2
3
4
PLATED BOLT
J1 BASE COVER
PIN
GASKET
B-84195EN/02
Specifications
Q’ty
A97L-0218-0496#M4X12BC
A290-7702-X202
JB-PH-H7A-8X16S45C
A290-7702-X214
Locking
Torque N-m (kgf-cm)
12
1
2
1
4.5Nm (46kgfcm)
4
3
2
1
Fig 4.4 (b) Replacing J1-axis sensor (1/2) (bottom side connector)
Parts name
1
2
3
4
13
14
15
16
17
18
19
20
PLATED BOLT
J1 BASE COVER
PIN
GASKET
Specifications
A97L-0218-0496#M4X12BC
A290-7702-X203
JB-PH-H7A-8X16S45C
A290-7702-X214
Q’ty
12
1
2
1
Locking
Torque N-m (kgf-cm)
4.5Nm (46kgfcm)
Cut the cable ties (1-F) which fix cables to clamp J1-1 and remove the connector (TS-J1) that relays
cable referring to Fig.5.3.1 (b) and (c) in Section 5.3.1.
According to Fig.5.3.1 (a) in Section 5.3.1, cut the cable tie (1-E).
Pull out the relay connector in the J2 base to the J1 base side. Do not pull it out forcibly with the
relayed connector caught.
Remove the bolts (5), and remove the clamp J1-1 (6).
Remove the J1 spacers (7)
Remove the bolts (8) and the washers (9), then remove the J1 base (10).
Remove the bolts (11), and remove the J1-axis sensor (12).
Replace J1-axis sensor (12) by new one and fit it without tilting it so that it does not jam on the
coupling part of the J1-axis sensor flange (13). At this time, check the tap position of the J1-axis
sensor flange (13) and align the cable phase of the J1-axis sensor (12). (Refer to Fig.4.4 (d))
- 40 -
4. REPLACING PARTS
B-84195EN/02
12
13
7
11
6
5
10
9
8
Fig 4.4 (c) Replacing J1-axis sensor (2/2)
Parts name
5
6
7
8
9
10
11
12
13
21
BOLT
CLAMP J1-1
J1 SPACER
BOLT
WASHER
J1 BASE
BOLT
J1 SENSOR
J1 SENSOR FRANGE
Specifications
A6-BA-3X8
A290-7702-X211
A290-7702-X527
A6-BA-6X20
A97L-0140-0471#6
A290-7702-X201
A6-BA-6X25
A97L-0318-0700
A290-7702-X205
Q’ty
4
1
4
16
16
1
16
1
1
Locking
Torque N-m (kgf-cm)
15.3Nm (156kgfcm)
15.3Nm (156kgfcm)
According to tightening procedure of Fig.4.4 (d), attach the J1-axis sensor (12) with bolts (11). In this
time, be careful to the following. When temporarily tighten four bolts first time, evenly tighten each
bolt little by little so that the loads applied to the bolts in the J1-axis sensor (12) whole becomes even.

Tighten bolts after conforming the J1-axis sensor (12) adhered to the J1-axis sensor flange (13).
Do not attract by tightening bolts in this work.

When tightening four bolts temporarily at first, tighten little by little so that the load is applied
evenly to the J1-axis sensor (12) whole.
WARNING
If procedure is not followed, safety function may lost and it may cause injury or
the personnel.
22
23
Fit the J1 base (10) without tilting it so that it does not jam on the coupling part of the J1-axis sensor
(12).
According to the tightening procedure in Fig.4.4 (e), attach the J1 base (10) with bolts (8). In this time,
be careful to the following.

Tighten bolts after conforming the J1 base (10) adhered to the J1-axis sensor (12). Do not attract
by tightening bolts in this work.

When tightening four bolts temporarily at first, tighten little by little so that the load is applied
evenly to the J1 base (10) whole.
- 41 -
4. REPLACING PARTS
B-84195EN/02
WARNING
If procedure is not followed, safety function may lost and it may cause injury or
the personnel.
24
25
26
27
28
Assemble the J1 spacer (7).
According to Fig. 5.3.1 (b),(c), pass the cable tie (1-F) through the clamp J1-1 (6). Then attach the
clamp J1-1 (6) with bolts (5).
Pass the cable removed in procedure 15 from the J1 base side to the J2 base side, and fix the cable to
clamp J1-2 with a cable ties (1-E). Do not pull out cables forcibly during the relay connectors are
caught in the pipe.
According to the reversed sequence of the procedure 4 to 14, form the cables in the J1 base, attach the
J1 base cover. Attach the motor, the clamp J1-2 and the LED unit. Then form the cables in the J2 base.
Attach the J2 base cover.
At this time, pay attention below.

When assembling the J1,J2-axis motors, refer to procedure 14 in Section 4.2 and procedure 15
in Section 4.5.

(If the camera cable is specified) After connecting the camera cable connector, wind insulation
tape 2 round or motor to cover the connector whole referring to Fig. 5.3.1 (a) in Subsection 5.3.1.

Assemble the LED unit so that the cables do not overlap the LED.

When assemble the J1 base cover and J2 base cover, do not pinch the cable and the protective
sheet stuck to the inside of the cover.
Perform single axis mastering of J1-axis after you perform quick mastering. Refer to the QUICK
MASTERING of the mechanical unit operator’s Manual (B-84194EN) and Section 6.4.
Check the tap position of the sensor flange and align the
センサフランジのタップ位置を確認し、
cable
phase of the sensor.
センサのケーブルの位相を合わせてください。
13
4
8
12
9
16
5
2
J2アーム側
J2
arm side
1
6
15
10
11
14
3
7
Sensor
flange taps position
センサフランジのタップ
Tightening procedure
1. 締結手順
To prevent the sensor from being assembled in a tilted position,tighten the four
1. bolts
センサが傾いた状態で組み付かないようにするため、センサ全体で均一に
1 to 4 little by little and evenly so that the bolt load is evenly placed to the whole
ボルトの負荷がかかるよう、
1 から 4 の4本のボルトを少しずつ均等に仮締めします。(*)
sensor. (*)
残りのボルトを
5 から
の順に仮締めします。
2. 2. Temporarily
tighten
the16remaining
bolts in the order of 5 to 16.
1 から 16with
の順に7.7Nm(79kgfcm)で締めます。
3. 3. Tighten
half the specified torque in the order of 1 to 16 to 7.7Nm (79kgfcm).
4. 1 から 19 の順に規定トルク15.3Nm(156kgfcm)で締めます。
4. Tighten with the specified torque in the order of 1 to 16 to 15.3Nm (156kgfcm).
(*)(*)
Make
sure that the sensor is contacted the whole surface on the sensor flange before
センサがセンサフランジに着座していることを確認してからボルトを締めるようにし、
tightening
the bolts. Do not pull the sensor with bolts to contact the whole surface.
ボルトで引きつけながら着座させないようにしてください。
Fig. 4.4 (d) Tightening procedure of bolts (assemble J1-axis sensor)
- 42 -
4. REPLACING PARTS
B-84195EN/02
4
8
13
12
9
16
5
2
J2
arm side
J2アーム側
1
6
15
10
11
7
14
3
Tightening procedure
締結手順
1.
To prevent the fastening parts⑦
from being assembled in
③a tilted position,tighten the four
1.
締結部品が傾いた状態で組み付かないようにするため、締結部品全体で均一に
bolts
1 to 4 little by little and evenly so that the bolt load is evenly placed to the whole fastening parts. (*)
ボルトの負荷がかかるよう、
1 から
4 の4本のボルトを少しずつ均等に仮締めします。(*)
2.
Temporarily
tighten the remaining bolts
in the
order of 5 to 16.
2.
残りのボルトを
から 16 torque
の順に仮締めします。
3.
Tighten
with half the5specified
in the order of 1 to 16 to 7.7Nm (79kgfcm).
3.
1 からwith
16the
の順に7.7Nm(79kgfcm)で締めます。
4.
Tighten
specified torque in the order of 1 to 16 to 15.3Nm (156kgfcm).
4. 1 から 16 の順に規定トルク15.3Nm(156kgfcm)で締めます。
(*) Make sure that the fastening parts is contacted the whole surface on the sensor before
(*) 締結部品がセンサに着座していることを確認してからボルトを締めるようにし、
tightening
the bolts. Do not pull the fastening parts with bolts to contact the whole surface.
ボルトで引きつけながら着座させないようにしてください。
Fig. 4.4 (e) Tightening procedure of bolts (assemble J1 base)
- 43 -
4. REPLACING PARTS
4.5
B-84195EN/02
REPLACING J2-AXIS MOTOR (M2)
Replacing procedure
1
2
To remove the J2-axis motors, set a dial gauge at the J2-axis, and prepare for single axis mastering.
Refer to Section 6.4.
Fix the J2 arm such as putting it on the stand to prevent it from falling to gravity direction when the
motor is removed.
CAUTION
If the J2-axis is not supported correctly, the J2 arm may fall to the gravity
direction and collide surrounding when removing the J2-axis motor.
3
4
5
6
7
8
9
10
11
Turn off controller power.
According to Fig.4.2 (a) in Section 4.2, remove the J2 base cover.
Remove the relay connector (IND1) of the LED unit.
According to Fig. 4.2 (b) in Section 4.2, remove the LED unit.
Remove the all connectors (M2M, M2BK) connected the motor from the J2-axis motor (2).
Remove bolts (1). Then remove the J2-axis motor (2) and the O-ring (5). In this time, be careful to the
following.

The tooth muscle of the gear (3) is diagonal. Therefore, when pulling out the motor, straightly
pull it during rotating the whole of the motor to axis rotation direction. If the motor is lay down
or removed without rotation, it might damage the gear teeth.

Grease will drop. So be careful the grease does not attach on the motor connectors or relay
connectors.
Wipe off grease on the gear (3). In this time, be careful not to damage the gear teeth.
Remove the bolt (4). Then pull out the gear (3) from the motor shaft.
Replace the J2-axis motor (2) by new one. Then attach the bolt (1) and the gear (3).
5
4
3
2
1
Fig. 4.5 (a) Replacing the J2-axis motor
- 44 -
4. REPLACING PARTS
B-84195EN/02
Parts name
1
2
3
4
5
12
BOLT
J2-AXIS MOTOR
GEAR
BOLT
O RING
Specifications
A6-BA-5X16
A06B-2127-B303
A290-7702-X204
A6-BA-5X20
A98L-0001-0347#S46
Q’ty
4
1
1
1
1
Locking
Torque N-m
(kgf-cm)
5.6Nm (57kgfcm)
LT243
7.9Nm (80kgfcm)
Sufficiently degrease the motor and the J2 base’s tightening surface, using a cloth dampened with
solvent. Do not spray solvent directly onto the surface. (Refer to Fig. 4.5 (b))
Grease
グリース
J2-axis
motor side
J2モータ側
J1 base ide
J1ベース側
Degreasing
：脱脂範囲area
Geasing
area
：塗布範囲
Fig. 4.5 (b) Degreasing area and greasing area when replacing the J2-axis motor
13
14
15
16
17
18
Confirm dirt is not attached on the gear (3). If dirt is seen, remove it with air.
According to Fig.4.5 (b), apply 2ml grease to the gear inserting position.
Attach the J2-axis motor (2) with bolts (1). In this time, be careful to the following.

Be sure to attach the O-ring (5).

When inserting the motor, be careful the motor does not tilt and the cable in the J2 arm contact
the motor.

The tooth muscle of the gear (3) is diagonal. Therefore, when inserting the motor, straightly insert
it during rotating the whole of the motor to axis rotation direction. If the motor is lay down or
inserted without rotation, it might damage the gear teeth.
Connect the J2-axis motor connectors (M2M,M2P,M2BK) to the J2-axis motor (2).
According to Fig.4.2 (a),(b) in Section 4.2, attach the LED unit and the J2 base cover. In this time, be
careful to the following.

When assembling the LED unit, be careful that the cables do not ride on the LED.

When assembling the J2 base cover, do not sandwich the cables.
Perform single axis mastering referring to Section 6.4.
- 45 -
4. REPLACING PARTS
4.6
B-84195EN/02
REPLACING J2-AXIS REDUCER
Replacing procedure
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
To remove the J1, J2-axis motor, set a dial gauge at the J1,J2-axis, and prepare for single axis
mastering after replacement. Refer to Section 6.4.
Set the Quick Master Reference Position. Refer to the QUICK MASTERING sections of the
mechanical unit Operator’s Manual (B-84194EN). (All the axes are set to 0º before shipment.)
Move the robot posture to J2=90°J3=0°J4=0°J5=0°J6=0°(J1-axis is arbitrary). Support the J2
arm to keep it horizontal by ways such putting the J2 arm on the stand. In this time, lay waste cloth
etc. to prevent the robot’s damage.
Turn off controller power.
According to Section 2.1, remove the J2 arm cover (root side), the gasket, the battery cover plate and
the batteries.
According to Fig.4.7 (a) in Section 4.7, remove the J2 cable cover.
According to Fig.5.3.2 (a), (b) in Subsection 5.3.2, cut cable ties (2-A),(2-B). Then remove the all
relay connectors (M3456P2, CAM3, TS3, M456M2, M3M2).
According to Fig.4.7 (a) in Section 4.7 (a), remove the clamp J2-2A and the J2 spacer. Then remove
the J2 arm.
According to Fig. 4.2 (a) in Section 4.2, remove the J2 base cover.
Remove the relay connector (IND1) of the LED unit.
According to Fig.4.2 (b) in Section 4.2, remove the LED unit.
Remove the all connectors (M1M, M1P,M1BK,M2M,M2P,M2BK) connected to the J1,J2-axis motor.
According to procedure 7 (Fig.4.2 (b)) in Section 4.2 and procedure8 (Fig.4.5 (a)) in Section 4.5,
remove the J1-axis motor and the J2-axis motor. (Removing the gear from the motor is not necessary.)
Wipe off the grease on the gear. In this time, be careful not to damage the gear.
According to Fig. 5.3.2 (c) in Subsection 5.3.2, remove the clamp J2-1. (Cutting the cable ties which
fix the cable on the clamp J2-1 is not necessary.)
Pull out the J2 arm lower side cables to the J2 base side. Do not pull out cables forcibly during the
relay connectors are caught in the pipe.
Remove bolts (1), (2). Then remove washers (3), (4).
Remove the J2-axis reducer (8) from J2 base using the removal taps in Fig. 4.6. (a).
Remove bolts (5). Then remove the J2-axis reducer (8) from the J2 sensor flange (11).
Removal taps
抜きタップ(M5)
(M5)
J1 base side
J1ベース側
Fig. 4.6 (a) Position of the removal taps for the J2-axis reducer
- 46 -
4. REPLACING PARTS
B-84195EN/02
9
10
11
8
1
2
3
1
5
6
7
4
Fig. 4.6 (b) Replacing the J2-axis reducer
Parts name
Specifications
Q’ty
1
2
3
4
5
6
7
BOLT
BOLT
WASHER A
WASHER B
BOLT
O RING
WAVE GENERATOR
14
5
6
1
12
1
1
8
J2-AXIS REDUCER
9
10
11
WAVE WASHER
O RING
J2 SENSOR FLANGE
A6-BA-5X30
A6-BA-5X20
A290-7702-X323
A290-7702-X324
A6-BA-5X35
(Reducer appendix)
(Reducer appendix)
10iA, 10iA/L A97L-0318-0292#80
20iA/L
A97L-0318-0292#120
(Reducer appendix)
(Reducer appendix)
A290-7702-X205
20
21
22
23
24
Locking
Torque N-m
(kgf-cm)
9.0Nm (92kgfcm)
9.0Nm (92kgfcm)
9.0Nm (92kgfcm)
1
1
1
1
Prepare the new J2-axis reducer (8). According to Fig. 4.3 (g) in Section 4.3, apply 8ml grease on the
sensor flange mounting part (part A).
Attach the new J2-axis reducer (8) with bolts (5). In this time, be careful to the following.

According to Fig. 4.3 (h) in Section 4.3, match the temporary fixing bolts of the J2-axis reducer
(8) and counter bore for temporary fixing bolt of the J2 sensor flange (11).

Replace the O-ring (6), (10) and the wave washer (9) by new article. Then be sue to attach them.

When tightening bolts (5), tighten the opposing side bolts evenly to 4.5Nm (46kgfcm). Then
tighten them to the regulated torque 9.0Nm (92kgfcm).
Before installing the new wave generator (7), apply 34 ml grease on the bearing (B part) of the wave
generator referring to Fig.4.3 (g) in Section 4.3.
Attach the new wave generator (7).
According to Fig.4.6 (c) match the phase of the J2-axis reducer (7) during rotating the wave generator
(7).
- 47 -
4. REPLACING PARTS
B-84195EN/02
Tap
of the bolt 1
図4.6(e)の
inボルト1のタップ
Fig.4.6 (e)
部
Match the phase of the sensor
flange taps of
part部のボルトの位相を
and
センサフランジの
部のタップと減速機の
部
the bolts of
part in上図のように合わせること。
the reducer, match thems as aboved figure.
Fig. 4.6 (c) Phase of the J2-axis reducer
25
26
27
According to Fig.4.6 (d) and Section 4.22, clean the sealant surface, then apply sealant on the J2 base.
According to Fig.4.3 (c), (e), match the phase of the J1-axis reducer (13) and the J2 base. According
to the tightening procedure in Fig.4.6 (e), attach the washers (3), (4) and the J2-axis reducer (8) with
bolts (1), (2).
According to the reversed sequence of procedure 9 to 16, attach the clamp J2-1 and the motor. Wire
the cables in the J2 base.
Then attach the LED unit and the J2 base cover. In this time, be careful to the following.

When assembling the J1, J2-axis motors, refer to procedure 14 in Section 4.2 and procedure 15
in Section 4.5.
In addition, before inserting the J1-axis motor, according to Fig. 4.2 (c) in Section 4.2, apply 2ml
grease to the motor inserting position. Before inserting the J2-axis motor, according to Fig.4.5
(b) in Section 4.5, apply 16ml grease to the motor inserting position.

(If the camera cable is specified) After connecting the camera cable connector, wind insulation
tape 2 round or motor to cover the connector whole referring to Fig. 5.3.1 (l) in Subsection 5.3.1.

When assembling the LED unit, be careful that the cables do not ride on the LED.

When assembling the J2 arm cover (root side), be careful not to sandwich the cables.
J1
base side
J1ベース側
Apply
LOCTITE 518 on the dotted line.
部にロックタイト518を塗布のこと。
Fig. 4.6 (d) LOCTITE applying area of the J2-axis
- 48 -
4. REPLACING PARTS
B-84195EN/02
19
10
4
7
M5X20
M5X20
12
14
17
6
2
M5X20
9
11
1
5
M5X20
16
15
13
3
8
M5X20
18
J1
base side
J1ベース側
Tightening procedure
締結手順
1 Tighten bolts to 4.5Nm (46kgfcm) in order of 1 to 19.
1. 1から19の順に4.5Nm(46kgfcm)で締めます。
2 Tighten bol2 to regulated torque 9.0Nm (92kgfcm) in order of 1 to 19.
2. 1から19の順に規定トルク9.0Nm(92kgfcm)で締めます。
Fig.4.6 (e) Tightening order of bolts and bolt position of the J2-axis reducer
28
According to the procedure 14 to 19 in Section 4.7, perform the J2 arm assembling to the clamp J22A assembling.
WARNING
If assembling is performed incorrectly, safety function may lost , and it may
cause injury of the personnel.
CAUTION
To wire the cable at J2=0º, move the robot to J2=0º in procedure 29 to 33, then
wire the cables in the J2 arm. In addition, for safety, attach the J2 arm cover
(root side) before turning on power.
29
30
31
32
33
34
35
36
37
38
Temporarily connect the relay cables without cable ties.
According to Section 2.1, attach the batteries on the battery clip. Then connect the battery connector.
According to Section 2.1, temporarily assemble the J2 arm cover (root side). Then turn on controller
power. When assembling the J2 arm cover (root side), be careful not to sandwich the cables.
“SRVO-062 BZAL alarm”will occur. Release the alarm referring procedure 2 in Section 6.2.
Move the robot posture J2=0°by jogging. Then turn off controller power.
According to Section 2.1, remove the temporary assembled J2 arm cover (root side).
Remove the temporarily connected relay connector. According to Fig.5.3.2 (a) in Subsection 5.3.2,
wire the cables, then reconnect the relay connector. In this time, if the camera cable is specified) After
connecting the camera cable connector, wind insulation tape 2 round or motor to cover the connector
whole referring to Fig. 5.3.1 (l) in Subsection 5.3.1.
According to Fig.4.7 (a) in Section 4.7, attach the J2 cable cover.
According to Section 2.1, attach the battery cover plate, the gasket and the J2 arm cover (root side).
When assembling the J2 arm cover (root side), be careful not to sandwich the cables.
Turn on controller power.
- 49 -
4. REPLACING PARTS
39
B-84195EN/02
Perform single axis mastering of J1, J2-axis after you perform quick mastering. Refer to the QUICK
MASTERING of the mechanical unit operator’s Manual (B-84194EN) and Section 6.4.
4.7
REPLACING J2-AXIS SENSOR
REPLACING PROCEDURE
1
To remove the parts from the J2-axis reducer, set a dial gauge at the J2-axis, and prepare for single
axis mastering after replacement. Refer to Subsection 6.4.
Set the Quick Master Reference Position. Refer to the QUICK MASTERING section of the
mechanical unit operator’s manual (B-84194EN). (All the axes are set to 0º before shipment.
Move the robot posture to J2=90°J3=0°J4=0°J5=0°J6=0°(J1-axis is arbitrary). Support the J2
arm so that it becomes be horizontal by ways such putting the J2 arm on the stand. In this time, lay a
waste cloth so that the robot is not damaged.
Turn off controller power.
Remove the J2 arm cover (root side), the gasket, the battery cover plate and the batteries referring to
Section 2.1.
Remove bolts (1). Then remove the washers (2) and the J2 cable cover (3).
Cut the cable ties (2-A),(2-B) which fix the cable on the clamp J2-2A.Then remove the all relay
connectors (M3456P2, CAM3, TS3, M456M2, M3M2). Refer to Fig.5.3.2 (a) in Subsection 5.3.2.
Remove bolts (4). Then remove the clamp J2-2A (5).
Remove the J2 spacer (6).
2
3
4
5
6
7
8
9
12
11
10
5
8
9
7
3
6
2
4
1
Fig.4.7 (a) Replacing the J2-axis sensor
Parts name
1
2
3
4
5
6
BOLT
WASHER
J2 CABLE COVER
BOLT
CLAMP J2-2A
J2 SPACER
Specifications
A6-BA-3X8
A97L-0318-0430#03008005
A290-7702-X334
A6-BA-3X8
A290-7702-X327
A290-7702-X210
- 50 -
Q’ty
4
4
1
1
1
4
Locking
Torque N-m
(kgf-cm)
0.6Nm (6.1kgfcm)
4. REPLACING PARTS
B-84195EN/02
Parts name
7
8
9
10
11
12
10
11
12
13
Specifications
BOLT
WASHER
J2 ARM
BOLT
J2-AXIS SENSOR
J2 SENSOR FRANGE
A6-BA-6X20
A97L-0140-0471#6
A290-7702-X302
A6-BA-6X25
A97L-0318-0700
A290-7702-X205
Q’ty
Torque N-m
(kgf-cm)
Locking
16
16
1
16
1
1
20.0Nm (204kgfcm)
20.0Nm (204kgfcm)
Remove the bolts (7). Then remove the washers (8) and the J2 arm (9).
Remove bolts (10). Then remove the J2-axis sensor (11).
Replace the J2-axis sensor (11) by new one.
Fit the sensor so that the faucet joint of the J2-axis sensor flange (12) is not damaged and it does not
tilt. In this time, confirm the tap hole position of the J2-axis sensor flange (12), Then match the cable
phase of the J2-axis sensor (11). (Refer to Fig.4.7 (b))
Assemble the J2-axis sensor (11) with bolts (7) referring to tightening order in Fig. 4.7 (b). In this
time, be careful to the following.

Tighten bolts after conforming the J2-axis sensor (11) adhered to the J2-axis sensor flange (12).
Do not attract by tightening bolts in this work.

When temporarily tighten four bolts first time, evenly tighten each bolt little by little so that the
loads applied to the bolts in the J2-axis sensor (11) whole becomes even.
WARNING
If assembling is performed incorrectly, safety function may lost , and it may
cause injury of the personnel.
3
7
14
11
10
15
6
1
2
5
16
9
12
13
8
4
Tap of the sensor flange
センサフランジのタップ
Confirm
the tap positon of the sensor flange.
センサフランジのタップ位置を確認し、
Then
match the phase of the sensor cable
センサのケーブルの位相を合わせてください。
Tigthening
order
締結手順
1 Temporaliry
tighten 1 to 4 bolts little by little evenly so that the sensor is not installed
1. センサが傾いた状態で組み付かないようにするため、センサ全体で均一に
tilted status
and the load is applied 1equalily
the whole of the sensor.(*)
ボルトの負荷がかかるよう、
から 4toの4本のボルトを少しずつ均等に仮締めします。(*)
2 Temporaliry
tighten other
bolts 16
by order
of 5 to 16.
2. 残りのボルトを
5 から
の順に仮締めします。
3 Tighten
torque of 7.7Nm (79kgfcm) by order of 1 to 16.
3. 1bolts
からwith
16 の順に7.7Nm(79kgfcm)で締めます。
4 Tighten
regulated torque 20.0Nm (204kgfcm) by order of 1 to 16.
4. 1bolts
からwith
16 の順に規定トルク20.0Nm(204kgfcm)で締めます。
(*)
bolts after conforming the sensor adhered to the sensor flange.
(*)Tighten
センサがセンサフランジに着座していることを確認してからボルトを締めるようにし、
ボルトで引きつけながら着座させないようにしてください。
Do not
attract by tightening bolts in this work.
Fig. 4.7 (b) Tightening order of bolts (sensor)
- 51 -
4. REPLACING PARTS
14
B-84195EN/02
Insert the J2 arm (9) until clearance between the J2 base and the J2 arm becomes 3mm using the spacer
fixture (spec. A290-7702-X955 Refer to Section 1.3). Refer to Fig. 4.7 (c).
Spacer fixture
スペーサ治具
3
Spacer fixture
スペーサ治具
Fig. 4.7 (c) J2 arm inserting
15
16
17
Insert two J2 guide pins (spec.:A290-7702-X954 refer to Section 1.3) to “5” and “6” referring to Fig.
4.7. (d). Adjust the J2 arm (9) incline so that no load is applied to the J2 guide pins and those can be
removed without resistance.
Pull out the spacer fixture, horizontally insert the J2 arm during keeping the incline of the J2 arm (9)
in procedure 15. Be careful not to damage the J2-axis sensor (11)’s faucet joint part.
According to the tightening procedure in Fig.4.7 (d), attach the J2 arm (9) with bolts (7). In this time,
be careful to the following.

Tighten bolts after conforming the J2 arm adhered to the J2-axis sensor (11). Do not attract by
tightening bolts in this work.

When temporarily tightening four bolts, tighten four bolts until those adhere to the surface during
keeping the incline of the J2 arm (9) in procedure 15,16. Then tighten bolts little by little in order
so that the load is applied uniformly to the whole of the J2 arm (9).
WARNING
If assembling is performed incorrectly, safety function may lost, and it may cause
injury of the personnel.
18
19
Attach the J2 spacer (6).
Firstly, pass the cable tie (2-B) which fix cable tie through the clamp J2-2A (5). Then attach the clamp
J2-2A (5) with bolts (4).
CAUTION
To wire the cable at J2=0º, move the robot to J2=0º in procedure 20 to 24, then
wire the cables in the J2 arm. In addition, for safety, attach the J2 arm cover
(root side) before turning on power.
20
21
Connect the relay cables without cable ties on the cables.
According to Section 2.1, attach the batteries to the battery clip. Then connect the battery connector.
- 52 -
4. REPLACING PARTS
B-84195EN/02
22
23
24
25
26
27
28
29
30
Attach the J2 arm cover (root side) referring to Section 2.1. Then turn on power.
When attaching the J2 arm cover (root side), do not sandwich cables.
SRVO-062 BZAL alarm will occur. So release the alarm referring to procedure 2 in Section 6.2.
Move the robot posture to J2=0°with jogging. Then turn off controller power.
Remove the J2 arm cover (root side) assembled in Section 2.1.
Remove the relay connectors. According to Fig. 5.3.2 (a) in Subsection 5.3.2, wire the cables, then
reconnect the relay connector. In this time, if the camera cable is specified, after connecting the camera
cable connector, wind insulation tape 2 round or motor to cover the connector whole referring to Fig.
5.3.1 (l) in Subsection 5.3.1.
Attach the washers (2) and the J2 cable cover (3) with bolts (1).
Attach the batteries, the battery cover plate, the gasket and the J2 cover referring to Section 2.1. When
assembling the J2 cover, do not sandwich the cables.
Turn on controller power.
Perform quick mastering and perform single axis mastering of J2-axis. Refer to the QUICK
MASTERING section of the mechanical unit operator’s Manual (B-84194EN) and Section 6.4 of this
manual.
3
7
11
14
10
15
6
1
Guid
pin setting position
ガイドピン設定位置
2
5
16
9
12
13
8
4
J2
arm side
J2アーム側
Tigthening order
締結手順
1 Keep
the J2 arm incline, temoporaliry tighten the four bolts (1 to 4) until those adhere.
1. J2アームの傾きを保ちながら、
1 から
の4本のボルトを着座するまで対角に仮締めします。
Temporaliry
tighten 1 to 4 bolts little by
little 4
evenly
so that the load is applied equalily to the whole of the J2 arm.(*)
J2アーム全体で均一にボルトの負荷がかかるよう、
1 から 4 の4本のボルトを少しずつ均等に仮締めします。(*)
2 Temporaliry
tighten other bolts by order of 5 to 16.
2. 残りのボルトを
5 から
16 の順に仮締めします。
3 Tighten
bolts with torque
of 7.7Nm
(79kgfcm) by order of 1 to 16.
3. 1 から
16with
の順に7.7Nm(79kgfcm)で締めます。
4 Tighten
bolts
regulated torque 20.0Nm (204kgfcm) by order of 1 to 16.
4. 1 から 16 の順に規定トルク20.0Nm(204kgfcm)で締めます。
(*)
bolts after conforming the J2 arm adhered to the J2-axis sensor.
(*)Tighten
J2アームがJ2軸センサに着座していることを確認してからボルトを締めるようにし、
Doボルトで引きつけながら着座させないようにしてください。
not attract by tightening bolts in this work.
Fig. 4.7 (d) Tightening order of bolts (J2 arm)
- 53 -
4. REPLACING PARTS
4.8
B-84195EN/02
REPLACING J3-AXIS MOTOR (M3)
Replacing procedure
1
Set a dial gauge at the J3-axis, and prepare for single axis mastering after replacement. Refer to
Subsection 6.4.
Fix the J3 arm such as putting it on the stand to prevent it from rotating when the motor is removed.
2
CAUTION
If the J3-axis is not supported correctly, the J3 arm may fall to the gravity
direction and collide surrounding when removing the J3-axis motor.
3
4
5
Turn off controller power.
Remove bolts (1). Then remove the J2 arm cover (tip side) (2) and the gasket (3).
According to Fig.5.3.3 (c), peel off the sheet J3 motor, then remove the connector (M3P) connected
to the J3-axis motor (5) and the relay connector(M3M3). To reuse the sheet J3 motor, be careful to the
following.

Carefully peel off the sheet J3 motor during being careful not to break it and no dirt adhere to it.
Remove bolts (4). Then remove the J3-axis motor (5) and the O-ring (8). In this time, be careful to the
following.

The tooth muscle of the gear (6) is diagonal. Therefore, when pulling out the motor, straightly
pull it during rotating the whole of the motor to axis rotation direction. If the motor is lay down
or removed without rotation, it might damage the gear teeth.

Grease will drop. So be careful the grease does not attach on the motor connectors or relay
connectors.
Wipe off grease on the gear (6). In this time, be careful not to damage the gear teeth.
Remove the connectors (M3M, M3BK) connected to the J3-axis motor (5).
Remove the bolt (7). Then pull out the gear (b) from the motor shaft.
6
7
8
9
1
2
3
5
6 7
8
4
Fig. 4.8 (a) Replacing the J3-axis motor
Parts name
1
2
3
4
GEOMET BOLT
J2 ARM COVER (TIP SIDE)
GASKET
BOLT
Specifications
A97L-0318-0426#4X12
A290-7702-X307
A290-7702-X314
A6-BA-5X16
- 54 -
Q’ty
6
1
1
4
Locking
Torque N-m
(kgf-cm)
4.5Nm (46kgfcm)
5.6Nm (57kgfcm)
4. REPLACING PARTS
B-84195EN/02
Parts name
5
6
7
8
10
11
12
13
14
15
16
17
18
J3-AXIS MOTOR
GEAR
BOLT
O RING
Specifications
A06B-2127-B303
A290-7702-X308
A6-BA-5X12
A98L-0001-0347#S46
Q’ty
1
1
1
1
Locking
Torque N-m
(kgf-cm)
LT243
7.9Nm (80kgfcm)
Replace the J3-axis motor (5) by new one. Then attach the bolt (7) and the gear (6).
Confirm dirt is not attached on the gear (6). If dirt is seen, remove it with air.
Apply 2ml grease on the opposite gear can be seen from the gear insert portion. Refer to Fig.4.8 (b).
Connect the connectors (M3M, M3BK) to the J3-axis motor (5).
Attach the J3-axis motor (5) with bolts (4). In this time, be careful to the following.

Be sure to install the O-ring (8).

When inserting the motor, be careful the motor does not tilt and the cable in the J2 arm contact
the motor.

The tooth muscle of the gear (6) is diagonal. Therefore, when inserting the motor, straightly insert
it during rotating the whole of the motor to axis rotation direction. If the motor is lay down or
inserted without rotation, it might damage the gear teeth.
Connect the connector (M3P) to the J3-axis motor (5). Then connect the relay connector (M3M3).
Refer to Fig. 5.3.3 (c).
Paste the sheet J3 motor referring to Fig.5.3.3 (c). In this time, be careful to the following.

If the sheet J3 motor is broken or cannot paste due to dirty, replace it by new one.
Attach the J2 arm cover (tip side) (2). In this time, be careful to the following.

When assembling the J2 arm cover (tip side), be careful not to sandwich the protection sheet and
cables.
Perform single axis mastering. Refer to Section 6.4.
Grease
グリース
Fig.4.8 (b) Grease applying area when replacing the J3-axis motor
- 55 -
4. REPLACING PARTS
4.9
B-84195EN/02
REPLACING J3-AXIS REDUCER
Replacing procedure
1
2
3
4
To remove the J3-axis reducer, set a dial gauge at the J3-axis, and prepare for single axis mastering
after replacement. Refer to Section 6.4.
Set the Quick Master Reference Position. Refer to the QUICK MASTERING section of the
mechanical unit operator’s manual (B-84194EN). (All the axes are set to 0º before shipment.
Move the robot to J2=J3=0°.Then move the robot so that the J2 arm cover (tip side) and the J3 casing
cover be removed. (recommended posture: J2=J3=0°, other axes are arbitrary)
To remove the J3-axis motor, fix the robot so that the J3-axis does not rotate by ways such as putting
the tip from J3 arm on the stand.
CAUTION
If the J3-axis is not supported correctly, the J3 arm may fall to the gravity
direction and collide surrounding when removing the J3-axis motor.
5
6
Turn off controller power.
According to the beginning of Chapter 4, take measures against static electricity.
CAUTION
Be sure to take measures against static electricity before removing the J3 casing
cover. If you touch the tool I/F board without measures, the tool I/F might break.
7
8
9
10
11
12
13
14
According to Fig. 4.10 (a) in Section 4.10, remove the J3 casing cover.
According to Fig.5.3.3 (a) in Subsection 5.3.3, cu the cable tie (3-C), then peel off the sheet J3 cover
from the clamp J4-1.
To reuse the sheet J3 cover, be careful to the following.

Carefully peel off the sheet J3 cover during being careful not to break it and no dirt adhere to it.

When reusing it, if the sheet J3 cover motor is broken or cannot paste due to dirty, replace it by
new one.
According to Fig. 5.3.3 (b) in Subsection 5.3.3, cut cable ties (3-A),(3-B), then remove the all relay
connectors (M456P3,M4M3,M5M3,M6M3,TS4,TS-J3,TS-J4,CAM-C or FS-C).
According to Fig.4.8 (a) in Section 4.8, remove the J2 arm cover (tip side).
According to Fig.5.3.3 (d), (e), remove the clamp J3-1A and the J3-1B, then pull out the J3 casing side
cables to the J2 arm side. Do not pull out cables forcibly during the relay connectors are caught in the
pipe.
According to Fig.5.3.3 (c), peel off the sheet J3 motor. Then remove the connector (M3P) connected
to the J3-axis motor and the relay connector (M3M3). To reuse the sheet J3 motor, be careful to the
following.

Carefully peel off the sheet J3 motor during being careful not to break it and no dirt adhere to it.
According to procedure 6 and Fig. 4.8 (a) in Section 4.8, remove the J3-axis motor. (Removing the
gear from the motor is not necessary.) In this time, grease will drip. So be careful not to adhere grease
to the motor connectors or relay connector.
Remove bolts (1). Then remove the J3 gearbox (2), the O-ring (3), the gear assembly (4), the wave
washer (5) and the plate (6). In this time, grease will drip. So be careful not to adhere grease to the
motor connectors or relay connector.
- 56 -
4. REPLACING PARTS
B-84195EN/02
6
5
4
3
2
1
Fig. 4.9 (a) Replacing the J3-axis reducer (1/2)
Parts name
15
1
2
3
BOLT
J3 GEARBOX
O RING
4
GEAR ASSY
5
6
WAVE WASHER
PLATE
Specifications
A6-BA-4X14
A290-7702-X304
A98L-0001-0347#S46
A290-7702-X309
A97L-0001-0984#88Z307
A97L-0001-0984#97Z307
A97L-0318-0499
A290-7702-X336
Q’ty
4
1
1
1
1
1
1
1
Locking
Torque N-m (kgf-cm)
4.5Nm (46kgfcm)
Remove bolts (7), (8). Then remove the J3-axis reducer (11) from the J2 arm using the removal taps
in Fig. 4.9 (c).
- 57 -
4. REPLACING PARTS
B-84195EN/02
12
13
14
11
10
9
7
8
Fig. 4.9 (b) Replacing the J3-axis reducer (2/2)
Parts name
Specifications
Q’ty
7
8
9
10
BOLT
BOLT
WAVE GENERATOR
BOLT
13
4
1
12
11
J3-AXIS REDUCER
12
13
14
WAVE WASHER
O RING
J3 SENSOR FLANGE
A6-BA-4X35
A6-BA-4X25
(Reducer appendix)
A6-BA-4X30
10iA, 10iA/L A97L-0318-0293#80
20iA/L
A97L-0318-0293#120
(Reducer appendix)
(Reducer appendix)
A290-7702-X315
Locking
Torque N-m (kgf-cm)
4.5Nm (46kgfcm)
4.5Nm (46kgfcm)
4.5Nm (46kgfcm)
1
1
1
1
*Other
bolts are M4 x 35
※その他のボルトはM4×35
Removal
taps
抜きタップ(M3)
(M3)
Bolt
ボルト
(M4
x25)
（M4×25）
Fig.4.9 (c) Position of the removal taps and tightening bolts for the J3-axis reducer
- 58 -
4. REPLACING PARTS
B-84195EN/02
16
17
18
19
20
21
22
Remove bolts (10). Then remove the J3-axis reducer (11) from the sensor flange (14).
Prepare the new J4-axis reducer (11). Apply 8ml grease to the sensor flange mounting part (part A)
referring to Fig. 4.3 (g).
Attach the new J3-axis reducer (11) with bolts (10). In this time, be careful to the following.

According to Fig. 4.3 (h) in Section 4.3, match the temporary fixing bolts of the J3-axis reducer
(11) and counter bore for temporary fixing bolt of the sensor flange.

Replace the O-ring (13) and the wave washer (12) by new articles and be sure to install them.

When tightening bolts (10), tighten the opposing side bolts evenly to 2.2Nm (22kgfcm). Then
tighten them to the regulated torque 4.5Nm (46kgfcm).
Before assembling the new wave generator (9), apply 17ml grease to the reducer inside, the bearing
(part B) of the wave generator (9). Refer to Fig. 4.3. (g) in Section 4.3.
Attach the new wave generator (9).
While rotating the wave generator (9), according to fig.4.9 (d), match the J3-axis reducer (11) phase.
According to Fig. 4.9 (e) and Section 4.22, clean the sealant and apply sealant on the J2 arm.
Taps
or Bolt (M4 x 25)
図4.9(c)の
inボルト(M4x25)用のタップ
Fig. 4.9 (c).
Match
the phase of the J3 casing
J3ケーシングと減速機の
部のボルトの位相を
and the bolts上図のように合わせること。
of
part the reducer as aboved figure
Fig. 4.9 (d) Phase of the J3-axis reducer
J2 base side
J2ベース側
Apply LOCTITE 518 to the dotted line.
部にロックタイト518を塗布のこと。
Fig. 4.9 (e) LOCTITE applying area of the J3-axis
- 59 -
4. REPLACING PARTS
23
23
24
25
B-84195EN/02
According to Fig.4.9 (c), (d), match the phase of the J3-axis reducer (11) and the J2 arm. According
to Fig.4.9 (c), attach the J3-axis reducer (11) with bolts (7), (8). When tightening bolts (7), (8), tighten
all bolt in diagonal order to 2.2Nm (22kgfcm), then tighten them to regulated torque torque4.5Nm
(46kgfcm).
Pass the cables pulled out at procedure 11 from the J2 arm side to the J3 casing side. Do not pull out
cables forcibly during the relay connectors are caught in the hollow hole.
According to Fig. 5.3.3 (d), (e), attach the clamp J3-1A and the J3-1B.
In order the plate (6), the wave washer (5), gear assembly (4), insert those to the J2 arm. Attach those
with bolt (1) so that the J3 gearbox (2) does not incline. In this time, be careful to the following.

Before inserting the gear assembly (4), according to Fig.4.9 (f), apply 2ml grease to the opposite
side gear can be seen from the gear assembly (4) insert position.

Be sure to install the O-ring (3).

When tightening bolts (1), tighten each bolt little by little in diagonal order so that the J3 gearbox
(2) is not installed in tilt status. Then tighten them to regulated torque 2.0Nm (20kgfcm).
Grease
グリース
Fig. 4.9 (f) Grease applying are when inserting the gear assembly (4)
26
27
28
29
30
31
According to procedure 14 and Fig. 4.8 (a), attach the J3-axis motor. In addition, according to Fig.4.8
(b) in Section 4.8, apply 27ml grease to the motor inserting positon before inserting the motor.
According to Fig. 5.3.3 (c), connect the connector (M3P) to the J3-axis motor. Then connect the relay
connector (M3M3).
According to Fig.5.3.3 (c), attach the sheet J3 motor. In this time, be careful to the following.

If the sheet J3 motor is broken or cannot paste due to dirty, replace it by new one.
According to Fig. 4.8 (a) in Section 4.8, assemble the J2 arm cover (tip side), be careful not to
sandwich the protection sheet or cables.
According to Fig. 4.10 (b) in Section 4.10, remove the tool I/F board cover and the clamp J3-2.
According to Fig.5.3.3 (b) in Subsection 5.3.3, pass the cable tie (3-A),(3-B) thorough the two part,
then attach it again. Tighten the I/F board cover to regulated torque 0.9Nm(9kgfcm).
According to reversed sequence of the procedure 7 to 9, wire the cables in the J3 casing, then attach
the J3 casing cover. In this time, be careful to the following.

(If the camera cable is specified) After connecting the camera cable connector, wind insulation
tape 2 round or motor to cover the connector whole referring to Fig. 5.3.1 (l) in Subsection 5.3.1.

When assembling the J3 arm cover, be careful not to sandwich the protection sheet and cables.
- 60 -
4. REPLACING PARTS
B-84195EN/02
32
Perform quick mastering and perform single axis mastering of J3-axis. Refer to the QUICK
MASTERING section of the mechanical unit operator’s Manual (B-84194EN) and Section 6.4 of this
manual.
4.10
REPLACING J3-AXIS SENSOR
REPLACING PROCEDURE
1
To remove the parts attached to the J3, J4-axis reducer, set a dial gauge at the J3, J4-axis, and prepare
for single axis mastering after replacement. Refer to Section 6.4.
Set the Quick Master Reference Position. Refer to the QUICK MASTERING section of the
mechanical unit operator’s manual (B-84194EN). (All the axes are set to 0º before shipment.
Move the robot to J2=J3=J4=0°.Then move the robot so that the J3 casing cover and the J3 arm unit
can be removed. (recommended posture: J2=J3=J4=0°, other axes are arbitrary)
Turn off controller power.
According to top of Chapter 4, take measures against static electricity.
2
3
4
5
CAUTION
Be sure to take measures against static electricity before removing the J3 casing
cover. If you touch the tool I/F board
without measures, the tool I/F might break.
6
Remove bolts (1). Then remove the J3 casing cover (2) and the gasket (3).
3
2
1
Fig. 4.10 (a) Replacing the J3-axis sensor (1/3)
1
2
3
7
Parts name
Specifications
GEOMET BOLT
J3 CASING COVER
GASKET
A97L-0318-0426#4X12
A290-7702-X405
A290-7702-X414
Q’ty
5
1
1
Locking
Torque N-m (kgf-cm)
4.5Nm (46kgfcm)
Cut the cable tie (3-C). Then peel off the sheet J3 cover from the clamp J4-1. Refer to Fig.5.3.3 (a) in
Subsection 5.3.3. To reuse the sheet J3 cover, be careful to the following.

Carefully peel off the sheet J3 motor during being careful not to break it and no dirt adhere to it.

When reusing it, if the sheet J3 motor is broken or cannot paste due to dirty, replace it by new
one.
- 61 -
4. REPLACING PARTS
8
9
10
B-84195EN/02
Cut cable ties (3-A),(3-B). Then remove the all rely connectors (M456P3,M4M3,M5M3,M6M3,TS4,
TS-J4, CAM-C or FS-C). Refer to Fig. 5.3.3 (b) in Subsection 5.3.3.
Remove the screws (4). Then remove the tool I/F board cover (5).
Remove all connectors (CRS54, CRS55) connected to the tool I/F board. Refer to Fig. 5.3.3 (b) in
Subsection 5.3.3.
10
9
8
7
6
5
4
Fig. 4.10 (b) Replacing the J3-axis sensor (2/3)
Parts name
4
5
6
7
8
9
10
11
12
13
14
15
16
SCREW
TOOL I/F BOARD COVER
SPACER BOLT
TOOL I/F BOARD
BOLT
CLAMP J3-2
J3 SPACER
Specifications
A6-SW2NA-3X6S
A290-7702-X417
A97L-0218-0745#10
A20B-8102-0360
A6-BA-3X8
A290-7702-X419
A290-7702-X317
Q’ty
Locking
3
1
3
1
3
1
3
Remove the spacer bolts (6). Then remove the tool I/F board (7).
Remove bolts (8). Then remove the clamp J3-2 (9).
Remove the J3 spacer (10).
Remove the J3 arm unit referring to Fig. 4.12 (a) in Section 4.12.
Remove bolts (11). Then remove the washers (12) and the J3 casing (13).
Remove bolts (14). Then remove the J3-axis sensor (15).
- 62 -
Torque N-m
(kgf-cm)
0.9Nm (9kgfcm)
0.9Nm (9kgfcm)
4. REPLACING PARTS
B-84195EN/02
13
16
12
15
14
11
Fig. 4.10 (c) Replacing the J3-axis sensor (3/3)
Parts name
11
12
BOLT
J3 WASHER PLATE
13
J3 CASING
14
15
16
BOLT
J3 SENSOR
J3 SENSOR FLANGE
17
18
Specifications
Q’ty
A6-BA-6X22
A290-7702-X418
10iA, 10iA/L A290-7702-X401
20iA/L
A290-7702-Y401
A6-BA-6X22
A97L-0318-0700
A290-7702-X315
16
4
Locking
Torque N-m (kgf-cm)
15.3 Nm (156kgfcm)
1
16
1
1
15.3 Nm (156kgfcm)
Replace the J3-axis sensor (15). Then fit the sensor so that not to damage the faucet joint of the J3axis sensor flange (16) and prevent the J3-axis sensor (15) becomes in a tilted status. In this time,
confirm the tap hole position of the J3-axis sensor flange, match the phase of the J3-axis sensor (15).
(See Fig. 4.10 (d).)
Attach the J3-axis sensor (15) with bolts referring to the tightening procedure in Fig.4.10 (d). In this
time, be careful to the following.

Tighten bolts after conforming the J3-axis sensor (15) adhered to the J3-axis sensor flange (16).
Do not attract by tightening bolts in this work.

When tightening four bolts temporarily at first, tighten little by little so that the load is applied
evenly to the J3-axis sensor (15) whole.
WARNING
If assembling is performed incorrectly, safety function may lost, and it may cause
injury of the personnel.
- 63 -
4. REPLACING PARTS
B-84195EN/02
Confirm
the tap positon of the sensor flange, then
センサフランジのタップ位置を確認し、
match
the sensor cable phase.
センサのケーブルの位相を合わせてください。
4
8
13
12
9
16
5
2
1
6
15
10
11
J2
base side
J2ベース側
7
14
3
Tap
positon of the sensor flange
センサフランジのタップ位置
Tightening procedure
1 締結手順
To prevent the sensor from being assembled in a tilted position,tighten the four bolts
11.toセンサが傾いた状態で組み付かないようにするため、センサ全体で均一に
4 l little by little and evenly so that the bolt load is evenly placed to the whole sensor. (*)
2 Temporarily
tighten the remaining bolts
in the
order of 5 to 16.
ボルトの負荷がかかるよう、
1 から
4 の4本のボルトを少しずつ均等に仮締めします。(*)
3 Tighten
with half the 5specified
in the order of 1 to 16 to 7.7Nm (79kgfcm).
2. 残りのボルトを
から 16torque
の順に仮締めします。
4 Tighten
with
specified torque in the order of 1 to 16 to regulated torque 15.3Nm (156kgfcm)
3. 1 から
16the
の順に7.7Nm(79kgfcm)で締めます。
4. 1 から 16 の順に規定トルク15.3Nm(156kgfcm)で締めます。
(*)(*)
Tighten
bolts after conforming the sensor adhered to the sensor flange.
センサがセンサフランジに着座していることを確認してからボルトを締めるようにし、
Do not
attract by tightening bolts in this work.
ボルトで引きつけながら着座させないようにしてください。
Fig. 4.10 (d) Tightening order of bolts (J3-axis sensor)
19
20
Fit the sensor so that not to damage the faucet joint of the J3-axis sensor (15) and prevent the J3 casing
(13) becomes in a tilted status. In this time, confirm the cable positon of the J3-axis sensor (15), match
the phase of the J3 casing (13). In addition, confirm that the notch of the J3 casing (13) matches the
phase of the J3 spacer installation tap. (Refer to Fig.4.10 (e))
According to the tightening procedure in Fig.4.10 (e), attach the J3 casing (13) with the J3 washer
plate (12) and bolts (11). In this time, be careful to the following.

Tighten after conforming the J3 casing (13) adhered to the J3-axis sensor (16). Do not attract by
tightening bolts in this work.

When tightening four bolts temporarily at first, tighten little by little so that the load is applied
evenly to the J3 casing (13) whole.
WARNING
If assembling is performed incorrectly, safety function may lost , and it may
cause injury of the personnel.
21
Attach the J3 spacer during be careful to the installation positon. (Refer to Fig. 4.10 (e))
- 64 -
4. REPLACING PARTS
B-84195EN/02
Be careful to the install position of the J3
J3スペーサ(3本)の組み付け位置に
spacer (3 pcs)
注意すること。
4
A
8
13
12
9
16
5
2
1
6
15
10
Detail
詳細 A
A
Notch
：切り欠き部
Confirm the sensor cable
センサのケーブル位置を確認し、
position, then match the
11
J3ケーシングの位相を合わせて
J3 casing phase.
ください。
7
J2
base side
J2ベース側
14
3
Tightening procedure
1 締結手順
To prevent the J3 casing from being assembled in a tilted position,tighten the four bolts
to 4 l little by little and evenly so that the bolt load is evenly placed to the whole sensor. (*)
1.1 J3ケーシングが傾いた状態で組み付かないようにするため、締結部品全体で均一に
2 Temporarily
tighten the remaining bolts
in the4order
of 5 to 16.
ボルトの負荷がかかるよう、
1 から
の4本のボルトを少しずつ均等に仮締めします。(*)
3 Tighten with half the specified torque in the order of 1 to 16 to 7.7Nm (79kgfcm).
2.
残りのボルトを
5
から
16
の順に仮締めします。
4 Tighten with the specified torque in the order of 1 to 16 to regulated torque 15.3Nm (156kgfcm)
3. 1 から 16 の順に7.7Nm(79kgfcm)で締めます。
4. 1 から 16 の順に規定トルク15.3Nm(156kgfcm)で締めます。
(*)
bolts after conforming the J3 caisng adhered to the sensor.
(*) Tighten
J3ケーシングがセンサに着座していることを確認してからボルトを締めるようにし、
Do ボルトで引きつけながら着座させないようにしてください。
not attract by tightening bolts in this work.
Fig. 4.10 (e) Tightening order of bolts (J3 casing installation) and the J3 spacer installation position
22
23
24
25
26
27
28
Attach the J3 arm unit referring to procedure 36 and Fig. 4.12 (a) in Section 4.12.
According to Fig.5.3.3 (b) in Subsection 5.3.3, pass the cable tie (3-B) which fix cables through the
clamp J3-2 (9). Then attach the clamp J3-2 (9) with bolts (8).
Attach the tool I/F board (7) with regulated Torque 0.9Nm(9kgfcm) with spacer bolts (6).
Connect the connectors (CRS54, CRS55) to the tool I/F board (7) referring to Fig.5.3.3 (b) in
Subsection 5.3.3.
According to Fig.5.3.3 (b) in Subsection 5.3.3, pass the cable tie (3-A) which fix cables on the tool I/F
board cover (5). Then tighten the too I/F board cover (5) with screws (4) to regulated torque 0.9Nm
(9kgfcm).
According to the reversed sequence of procedure 6 to 8, wire the cables in the J3 casing. Then attach
the J3 casing cover (5) In this time, be careful to the following.

(If the camera cable is specified) After connecting the camera cable connector, wind insulation
tape 2 round or motor to cover the connector whole referring to Fig. 5.3.1 (l) in Subsection 5.3.1.
 When assembling the J3 casing cover, be careful not to sandwich the protection sheet and cables.
Perform quick mastering and perform single axis mastering of J3,J4-axis. Refer to the QUICK
MASTERING section of the mechanical unit operator’s Manual (B-84194EN) and Section 6.4 of this
manual.
- 65 -
4. REPLACING PARTS
4.11
B-84195EN/02
REPLACING J4-AXIS MOTOR (M4)
Replacing procedure
1
Set a dial gauge at the J4-axis, and prepare for single axis mastering after replacement. Refer to
Subsection 6.4.
Set the Quick Master Reference Position. Refer to the QUICK MASTERING section of the
mechanical unit operator’s manual (B-84194EN). (All the axes are set to 0º before shipment.
Turn off controller power.
Remove bolts (1). Then remove the J3 arm cover (2) and the gasket (3).
Cut cable ties (4-B), (4-C). Then remove the relay connectors (M5M4, M6M4, M5P4, M6P4, TS5,
CAM-D or FS-D) referring to Fig.5.3.4 (a) in Subsection 5.3.4.
2
3
4
5
3
2
1
Fig. 4.11 (a) Replacing the J4-axis motor (1/3)
1
2
3
6
Parts name
GEOMET BOLT
J3 ARM COVER
GASKET
Specifications
A97L-0318-0426#4X12
A290-7702-X406
A290-7702-X415
Q’ty
4
1
1
Locking
Torque N-m (kgf-cm)
4.5Nm (46kgfcm)
Remove the J4-axis cover (4).
4
4
Fig.4.11 (b) Replacing the J4-axis motor (2/3)
Parts name
4
J4 AXIS COVER
Specifications
10iA, 10iA/L
A290-7702-X409
20iA/L
A290-7702-Y409
- 66 -
Q’ty
2
Locking
Torque N-m (kgf-cm)
4. REPLACING PARTS
B-84195EN/02
7
Remove bolts (5). Then remove the O-ring (7) and the J3 arm unit (6). In this time, pull out cables in
the J3 arm to the J4 unit side. Do not pull out cables forcibly during the relay connectors are caught.
Peel of the sheet J4 motor, remove all connectors (M4M, M4BK, M4P) connected to the J4-axis motor.
Refer to Fig. 5.3.4 (b). To reuse the sheet J4 motor, be careful to the following.
 Carefully peel off the sheet J4 motor during being careful not to break it and no dirt adhere to it.
Remove bolts (8). Then remove the J4-axis motor (9) and the O-ring (12). In this time, be careful to
the following.

The tooth muscle of the gear (10) is diagonal. Therefore, when pulling out the motor, straightly
pull it during rotating the whole of the motor to axis rotation direction. If the motor is lay down
or removed without rotation, it might damage the gear teeth.

Grease will drop. So be careful the grease does not attach on the motor connectors or relay
connectors.
Wipe off grease on the gear (10). In this time, be careful not to damage the gear teeth.
Remove bolts (11). Then pull out the gear (10) from the motor shaft.
Replace the J4-axis motor (9) bye new one. Then attach the bolt (11) and the gear (10).
8
9
10
11
12
7
10
11
5
12
9
8
6
Fig. 4.11 (c) Replacing the J4-axis motor (3/3)
Parts name
5
BOLT
6
J3 ARM UNIT
7
O RING
8
9
BOLT
J4-AXIS MOTOR
10
GEAR
11
12
BOLT
O RING
13
14
Specifications
10iA, 10iA/L
A6-BA-3X12
20iA/L
A6-BA-3X14
10iA, 10iA/L
A290-7702-T501
20iA/L
A290-7702-T511
10iA, 10iA/L
A98L-0001-0347#S80
20iA/L
A98L-0001-0347#S90
A6-BA-4X12
A06B-2123-B303
10iA, 10iA/L
A290-7702-X407
20iA/L
A290-7702-Y407
A97L-0218-0504#M3X10
A98L-0001-0347#S35
Q’ty
Locking
12
Torque N-m (kgf-cm)
2.0Nm (20kgfcm)
1
1
2
1
4.5Nm (46kgfcm)
1
1
1
LT243
2.0Nm (20kgfcm)
Confirm dirt is not attached on the gear (10). If dirt is seen, remove it with air.
According to Fig.4.11 (d), apply 2ml grease to the opposite gear can be seen from the gear inserting
position.
- 67 -
4. REPLACING PARTS
15
16
17
18
19
B-84195EN/02
Attach the J4-axis motor (9) with bolts (8). In this time, be careful to the following.

Be sure to install the O-ring (12).

The tooth muscle of the gear (10) is diagonal. Therefore, when inserting the motor, straightly
insert it during rotating the whole of the motor to axis rotation direction. If the motor is lay down
or inserted without rotation, it might damage the gear teeth.
According to Fig.5.3.4 (b), connect the connectors (M4M,M4BK,M4P) to the J4-axis motor. Then
paste the sheet J4 motor. In this time, be careful to the following.

Tighten the J4-axis motor connector (M4M,M4BK) to 0.11Nm(1.1kgfcm).

If the sheet J4 motor is broken or cannot paste due to dirty, replace it by new one.
During passing the J4 unit cable from the J4 unit side to the J3 arm side, Then attach the O-ring (7)
and the J3 arm unit (6) with bolts (5). In this time, be careful to the following.

Be sure to install the O-ring (7).

Do not pull out cables forcibly during the relay connectors are caught.

When tightening bolts (5), tighten all bolts in diagonal order to regulated torque 2.0Nm
(20kgfcm).
According to the reversed sequence of procedure 4 to 6, wire the cable in the J3 arm, then attach the
J4-axis cover and the J3 arm cover. In this time, be careful to the following.

(If the camera cable is specified) After connecting the camera cable connector, wind insulation
tape 2 round or motor to cover the connector whole referring to Fig. 5.3.1 (l) in Subsection 5.3.1.

When assembling the J3 arm cover, be careful not to sandwich the cables.
Perform quick mastering and perform single axis mastering of J4-axis. Refer to the QUICK
MASTERING section of the mechanical unit operator’s Manual (B-84194EN) and Section 6.4 of this
manual.
Grease
グリース
Fig. 4.11 (d) Grease applying area when the J4-axis motor is replaced
- 68 -
4. REPLACING PARTS
B-84195EN/02
4.12
REPLACING J4-AXIS REDUCER
Replacing procedure
Procedure 1-15 (Common to CRX-10iA, CRX-10iA/L, CRX-20iA/L)
1
To remove the J4-axis reducer, set a dial gauge at the J4-axis, and prepare for single axis mastering
after replacement. Refer to Section 6.4.
2
Set the Quick Master Reference Position. Refer to the QUICK MASTERING section of the
mechanical unit operator’s manual (B-84194EN). (All the axes are set to 0º before shipment.
3
Move the robot to J4=0°.Then move the robot so that the J3 casing cover, the J3 arm cover and the J3
arm unit can be removed. (recommended posture: J3=J4=0°, other axes are arbitrary)
4
Turn off controller power.
5
According to Fig.4.11 (a) in Section 4.11, remove the J3 arm cover.
6
According to Fig. 5.3.4 (a) in Subsection 5.3.4, cut cable ties (4-A),(4-C), then remove the all relay
connectors (M5M4, M6M4, M5P4, M6P4,TS5, CAM-D or FS-D).
7
According to the beginning of Chapter 4, take measures against static electricity.
CAUTION
Be sure to take measures against static electricity before removing the J3 casing
cover. If you touch the tool I/F board without measures, the tool I/F might break.
8
9
According to Fig. 4.10 (a) in Section 4.10, remove the J3 casing cover.
According to Fig.5.3.3 (a) in Subsection 5.3.3, cut the cable tie (3-C), then remove the sheet J3 cover
from the clamp J4-1. To reuse the sheet J3 motor, be careful to the following.

Carefully peel off the sheet J3 cover during being careful not to break it and no dirt adhere to it.

When reusing it, if the sheet J3 motor is broken or cannot paste due to dirty, replace it by new
one.
According to Fig.5.3.3 (b), cut the cable tie (3-A), then remove the all relay connectors (M456P3,
M4M3,M5M3,M6M3,TS4, TS-J4, CAM-C or FS-C).
According to Fig. 4.11 (b) in Section 4.11, remove the J4-axis cover,
Remove bolts (1). Then remove the J3 arm unit (2).
10
11
12
2
1
Fig. 4.12 (a) Replacing the J4-axis reducer (1/3)
Parts name
1
2
BOLT
J3 ARM UNIT
Specifications
A6-BA-3X25
10iA, 10iA/L
20iA/L
Q’ty
12
A290-7702-T501
A290-7702-T511
- 69 -
1
Locking
Torque N-m
(kgf-cm)
2.0Nm (20kgfcm)
4. REPLACING PARTS
13
B-84195EN/02
Remove bolts (3). Then remove the J4 unit (4) from the J3 arm unit (2). In this time, pull out cable in
the J3 arm tip side to the J4 unit side. Do not pull out cables forcibly during the relay connectors are
caught.
4
3
Fig. 4.12 (b) Replacing the J4-axis reducer (2/3)
Parts name
14
15
3
BOLT
4
J4 UNIT
Specifications
10iA, 10iA/L
A6-BA-3X12
20iA/L
A6-BA-3X14
10iA, 10iA/L
A290-7702-V401
20iA/L
A290-7702-V411
Q’ty
12
Locking
Torque N-m (kgf-cm)
2.0Nm (20kgfcm)
1
According to Fig.5.3.4 (b) in Subsection 5.3.4, peel off the sheet J4 motor, then remove the connectors
(M4M, M4BK, M4P) connected to the J4-axis motor. To reuse the sheet J4 motor, be careful to the
following.

Carefully peel off the sheet J4 motor during being careful not to break it and no dirt adhere to it.
According to Fig.5.3.4 (b) in Subsection 5.3.4, cut the cable tie (4-E).
Procedure 16-29 (CRX-10iA, CRX-10iA/L)
16 Remove bolts (5). Then remove the clamp J4-2 (6).
- 70 -
4. REPLACING PARTS
B-84195EN/02
6
7
5
8
9
10
13
14
11
12
15
16
17
18
19
20
21
Fig. 4.12 (c) Replacing the J4-axis reducer (3/3) (CRX-10iA, CRX-10iA/L)
CRX-10iA, CRX-10iA/L
5
6
7
8
9
Parts name
BOLT
CLAMP J4-2
BOLT
J4 GEARBOX
O RING
10
GEAR ASSEMBLY
11
12
13
14
15
16
17
18
19
20
21
WAVE WASHER
PLATE
BOLT
BOLT
J4 FLANGE
O RING
WAVE GENERATOR
BOLT
J4-AXIS REDUCER
WAVE WASHER
O RING
Specifications
A6-BA-3X8
A290-7702-X421
A6-BA-3X12
A290-7702-X404
A98L-0001-0347#S29
A290-7702-X408
A97L-0001-0984#86Z307
A97L-0001-0984#84Z307
A97L-0318-0500
A290-7702-X426
A6-BA-3X22
A6-BA-3X30
A290-7702-X403
(Reducer appendix)
(Reducer appendix)
A6-BA-3X25
A97L-0318-0294#50
(Reducer appendix)
(Reducer appendix)
- 71 -
Q’ty
2
1
4
1
1
1
1
1
1
1
3
9
1
1
1
12
1
1
1
Locking
Torque N-m (kgf-cm)
2.0Nm (20kgfcm)
2.0Nm (20kgfcm)
2.0Nm (20kgfcm)
2.0Nm (20kgfcm)
4. REPLACING PARTS
17
18
19
20
B-84195EN/02
Pull out J4-axis sensor side cables to the J4-axis motor side. Do not pull out cables forcibly during the
relay connectors are caught in the pipe.
According to Fig.4.11 (c) in Section 4.11, remove the J4-axis motor.
Remove bolts (7). Then remove the J4 gearbox (8), the O-ring (9), the gear assembly (10), the wave
washer (11) and the plate (12).
Remove bolts (13), (14). Then remove the J4 flange (15) using the removal taps in Fig.4.12 (d).
Bolts
ボルト
(M3 x 22)
(M3x22)
Removal tap
(M3)
抜きタップ(M3）
Removal tap
抜きタップ(M3）
(M3)
*Other bolts are M3 x 30
※その他のボルトはM3x30
Fig.4.12 (d) Position of the removal taps and tightening bolt for J4-axis reducer (CRX-10iA, CRX-10iA/L)
21
22
23
24
25
26
27
Remove bolts (18), then remove the J4-axis reducer (19).
Prepare the new J4-axis reducer (19). According to Fig. 4.3 (g) in Section 4.3, apply 4ml grease on
the sensor flange mounting part (part A).
Attach the new J4-axis reducer (19) with bolts (18). In this time, be careful to the following.

According to Fig. 4.3 (h) in Section 4.3, match the temporary fixing bolts of the J4-axis reducer
(13) and counter bore for temporary fixing bolt of the J1 sensor flange (15).

Be sure to replace the O-ring (16), (21) and the wave washer (20) by new articles and install them.

When tightening bolts (18), tighten the opposing side bolts evenly to 1.0Nm(10kgfcm). Then
tighten them to the regulated torque 2.0Nm(20kgfcm).
Before assembling the new wave generator (17), apply 7ml grease to the reducer inside, the bearing
(part B) of the wave generator (17). Refer to Fig. 4.3. (g) in Section 4.3.
Attach the new wave generator (17).
Match the phase of the J4-axis reducer (19) during rotating the wave generator (17). Refer to Fig. 4.12
(e).
According to Fig.4.12 (f) and Section 4.22, clean the sealant surface, then apply sealant on the J4
flange (15).
- 72 -
4. REPLACING PARTS
B-84195EN/02
Circular
Cross
roller サーキュラ
クロスローラ
spline
bearing
ベアリング スプライン
C
B
Section
断面 C-C
C-C
C
B
Detail
詳細 A
A
Section
断面 B-BB-B
(tap (a))
(タップ(a)
Tap of the bolt (M3 x 22)
in
Fig.4.12 (d)
図4.12(d)のボルト(M3x22)のタップ
A
Tap (a) for the reducer
：減速機取付用のタップ(a)
Clamp
J4-1
クランプJ4-1
Match the phase of the clamp J4-1 and
クランプJ4-1と減速機取付用のタップ(a)の位相を
the tap (a)
of the 上図のように合わせること。
reducer, match thems as aboved figure.
Fig. 4.12 (e) Phase of the J4-axis reducer (CRX-10iA, CRX-10iA/L)
Apply LOCTITE 518 to the dotted line.
部にロックタイト518を塗布のこと。
Fig.4.12 (f) Applying of LOCTITE (CRX-10iA, CRX-10iA/L)
28
According to Fig.4.12 (d), (e), match the phase of the J4-axis reducer (19) and the J4 flange (15). Then
according to Fig.4.12 (d), attach the J4flange (15) with bolts (13), (14). When tightening bolts (13),
(14), tighten the opposing bolts evenly to 1.0Nm(10kgfcm), then tighten it to torque 2.0Nm(20kgfcm).
- 73 -
4. REPLACING PARTS
29
B-84195EN/02
Insert parts to the J4 flange (15) in order of the plate (12), the wave washer (11), gear assembly (10).
Then attach the J4 gearbox (8) with bolts (7). In this time, be careful to the following.

Before inserting the gear assembly (10), according to Fig.4.12 (g), apply 2ml grease to the
opposite side gear can be seen from the gear assembly (10) insert position.

Be sure to insert the O-ring (9).

When tightening bolts (7), tighten bolt little by little evenly so that the J4 gearbox (8) does not
tilt. Then tighten to regulated torque 2.0Nm (20kgfcm).
Grease
グリース
.
Fig.4.12 (g) Grease applying are when inserting the gear assembly (10)
Procedure16-29 (CRX-20iA/L)
16 Remove bolts (5). Then remove the clamp J4-2 (6).
- 74 -
4. REPLACING PARTS
B-84195EN/02
6
7
8
5
13 12
9
10
11
14
15
16
17
18
19
20
21
Fig. 4.12 (h) Replacing the J4-axis reducer (3/3) (CRX-20iA/L)
CRX-20iA/L
5
6
7
8
9
10
Parts name
BOLT
CLAMP J4-2
BOLT
J4 GEARBOX
O RING
WAVE WASHER
11
GEAR ASSY
12
13
14
15
16
17
18
19
20
21
BOLT
BOLT
J4 FLANGE
O RING
O RING
WAVE GENERATOR
BOLT
J4-AXIS REDUCER
WAVE WASHER
O RING
Specifications
A6-BA-3X8
A290-7702-X421
A6-BA-3X12
A290-7702-Y404
A98L-0001-0347#S29
A97L-0318-0729
A290-7702-Y408
A97L-0001-0984#86Z307
A97L-0001-0984#84Z307
A6-BA-3X25
A6-BA-3X50
A290-7702-Y403
(Reducer appendix)
(Reducer appendix)
(Reducer appendix)
A6-BA-3X22
A97L-0318-0315#80
(Reducer appendix)
(Reducer appendix)
- 75 -
Q’ty
2
1
4
1
1
1
1
1
1
14
2
1
1
1
1
12
1
1
1
Locking
Torque N-m (kgf-cm)
2.0Nm (20kgfcm)
2.0Nm (20kgfcm)
2.0Nm (20kgfcm)
2.0Nm (20kgfcm)
4. REPLACING PARTS
17
18
19
20
B-84195EN/02
Pull out J4-axis sensor side cables to the J4-axis motor side. Do not pull out cables forcibly during the
relay connectors are caught in the pipe.
According to Fig.4.11 (c) in Section 4.11, remove the J4-axis motor.
Remove bolts (7). Then remove the J4 gearbox (8), the O-ring (9), the wave washer (10) and the gear
assembly (11).
Remove bolts (12), (13). Then remove the J4 flange (14).
Fig.4.12 (i) Position of the tightening bolt for J4-axis reducer (CRX-20iA/L)
21
22
23
24
25
26
Remove bolts (18), then remove the J4-axis reducer (19).
Prepare the new J4-axis reducer (19). According to Fig. 4.3 (g) in Section 4.3, apply 4ml grease on
the sensor flange mounting part (part A).
Attach the new J4-axis reducer (19) with bolts (18). In this time, be careful to the following.

According to Fig. 4.3 (h) in Section 4.3, match the temporary fixing bolts of the J4-axis reducer
(13) and counter bore for temporary fixing bolt of the J1 sensor flange (15).

Be sure to replace the O-ring (15), (16), (21) and the wave washer (20) by new articles and install
them.

When tightening bolts (18), tighten the opposing side bolts evenly to 1.0Nm(10kgfcm). Then
tighten them to the regulated torque 2.0Nm(20kgfcm).
Before assembling the new wave generator (17), apply 7ml grease to the reducer inside, the bearing
(part B) of the wave generator (17). Refer to Fig. 4.3. (g) in Section 4.3.
Attach the new wave generator (17).
Match the phase of the J4-axis reducer (19) during rotating the wave generator (17). Refer to Fig. 4.12
(j).
Fig. 4.12 (j) Phase of the J4-axis reducer (CRX-20iA/L)
- 76 -
4. REPLACING PARTS
B-84195EN/02
27
28
According to Fig.4.12 (i), (j), match the phase of the J4-axis reducer (19) and the J4 flange (14). Then
according to Fig.4.12 (i), attach the J4flange (14) with bolts (12), (13). When tightening bolts (12),
(13), tighten the opposing bolts evenly to 1.0Nm(10kgfcm), then tighten it to torque 2.0Nm(20kgfcm).
According to Fig.4.12 (k), paste the wave washer (10) to the J4 gearbox (8) with the grease.
図 4.12 (k) Pasting of the wave washer to the J4 gearbox (CRX-20iA/L)
29
Insert the gear assembly (10) to the J4 flange (14). Then attach the J4 gearbox (8) with bolts (7). In
this time, be careful to the following.

Before inserting the gear assembly (10), according to Fig.4.12 (g), apply 2ml grease to the
opposite side gear can be seen from the gear assembly (10) insert position.

Be sure to insert the O-ring (9).

When tightening bolts (7), tighten bolt little by little evenly so that the J4 gearbox (8) does not
tilt. Then tighten to regulated torque 2.0Nm (20kgfcm).
Procedure 30-39 (Common to CRX-10iA, CRX-10iA/L, CRX-20iA/L)
30 According to procedure 15 and Fig. 4.11 (c) in Section 4.11, attach the J4-axis motor. In addition,
according to Fig.4.11 (d) in Section 4.11, apply 14ml grease to the motor inserting positon before
inserting the motor.
31 Pass the cables pulled out at procedure 17 from the J4-axis motor side to the J4-axis sensor side. Do
not pull out cables forcibly during the relay connectors are caught in the pipe.
32 Attach the clamp J4-1 (6) with bolts (5).
33 According to Fig.5.3.4 (b) in Subsection 5.3.4, fix the cables on the clamp J4-1 with the cable tie (4E).
34 According to Fig.5.3.4 (b) in Subsection 5.3.4, connect the connectors (M4M, M4BK,M4P) to the J4axis motor, paste the sheet J4 motor. In this time, be careful to the following.

Tighten J4-axis motor connectors (M4M,M4BK) to 0.11Nm(1.1kgfcm).

If the sheet J4 motor is broken or cannot paste due to dirty, replace it by new one.
35 During the pass the cables in the J4 unit (4) from the J4 unit side to the J3 arm side, attach the J4 unit
(4) to the J3 arm unit (2). In this time, be careful to the following.

Do not pull out cables forcibly during the relay connectors are caught

When tightening bolts (3), tighten all bolts in diagonal order to regulated torque 2.0Nm
(20kgfcm).
36 Attach the J3 arm unit (2) with bolt (1). In this time, be careful to the following.

When tightening bolts (1), tighten all bolts in diagonal order to regulated torque 2.0Nm(20kgfcm).
37 According to Fig.5.3.3 (b) in Subsection 5.3.3, pass the cable tie (3-A) which fix cables on the tool I/F
board. Then attach the tool I/F board cover with regulated torque 0.9Nm (9kgfcm) using screws (4 in
Fig.4.10 (b)) (Refer to Fig.4.10 (b) in Section 4.10)
38 According to the reversed sequence of procedure 5 to 11, wire the cables in the J3 casing, attach the
J4-axis cover and the J3 casing cover. Wire the cable in the J3 arm. Then attach the J3 arm cover. In
this time, be careful to the following.
- 77 -
4. REPLACING PARTS
B-84195EN/02

39
(If the camera cable is specified) After connecting the camera cable connector, wind insulation
tape 2 round or motor to cover the connector whole referring to Fig. 5.3.1 (l) in Subsection 5.3.1.

When assembling the J3 casing cover and the J3 arm cover, be careful not to sandwich the
protection sheet and cables.
Perform quick mastering and perform single axis mastering of J4-axis. Refer to the QUICK
MASTERING section of the mechanical unit operator’s Manual (B-84194EN) and Section 6.4 of this
manual.
4.13
REPLACING J4-AXIS SENSOR
REPLACING PROCEDURE
1
2
3
4
5
To remove the parts attached to the J4-axis reducer, set a dial gauge at the J4-axis, and prepare for
single axis mastering after replacement. Refer to Section 6.4.
Set the Quick Master Reference Position. Refer to the QUICK MASTERING section of the
mechanical unit operator’s manual (B-84194EN). (All the axes are set to 0º before shipment.
Move the robot to J4=0°.Then move the robot so that the J3 casing cover and the J3 arm unit can be
removed. (recommended posture ：J3=0°,J4=0°, other axes are arbitrary)
Turn off controller power.
According to the beginning of Chapter 4, take measures against static electricity.
CAUTION
Be sure to take measures against static electricity before removing the J3 casing
cover. If you touch the tool I/F board without measures, the tool I/F might break.
6
7
8
9
10
11
Remove the J3 casing cover referring to Fig.4.10 (a) in Section 4.10.
Cut the cable tie (3-C). Then peel off the sheet J3 cover from the clamp J4-1. Refer to Fig.5.3.3 (a) in
Subsection 5.3.3. To reuse the sheet J3 motor, be careful to the following.

Carefully peel off the sheet J3 cover during being careful not to break it and no dirt adhere to it.

When reusing it, if the sheet J3 motor is broken or cannot paste due to dirty, replace it by new
one.
Cut the cable tie (3-A), then remove the all relay connectors (M456P3, M4M3, M5M3, M6M3,TS4,
TS-J4, CAM-C or FS-C) referring to Fig.5.3.3 (b) in Subsection 5.3.3.
Remove the J3 arm unit referring to Fig.4.12 (a) in Section 4.12.
Cut the cable tie (4-E). Then remove the sheet J4-1. Refer to Fig.5.3.4 (b) in Subsection 5.3.4.
Remove bolts (1). Then remove the clamp J4-1 (2).
3
6
2
1
4
7
8
5
Fig. 4.13 (a) Replacing the J4-axis sensor (CRX-10iA, CRX-10iA/L)
- 78 -
4. REPLACING PARTS
B-84195EN/02
CRX-10iA, CRX-10iA/L
Parts name
1
2
3
4
5
6
7
8
Specifications
BOLT
CLAMP J4-1
J4 SPACER
BOLT
J4 ADAPTER
BOLT
J4 SENSOR
J4 SENSOR FLANGE
A6-BA-2.5X6
A290-7702-X420
A290-7702-X413
A6-BA-3X20
A290-7702-X412
A6-BA-4X14
A97L-0318-0701
A290-7702-X410
Q’ty
Locking
4
1
4
16
4
16
1
1
Torque Nm (kgfcm)
2.0Nm (20kgfcm)
4.5Nm (46kgfcm)
8
3
2
6
1
7
5
4
Fig. 4.13 (b) Replacing the J4-axis sensor (CRX-20iA/L)
CRX-20iA/L
Parts name
1
2
3
4
5
6
7
8
12
13
14
15
16
BOLT
CLAMP J4-1
J4 SPACER
BOLT
J4 ADAPTER
BOLT
J4 SENSOR
J4 SENSOR FLANGE
Specifications
A6-BA-2.5X6
A290-7702-Y420
A290-7702-Y413
A6-BA-4X22
A290-7702-Y412
A6-BA-5X18
A97L-0318-0727
A290-7702-Y410
Q’ty
4
1
4
16
4
16
1
1
Locking
Torque Nm (kgfcm)
4.5Nm (46kgfcm)
9.0Nm (92kgfcm)
Remove the J4 spacer (3).
Remove bolts (4). Then remove the J4 adaptor (5).
Remove bolts (6). Then remove the J4-axis sensor (7).
Replace the J4-axis sensor (7) by new one. Fit the sensor so that not to damage the faucet joint of the
J4-axis sensor flange and prevent the J4-axis sensor (7) becomes in a tilted status. In this time, confirm
the tap hole position of the J4-axis sensor flange (8) and match the cable phase of the J4-axis sensor
(7). (Refer to Fig.4.13 (c), (d))
According to tightening procedure of Fig.4.13 (c), (d), attach the J4-axis sensor (7) with bolts (6). In
this time, be careful to the following.

Tighten bolts after conforming the J4-axis sensor flange (8) adhered to the J4-axis sensor flange
(8). Do not attract by tightening bolts in this work.

When tightening four bolts temporarily at first, tighten little by little so that the load is applied
evenly to the J4-axis sensor (7) whole.
- 79 -
4. REPLACING PARTS
B-84195EN/02
WARNING
If assembling is performed incorrectly, safety function may lost , and it may
cause injury of the personnel.
4
8
13
12
9
16
5
2
1
6
15
10
11
14
7
Tap position of the
センサフランジのタップ位置
sensor flange
3
J6
casing
side.
J6ケーシング側
Confirm
the tap position of the sensor flange, match the
センサフランジのタップ位置を確認し、
phase
of the sensor cable
センサのケーブルの位相を合わせてください。
Tightening
締結手順procedure
1. 1. センサが傾いた状態で組み付かないようにするため、センサ全体で均一に
Tighten the four bolts 1 to 4 little by little and evenly so that the bolt load is evenly placed to
the whole sensor. (*)
ボルトの負荷がかかるよう、
1 から 4 の4本のボルトを少しずつ均等に仮締めします。(*)
5 から
の順に仮締めします。
2. 2. 残りのボルトを
Temporarily tighten
the16remaining
bolts in the order of 5 to 16.
から 16with
の順に2.2Nm(22kgfcm)で締めます。
3. 3. 1Tighten
half the specified torque in the order of 1 to 16 to 2.2Nm (22kgfcm).
から 16with
の順に規定トルク4.5Nm(46kgfcm)で締めます。
4. 4. 1Tighten
the specified torque in the order of 1 to 16 to 4.5Nm (46kgfcm).
(*)
bolts after conforming the sensor adhered to the sensor flange.
(*)Tighten
センサがセンサフランジに着座していることを確認してからボルトを締めるようにし、
Do not
attract by tightening bolts in this work.
ボルトで引きつけながら着座させないようにしてください。
Fig.4.13 (c) Tightening order of bolts (J4-axis sensor) and the J4 spacer installation position
(CRX-10iA, CRX-10iA/L)
- 80 -
4. REPLACING PARTS
B-84195EN/02
Fig.4.13 (d) Tightening order of bolts (J4-axis sensor) and the J4 spacer installation position
(CRX-20iA/L)
17
18
Fit the sensor so that not to damage the faucet joint of the J4-axis sensor (7) and prevent the J4 adaptor
(5) becomes in a tilted status. In this time, match the phase of the notch of the J4 adapter (5) and the
J4 spacer (3) installation taps. In addition, confirm the J4-axis cover installation hole. (Refer to
Fig.4.13 (e), (f).)
According to the tightening procedure in Fig.4.13 (e), (f), attach the J4 adaptor (5) with bolts (4). In
this time, be careful to the following.

Tighten bolts after conforming the J4 adaptor (5) adhered to the J4-axis sensor (7). Do not attract
by tightening bolts in this work.

When tightening four bolts temporarily at first, tighten little by little so that the load is applied
evenly to the J4 adaptor (5) whole.
WARNING
If assembling is performed incorrectly, safety function may lost , and it may
cause injury of the personnel.
19
20
21
22
23
24
Attach the J4 spacer (3) during being careful to the installation position. (Refer to Fig.4.13 (c))
Attach the clamp J4-1 (2) with bolts (1).
Fix the sheet J4-1 and cables with the cable tie (4-E) referring to Fig.5.3.4 (b).
Install the J3 arm unit. Refer to procedure 36 and Fig. 4.2 (a) in Section 4.12.
Remove the tool I/F board cover. Pass the cable ties (3-A) which fix cables through the parts. Then
assemble it with regulated torque. 0.9Nm (9kgfcm) (Refer to Fig.4.10 (b) in Section 4.10.)
Wire the cables inside the J3 casing and attach the J3 casing cover according to reversed sequence of
procedure 6 to 8.
- 81 -
4. REPLACING PARTS
B-84195EN/02

25
(If the camera cable is specified) After connecting the camera cable connector, wind insulation
tape 2 round or motor to cover the connector whole referring to Fig. 5.3.1 (l) in Subsection 5.3.1.

When assembling the J3 casing cover, be careful not to sandwich the protection sheet and cables.
Perform single axis mastering of J4-axis after you perform quick mastering. Refer to the QUICK
MASTERING of the mechanical unit operator’s Manual (B-84194EN) and Section 6.4.
4
8
13
12
9
16
5
B
Hole for J4-axis cover
J4軸カバー取り付け穴
installation.
2
Detail
詳細 B
B
1
6
A
15
10
11
14
7
Detail
C
詳細 A
Notch
：切り欠き部
3
J6
casing side.
J6ケーシング側
Be
careful
to
the
installation
positon
J4スペーサ(4本)の組み付け位置に
注意すること。
of
the J4 spacer (4 pcs).
Tightening
procedure
締結手順
1. J4アダプタが傾いた状態で組み付かないようにするため、締結部品全体で均一に
1 To prevent
the J4 adaptor from being assembled in a tilted position,tighten the four bolts 1 to 4
からis4 evenly
の4本のボルトを少しずつ均等に仮締めします。(*)
little by ボルトの負荷がかかるよう、
little and evenly so that the bolt1 load
placed to the whole fastening parts. (*)
2. 残りのボルトを
5 から 16 bolts
の順に仮締めします。
2 Temporarily
tighten the remaining
in the order of 5 to 16.
3. 1with
からhalf
16the
の順に1.0Nm(10kgfcm)で締めます。
3 Tighten
specified torque in the order of 1 to 16 to 1.0Nm(10kgfcm).
4. 1with
からthe16specified
の順に規定トルク2.0Nm(20kgfcm)で締めます。
4 Tighten
torque in the order of 1 to 16 to 2.0Nm(20kgfcm).
(*)(*)
Tighten
bolts after conforming the J4 adaptor adhered to the sensor.
J4アダプタがセンサに着座していることを確認してからボルトを締めるようにし、
Do not
attract by tightening bolts in this work.
ボルトで引きつけながら着座させないようにしてください。
Fig.4.13 (e) Tightening order of bolts (J4 adaptor installation) (CRX-10iA, CRX-10iA/L)
- 82 -
4. REPLACING PARTS
B-84195EN/02
Fig.4.13 (f) Tightening order of bolts (J4 adaptor installation) (CRX-20iA/L)
- 83 -
4. REPLACING PARTS
4.14
B-84195EN/02
REPLACING J5-AXIS MOTOR (M5)
Replacing procedure
1
Set a dial gauge at the J5 -axis, and prepare for single axis mastering after replacement. Refer to
Section 6.4.
Set the Quick Master Reference Position. Refer to the QUICK MASTERING section of the
mechanical unit operator’s manual (B-84194EN). (All the axes are set to 0º before shipment.
Move the robot to J5=0°.Then move the robot so that the J5 motor unit can be removed.
(recommended posture: J3=0°,J4=90°,J5=0°, other axes are arbitrary)
Turn off controller power.
Remove the J3 arm cover referring to Fig. 4.11 (a) in Section 4.11.
According to Fig. 5.3.4 (a) in Subsection 5.3.4, cut the cable ties (4-A),(4-C). Then remove the all
relay connectors (M5M4, M6M4, M5P4, M6P4,TS5, CAM-D or FS-D).
Remove bolts (1). Pass the cables. Then remove the clamp J5-2 (2). In this time, do not pull out cables
forcibly during the relay connectors are caught at the J5 motor unit.
Remove bolts (3). Then remove the J5 holder cover (4) and the O-ring (5). In this time, grease will
drip. So be careful not to adhere grease to the motor connectors or relay connector.
2
3
4
5
6
7
8
3
4
5
1
2
Fig. 4.14 (a) Replacing the J5-axis motor (1/4)
Parts name
1
2
3
4
5
BOLT
CLAMP J5-2
BOLT
J5 HOLDER COVER
O-RING
Specifications
A6-BA-3X8
A290-7702-X540
A6-BA-3X8
A290-7702-X513
A98L-0001-0347#S50
- 84 -
Q’ty
2
1
4
1
1
Locking
Torque N-m
(kgf-cm)
2.0Nm (20kgfcm)
4. REPLACING PARTS
B-84195EN/02
9
Attach the J5 motor unit fixture (6) with bolts (6’).
6'
6
Fig.4.14 (b) Replacing the J5-axis motor (2/4)
6
10
Parts name
Specifications
Q’ty
J5 MOTOR UNIT JIG
A6-BA-3X12 (for fixture installation (6’))
A290-7702-X951
A290-7702-X952
A6-BA-3X12 (For fixture assembling)
(Refer to Fig. 1.3 (d) in Section 1.3.)
4
1
1
2
Locking
Torque N-m (kgf-cm)
Remove bolts (7). Then remove the J5 motor unit (8) during passing the cable. In this time, be careful
to the following.

Pull out the J5 motor unit (8) during being careful not to damage the gear (a) of the J5 motor unit
(8) by the contact with the J3 arm inside and the pipe.

When passing the cable, do not pull out cables forcibly during the relay connectors are caught in
the J5 motor unit.
8
8
7
Gear
(a)
ギヤ(a)
J3
arm
J3アーム
Pipe
パイプ
Fig. 4.14 (c) Replacing the J5-axis motor (3/4)
Parts name
7
8
BOLT
J5 MOTOR UNIT
Specifications
A6-BA-4X20
A290-7702-V503
Q’ty
4
1
- 85 -
Locking
Torque N-m (kgf-cm)
3.4Nm (35kgfcm)
4. REPLACING PARTS
11
12
13
14
15
16
17
18
B-84195EN/02
Remove all connectors (M5M,M5BK,M5P) connected to the J5-axis motor (10).
Remove bolts (9). Then remove the J5-axis motor (10) and the O-ring (13). In this time, grease will
drip. So be careful not to adhere grease to the motor connectors or relay connector.
Remove the bolt (12). Then remove the gear (11).
Replace the J5-axis motor (10) by new one. Then attach the bolts (12) and the gear (11).
Confirm dirt is not attached on the gear (11). If dirt is seen, remove it with air.
Apply 4ml grease on the gear (11) referring to Fig.4.14 (e).
Attach the J5-axis motor (10) with bolts (9). In this time, be sure to install the O-ring (13).
Connect the connectors (M5M, M5BK, M5P) to the J5-axis motor. In this time, tighten the connectors
(M5M, M5BK) to 0.11Nm(1.1kgfcm).
13
11
12
9
10
Fig. 4.14 (d) Replacing the J5-axis motor (4/4)
9
10
11
12
13
Parts name
BOLT
J5-AXIS MOTOR
GEAR
BOLT
O RING
Specifications
A6-BA-4X14
A06B-2123-B303
A290-7702-X507
A97L-0218-0504#M3X10
A98L-0001-0347#S35
A
Q’ty
2
1
1
1
1
Locking
Torque N-m (kgf-cm)
3.4Nm (35kgfcm)
LT243
2.0Nm (20kgfcm)
A
Grease
グリース
Gear
ギヤ
Section A-A
断面 A-A
J5-axis
motor
J5軸モータ
Greasing area
：塗布範囲
Fig.4.14 (e) Grease applying area when replacing the J5-axis motor
- 86 -
4. REPLACING PARTS
B-84195EN/02
19
According to Fig.4.14 (f), apply 2ml grease on the opposite side part of the gear insert position.
Grease
グリース
Fig.4.14 (f) Grease applying are when inserting the J5 motor unit
20
21
22
23
24
Pass the cable from the J6 casing side through the J5 motor unit (8). Then insert the J5 motor unit (8)
into the J3 arm. In this time, be careful to the following.

Insert the J5 motor unit (8). Be careful not to damage the gear (a) of the J5 motor unit (9) by
contact with the J3 arm inside and the pipe.

When passing the cables, do not pull out cables forcibly during the relay connectors are caught
at the J5 motor unit.
According to tightening procedure in Fig.4.14 (g), attach the J5 motor unit (8) with bolts (7). In this
time, be careful to the following.

Confirm the cables are not sandwiched between the J5 motor unit (8) and the J3 arm.

Support the fixture so that it does not assembled in the tilt status and become horizontal to the J3
arm tightening surface.
Remove bolts (6’). Then remove the J5 motor unit fixture (6).
According to the reversed sequence of procedure 5 to 8, attach the J5 holder cover (4), wire the cables
in the J3 arm. Then attach the J3 arm cover. In this time, be careful to the following.

When attaching the J5 holder cover (4), do not sandwich the O-ring (5).

(If the camera cable is specified) After connecting the camera cable connector, wind insulation
tape 2 round or motor to cover the connector whole referring to Fig. 5.3.1 (l) in Subsection 5.3.1.

When assembling the J3 arm cover, be careful not to sandwich the protection sheet and cables.
Perform quick mastering and perform single axis mastering of J5-axis. Refer to the QUICK
MASTERING section of the mechanical unit operator’s Manual (B-84194EN) and Section 6.4 of this
manual.
- 87 -
4. REPLACING PARTS
B-84195EN/02
1
3
J2 arm side
J2アーム側
2
4
When temporarily assembling, be careful so
仮締めの際にはJ5モータユニットが
that the J5 motor unit is
傾かないように、
not
installed in the tilt status,
J5モータユニットがJ3アームの締結面に
and
the J5 motor unit become parallel
平行となるよう治具を支えてください。
against
the J3 arm tightening surface.
Tightening procedure
締結手順
1 To prevent the motor is attached in the tilt status and the bolt load is applied evelnly to the J5 motor unit whole,
1.J5モータユニットが傾かないように、J5モータユニット全体で均一に
temporarily tighten 1 to 4 bolts little by little .
ボルトの負荷がかかるよう、1
4 の4本のボルトを少しずつ均等に仮締めします。
2 Tighten
bolts in order of 1 to 4 to 1.0Nmから
(10kgfcm).
3 2.
Tighten
bolts
order of 1 to 4 to 2.0Nm (20kgfcm).
1 から
4 inの順に1.0Nm(10kgfcm)で締めます。
4 3.
Tighten
bolts
order of 1 to 4 to regulated torque 3.4Nm (35kgfcm).
1 から
4 inの順に2.0Nm(20kgfcm)で締めます。
4. 1 から 4 の順に規定トルク3.4Nm(35kgfcm)で締めます。
Fig.4.14 (g) Tightening procedure of the J5 motor unit
- 88 -
4. REPLACING PARTS
B-84195EN/02
4.15
REPLACING J5-AXIS REDUCER
Replacing procedure
1
To remove the J5-axis reducer, set a dial gauge at the J5-axis, and prepare for single axis mastering
after replacement. Refer to Section 6.4.
Set the Quick Master Reference Position. Refer to the QUICK MASTERING section of the
mechanical unit operator’s manual (B-84194EN). (All the axes are set to 0º before shipment.
Move the robot to J5=0°.Then move the robot so that the J5 motor unit can be removed. (recommended
posture ：J3=0°,J4=90°,J5=0°, other axes are arbitrary)
Turn off controller power.
According to Fig.4.11 (a) in Section 4.11, remove the J3 arm cover.
According to Fig. 5.3.4 (a) in Subsection 5.3.4, cut cable ties (4-A), (4-C), then remove the all relay
connectors (M5M4, M6M4, M5P4, M6P4,TS5, CAM-D or FS-D).
According to procedure 7 to 10 (Fig. 4.14 (a) to Fig.4.14 (c)) in Section 4.14, remove the clamp J5-2
and the J5 motor unit. (Removing the J5 motor unit from the motor is not necessary.)
Remove bolts (1), (2), (3). While pulling the cables in the J3 arm, remove the J5-axis reducer (8) from
the J3 arm (4) using the removal taps in Fig.4.15 (b). In this time, be careful to the following.

In this time, grease will drip. So be careful not to adhere grease to the motor connectors or relay
connector.

Do not pull it out forcibly with the relayed connector caught in the hollow hole.
2
3
4
5
6
7
8
3
2
1
4
5
6
7
8
9
10
Fig.4.15 (a) Replacing the J5-axis reducer
1
2
3
Parts name
BOLT
BOLT
BOLT
4
J3 ARM
5
6
7
O RING
WAVE GENERATOR
BOLT
8
J5-AXIS REDUCER
Specifications
A6-BA-3X14
A6-BA-3X30
A6-BA-3X22
10iA, 10iA/L
A290-7702-X402
20iA/L
A290-7702-Y402
(Reducer appendix)
(Reducer appendix)
A6-BA-3X25
10iA, 10iA/L A97L-0318-0294#50
20iA/L
A97L-0318-0294#100
- 89 -
Q’ty
4
9
3
Locking
Torque N-m (kgf-cm)
2.0Nm (20kgfcm)
2.0Nm (20kgfcm)
2.0Nm (20kgfcm)
1
1
1
12
1
2.0Nm(20kgfcm)
4. REPLACING PARTS
9
10
Parts name
WAVE WASHER
O RING
B-84195EN/02
Specifications
(Reducer appendix)
(Reducer appendix)
Q’ty
1
1
Locking
Torque N-m (kgf-cm)
Removal
taps
抜きタップ(M3)
(M3)
Bolt
ボルト
(M3
x 14)
(M3X14)
Bolt
ボルト
(M3
x 22)
(M3x22)
*Other
bolts are M3 x 30
※その他のボルトはM3X30
Fig.4.15 (b) Position of the removal taps for the J5-axis reducer and tightening bolts
9
10
11
12
13
14
15
Remove bolts (7). Then remove the J5-axis reducer (8). In this time, grease will drip. So be careful
not to adhere grease to the motor connectors or relay connector.
Prepare the new J5-axis reducer (8). Apply 4ml grease to the sensor flange mounting part (part A)
referring to Fig. 4.3 (g) in Section 4.3.
Attach the new J5-axis reducer (8) with bolts (7). In this time, be careful to the following.

According to Fig. 4.3 (h) in Section 4.3, match the temporary fixing bolts of the J5-axis reducer
(8) and counter bore for temporary fixing bolt of the sensor flange).

Replace the O-ring (5), (10) and the wave washer (9) by new articles and be sure to install them.

When tightening bolts (7), tighten the opposing side bolts evenly to 1.0Nm(10kgfcm). Then
tighten them to the regulated torque 2.0Nm (20kgfcm).
Before assembling the new wave generator (6), apply 9ml grease to the reducer inside, the bearing
(part B) of the wave generator (7). Refer to Fig. 4.3. (g) in Section 4.3.
Attach the new wave generator (6).
According to Fig.4.15 (c), match the wave generator phase (6) to the J5-axis reducer (8) during rotating
the wave generator (6).
According to Fig.4.15 (d) and Section 4.22, clean the sealant surface, apply sealant on the J5-axis
reducer (8).
- 90 -
4. REPLACING PARTS
B-84195EN/02
Cross roller
クロスローラ
bearing
ベアリング
Circular
サーキュラ
spline
C
スプライン
C
Section
断面 C-C
C-C
B
B
Detail
詳細 AA
Section
B-B
断面 B-B
(tap
(a))
(タップ(a))
Tap for bolt (M3 x 14)
A
図4.15(d)の
in Fig. 4.15 (d)
ボルト(M3x14)用のタップ
Reducer taps (a)
：減速機取付用のタップ(a)
Match the phase of the J6 casing
J6ケーシングと減速機取付用のタップ(a)の位相を
and the reducer
taps (a) as the aboved figure.
上図のように合わせること。
Fig. 4.15 (c) Phase of the J5-axis reducer
Apply
LOCITE 518 on the dotted line.
部にロックタイト518を塗布のこと。
Fig.4.15 (d) LOCTITE applying
16
17
According to Fig 4.15 (b), (c), match the phase of the J5-axis reducer (8) and the J3 arm (4). During
passing the cables, according to Fig.4.15 (b), attach the J3 arm (4) with bolts (1), (2), (3). In this time,
be careful to the following.

When passing the cables, do not pull it out forcibly with the relayed connector caught.

When tightening bolts (1), (2), (3), tighten all bolts in diagonal order to 1.0Nm (10kgfcm). Then
tighten them to regulated torque 2.0Nm (20kgfcm).
According to procedure 20 to 22 in Section 4.14, attach the J5 motor unit. According to Fig.4.14 (f)
in Section 4.14, apply 11ml grease to the motor inserting positon before inserting the motor.
- 91 -
4. REPLACING PARTS
18
19
B-84195EN/02
According to the reversed sequence of procedure 5 to 7, attach the clamp J5-2, wire the cables in the
J3 arm. Then attach the J3 arm cover. In this time, be careful to the following.

(If the camera cable is specified) After connecting the camera cable connector, wind insulation
tape 2 round or motor to cover the connector whole referring to Fig. 5.3.1 (l) in Subsection 5.3.1.

When assembling the J3 arm cover, be careful not to sandwich the protection sheet and cables.
Perform quick mastering and perform single axis mastering of J5-axis. Refer to the QUICK
MASTERING section of the mechanical unit operator’s Manual (B-84194EN) and Section 6.4 of this
manual.
4.16
REPLACING J5-AXIS SENSOR
CAUTION
Removing the J6-axis motor is required in this work. The wrist can rotate if the
J6-axis is removed. So take measures such putting the end effector on a stand if
it exist to prevent it from colliding surroundings.
Replacing procedure
1
2
3
4
5
6
7
8
9
10
11
To remove the J6-axis motor and the parts attached to the J5-axis reducer, set a dial gauge at the J5,
J6-axis, and prepare for single axis mastering after replacement. Refer to Section 6.4.
Move the robot to J5=J6=0°.Then move the robot so that the J3 arm cover and the J6 casing cover can
be removed. (recommended posture ：J3=J4=J5=J6=0°, other axes are arbitrary)
Turn off controller power.
According to Fig.4.11 (a) in Section 4.11, remove the J3 arm cover.
According to Fig. 5.3.4 (a) in Subsection 5.3.4, cut the cable tie (4-A), (4-C). The remove the all relay
connectors (M5M4, M6M4, M5P4, M6P4, TS5, CAM-D or FS-D)
According to Fig.4.17 (a) in Section 4.17, remove the J6 casing cover.
According to Fig. 5.3.5 (a) in Subsection 5.3.5, cut the cable tie (5-A), (5-B). Then remove the all
relay connectors and the J6-axi motor connectors (M6M, M6P, M6BK, EE1, EE2, TS6, TS-J5, CAME or FS-E).
According to Fig.4.17 (b) in Section 4.17, remove the J6-axis motor. (Removing the gear from the
motor is not necessary.)
Remove bolts (1), pass the cables, then remove the clamp J6-1 (2). Do not pull out cables forcibly
during the relay connectors are caught in the pipe.
Remove the bolts (3), and remove the brake (4).
Remove the bolts (5), then remove the gear unit (6) and the O-ring (7).
- 92 -
4. REPLACING PARTS
B-84195EN/02
3
4
5
7
6
2
1
Fig.4.16 (a) Removing the J5-axis sensor (1/2)
Parts name
1
2
3
4
5
6
7
12
13
14
15
16
17
18
BOLT
CLAMP J6-1
BOLT
BRAKE
BOLT
GEAR UNIT
O RING
Specifications
Q’ty
A6-BA-3X8
A290-7702-X502
A6-BA-2.5X30
A97L-0318-0660
A6-BA-3X8
A290-7702-V507, A290-7702-X525
A98L-0001-0347#S26
2
1
2
1
4
1
1
Locking
Torque N-m (kgf-cm)
0.86Nm (8.8kgfcm)
2.0Nm (20kgfcm)
Remove the bolts (8), and remove the clamp J5-3 (9). (It is not necessary to cut the cable tie, which
fix cables to clamp J5-3.)
Pull out J3 arm side cables to the J6 casing side. Do not pull it out forcibly with the relayed connector
caught in the hollow hole.
Remove bolts (10). Then remove the clamp J5-4 (11).
Remove bolts (13). Then remove the J6 casing (14). In this time, be careful not to apply excessive
load due to parts part interference etc. on the J5 spacer (12).
Remove the J5 spacer (12).
Remove the bolts (15). Then remove the J5-axis sensor (16).
Replace the J5-axis sensor (16) by new one. Fit it being careful not to the damage the faucet joint part
of the J5-axis sensor flange (17) and prevent the J5-axis sensor (16) from tilting. In this time, confirm
the tap hole position of the J5-axis sensor flange, match the phase of the J5-axis sensor (16). (Refer to
Fig.4.16 (c))
- 93 -
4. REPLACING PARTS
B-84195EN/02
17
15
16
14
12
13
11
10 9
8
Fig. 4.16 (b) Removing the J5-axis sensor (2/2)
Parts name
8
9
10
11
12
13
14
15
16
17
19
BOLT
CLAMP J5-3
BOLT
CLAMP J5-4
J5 SPACER
BOLT
J6 CASING
BOLT
J5 SENSOR
J5 SENSOR FRANGE
Specifications
A6-BA-3X8
A290-7702-X541
A6-BA-2.5X6
A290-7702-X542
A290-7702-X527
A6-BA-3X14
A290-7702-V502
A6-BA-4X14
A97L-0318-0701
A290-7702-X410
Q’ty
2
1
3
1
3
16
1
16
1
1
Locking
Torque N-m (kgf-cm)
2.0Nm(20kgfcm)
4.5Nm (46kgfcm)
According to the tightening procedure of Fig.4.16 (c), attach the J5-axis sensor (16) with bolts. In this
time, be careful to the following.

Tighten bolts after conforming the J5-axis sensor (16) adhered to the J5-axis sensor flange (17).
Do not attract by tightening bolts in this work.

When tightening four bolts temporarily at first, tighten little by little so that the load is applied
evenly to the J5-axis sensor (16) whole.
WARNING
If procedure is not followed, safety function may lost and it may cause injury or
the personnel.
20
Assemble the J5 spacer (12) with pay attention to the assembly position. (Refer to Fig.4.16 (c))
- 94 -
4. REPLACING PARTS
B-84195EN/02
Pay
attention to the assembly position
of J5スペーサ(3本)の組み付け位置に
J5 spacers (3 pieces).
注意すること。
15
5
1
9
11
13
7
4
3
8
14
12
10
6
16
Check
the tap position of the
センサフランジの
sensor flange and align the cable
タップ位置を確認し、
phase of the sensor.
センサのケーブルの位相を
合わせてください。
2
Sensor flange taps position
センサフランジのタップ位置
Tightening procedure
1 締結手順
To prevent the sensor from being assembled in a tilted position,tighten the four bolts 1 to 4 little by
1.little
センサが傾いた状態で組み付かないようにするため、センサ全体で均一に
and evenly so that the bolt load is evenly placed to the whole sensor. (*)
ボルトの負荷がかかるよう、
からin4the
の4本のボルトを少しずつ均等に仮締めします。(*)
2 Temporarily tighten the remaining1bolts
order of 5 to 16.
残りのボルトを
5 specified
から 16 の順に仮締めします。
3 2.
Tighten
with half the
torque in the order of 1 to 16 2.2Nm(22kgfcm) .
1 からwith
16 the
の順に2.2Nm(22kgfcm)で締めます。
4 3.
Tighten
specified torque in the order of 1 to 16 4.5Nm(46kgfcm).
4. 1 から 16 の順に規定トルク4.5Nm(46kgfcm)で締めます。
(*) Make sure that the sensor is contacted the whole surface on the sensor flange before
(*) tightening
センサがセンサフランジに着座していることを確認してからボルトを締めるようにし、
the bolts. Do not pull the sensor with bolts to contact the whole surface.
ボルトで引きつけながら着座させないようにしてください。
Fig. 4.16 (c) Tightening procedure of bolts (J5-axis sensor) and J5 spacer assembly position
21
22
Fit the J6 casing (14) without tilting it so that it does not jam on the coupling part of the J5-axis sensor
(16). At this time, be careful not to place an excessive load on the J5 spacer (12) due to parts
interference.
Assemble the J6 casing (14) with bolts (13), referring to the tightening procedure in Fig. 4.16 (d). At
this time, make sure that the J6 casing (14) is contacted the whole surface on the J5-axis sensor (16)
before tightening the bolts. Do not pull the J6 casing (14) with bolts to contact the whole surface. Also,
tighten each bolt little by little and evenly so that the bolt load is evenly placed to the whole J6 casing
(14) when you temporarily tighten the first four bolts.
WARNING
If procedure is not followed, safety function may lost and it may cause injury or
the personnel.
- 95 -
4. REPLACING PARTS
B-84195EN/02
1
5
15
9
11
13
7
4
3
8
12
14
16
10
6
2
Tightening
procedure
締結手順
1. To prevent
the fastening parts from being assembled in a tilted position,tighten the four bolts 1 to 4 little
1. 締結部品が傾いた状態で組み付かないようにするため、締結部品全体で均一に
by littleボルトの負荷がかかるよう、
and evenly so that the bolt load1isから
evenly
placed to the whole fastening parts. (*)
4 の4本のボルトを少しずつ均等に仮締めします。(*)
2. Temporarily
tighten the remaining
in the order of 5 to 16.
2. 残りのボルトを
5 から 16 bolts
の順に仮締めします。
3. Tighten
specified torque (1.0Nm(10kgfcm)) in the order of 1 to 16.
3. 1with
からhalf
16the
の順に1.0Nm(10kgfcm)で締めます。
4. Tighten
torque (2.2Nm(20kgfcm)) in the order of 1 to 16 .
4. 1with
からthe
16specified
の順に規定トルク2.0Nm(20kgfcm)で締めます。
(*) Make sure that the fastening parts is contacted the whole surface on the sensor before tightening
(*) 締結部品がセンサに着座していることを確認してからボルトを締めるようにし、
the bolts.
Do not pull the fastening parts with bolts to contact the whole surface.
ボルトで引きつけながら着座させないようにしてください。
Fig. 4.16 (d) Tightening procedure of bolts (J6 casing)
23
24
25
26
Assemble the clamp J5-4 (11) with bolts (10).
Pass the cable removed in procedure 13 from the J6 casing side to the J3 arm side, and assemble the
clamp J5-3 (9) with bolts (8). Do not pull it out forcibly with the relayed connector caught.
Attach the gear unit (6) with bolts (5). In this time be careful to the following.

Be sure to insert the O-ring (7).

Before inserting the gear unit (6), according to Fig.4.16 (e), apply 2ml grease to the opposite side
gear can be seen from the gear unit (6) insert position.
Attach the brake (4) with bolts (3).
Grease
グリース
Fig. 4.16 (e) Grease applying area when inserting the gear unit
- 96 -
4. REPLACING PARTS
B-84195EN/02
27
According to the reversed sequence of procedure 4 to 9, attach the gear unit, the brake, the J6-axis
motor and the clamp J6-1. Wire the cables in the J6 casing and the J3 arm. Then attach the J6 casing
cover and the J3 arm cover. At this time, pay attention below.

When assembling the J6-axis motor, refer to procedure 12 and Fig. 4.17 (b) in Section 4.17.
Before inserting the J6-axis motor, apply 2ml grease to the motor inserting position as shown in
Fig. 4.17 (c) in Section 4.17.

(If the camera cable is specified) After connecting the camera cable connector, wind insulation
tape 2 round or more to cover the connector whole referring to Fig. 5.3.1 (l) in Subsection 5.3.1.

Tighten the J6-axis motor connector (M6M) with 0.11Nm (1.1kgfcm).

When assembling the J6 casing cover and the J3 arm cover, be careful not to sandwich the
protection sheet and cables.
Perform single axis mastering. Refer to Section 6.4. At this time, perform mastering both of J6-axis
and J5-axis.
28
4.17
REPLACING J6-AXIS MOTOR (M6)
CAUTION
The wrist can rotate if the J6-axis is removed. So take measures such putting
the end effector on a stand if it exist to prevent it from colliding surroundings.
Replacing procedure
1
Set a dial gauge at the J6-axis, and prepare for single axis mastering after replacement. Refer to Section
6.4.
Turn off controller power.
Remove bolts (1). Then remove the J6 casing cover (2) and the gasket (3).
2
3
3
2
1
Fig. 4.17 (a) Replacing the J6-axis motor (1/2)
Parts name
1
2
3
GEOMET BOLT
J6 CASING COVER
GASKET
Specifications
A97L-0318-0426#4X12
A290-7702-X502
A290-7702-X529
- 97 -
Q’ty
5
1
1
Locking
Torque N-m (kgf-cm)
4.5Nm (46kgfcm)
4. REPLACING PARTS
4
5
B-84195EN/02
Remove the J6-axis connector (M6M, M6P) from the J6-axis motor (5).
Remove bolts (4). Then remove the J6-axis motor (5) and the O-ring (8). In this time, be careful to the
following.

The tooth muscle of the gear (6) is diagonal. Therefore, when pulling out the motor, straightly
pull it during rotating the whole of the motor to axis rotation direction. If the motor is lay down
or removed without rotation, it might damage the gear teeth.

In this time, grease will drip. So be careful not to adhere grease to the motor connectors or relay
connector.
Wipe off grease on the gear (6). In this time, be careful not to damage the gear teeth.
Remove bolts (7). Then remove the gear (6) from the motor shaft.
Replace the J6-axis motor (5) by new one. Then attach the bolts (7) and the gear (6).
Confirm dirt is not attached on the gear (6). If dirt is seen, remove it with air.
Apply 2ml grease on the opposite gear can be seen from the gear insert portion. Refer to Fig.4.17 (c).
Attach the J6-axis motor (5) with bolts (4). In this time, be careful to the following.

Be sure to install the O-ring (8).

The tooth muscle of the gear (6) is diagonal. Therefore, when inserting the motor, straightly insert
it during rotating the whole of the motor to axis rotation direction. If the motor is lay down or
inserted without rotation, it might damage the gear teeth.
Connect the J6-axis connector (M6M,M6P) to the J6-axis motor (5). Tighten the J6-axis motor
connector (M6M) to 0.11Nm(1.1kgfcm).
Attach the gasket (3) and the J6 casing cover (2). In this time, be careful to the following.

When assembling the J6 casing cover (2), be careful not to sandwich the protection sheet and
cables.
Perform single axis mastering. Refer to Section 6.4.
6
7
8
9
10
11
12
13
14
6
7
8
4
5
Fig. 4.17 (b) Replacing the J6-axis motor (2/2)
Parts name
4
5
6
7
8
BOLT
J6-AXIS MOTOR
GEAR
BOLT
O RING
Specifications
A6-BA-4X14
A06B-2123-B003
A290-7702-X508
A97L-0218-0504#M3X10
A98L-0001-0347#S35
- 98 -
Q’ty
2
1
1
1
1
Locking
Torque N-m (kgf-cm)
4.5Nm (46kgfcm)
LT243
2.0Nm (20kgfcm)
4. REPLACING PARTS
B-84195EN/02
Grease
グリース
Fig. 4.17 (c) Grease applying area when the J6-axis motor is replaced
4.18
REPLACING J6-AXIS REDUCER
Replacing procedure
1
2
3
4
5
6
7
8
9
To remove the J6-axis reducer, set a dial gauge at the J6-axis, and prepare for single axis mastering
after replacement. Refer to Section 6.4.
Move the robot to J6=0°.Then move the robot so that the J6-axis motor can be removed.
(recommended posture ：J3=0°,J4=0°, J5=-90°,J6=0°, other axes are arbitrary)
Turn off controller power.
According to Fig.4.17 (a) in Section 4.17, remove the J6 casing cover.
According to Fig. 5.3.5 (a) in Subsection 5.3.5, cut cable ties (5-A),(5-B), then remove all the relay
connectors (M6BK,EE1,EE2,TS6,CAM-E or FS-E) and all connectors (M6M,M6P) connected to the
J6-axis motor.
According to procedure 5 in Section 4.17 and Fig. 4.17 (b), remove the J6-axis motor. (Removing the
gear from the motor is not necessary.)
According to Fig. 4.16 (a) in Section 4.16, remove the clamp J6-1, then pull out the cables in the pipe
of the clamp J6-1. Do not pull out cables forcibly during the relay connectors are caught in the pipe.
According to Fig. 4.16 (a) in Section 4.16, remove the brake and the gear unit.
Remove bolts (1), (2), (3), (4). Remove the J6-axis reducer (9) from the J6 casing (5) using the removal
taps in Fig.4.18 (b) during pulling out the J6 casing cables. In this time, be careful to the following.

In this time, grease will drip. So be careful not to adhere grease to the motor connectors or relay
connector.

Do not pull out cables forcibly during the relay connectors are caught in the hollow hole.
- 99 -
4. REPLACING PARTS
B-84195EN/02
2
3
1
4
5
6
7
8
9
10
11
12
Fig. 4.18 (a) Replacing the J6-axis reducer
Parts name
Specifications
Q’ty
1
2
3
4
5
6
7
8
BOLT
BOLT
BOLT
BOLT
J6 CASING
O RING
WAVE GENERATOR
BOLT
2
2
2
7
1
1
1
12
9
J6-AXIS REDUCER
10
11
12
WAVE WASHER
O RING
J6 SENSOR FRANGE
A6-BA-3X8
A6-BA-3X22
A6-BA-3X14
A6-BA-3X30
A290-7702-X501
(Reducer appendix)
(Reducer appendix)
A6-BA-3X25
10iA, 10iA/L
A97L-0318-0294#50
20iA/L
A97L-0318-0294#80
(Reducer appendix)
(Reducer appendix)
A290-7702-X410
Locking
Torque N-m (kgf-cm)
2.0Nm (20kgfcm)
2.0Nm (20kgfcm)
2.0Nm (20kgfcm)
2.0Nm (20kgfcm)
2.0Nm (20kgfcm)
1
1
1
1
Bolts
ボルト
(M3
x 22)
(M3x22)
Bolts
ボルト
(M3
x 14)
(M3x14)
Removal taps
(M3)
抜きタップ(M3）
Bolts
ボルト
(M3 x 8)
(M3x8)
*Other
bolts are M3 x 30
※その他のボルトはM3x30
Fig. 4.18 (b) Positions of the removal taps and tightening bolts for J6-axis reducer
- 100 -
4. REPLACING PARTS
B-84195EN/02
10
11
12
13
14
Remove bolts (8). Then remove the J6-axis reducer (9) from the J6 sensor flange (12). In this time,
grease will drip. So be careful not to adhere grease to the motor connectors or relay connector.
Prepare the new J6-axis reducer (9). Apply 4ml grease to the sensor flange mounting part (part A)
referring to Fig. 4.3 (g) in Section 4.3.
Attach the new J6-axis reducer (9) with bolts (8). In this time, be careful to the following.

According to Fig. 4.3 (h) in Section 4.3, match the temporary fixing bolts of the J6-axis reducer
(9) and counter bore for temporary fixing bolt of the sensor flange).

Replace the O-ring (6),(11) and the wave washer (10) by new articles and be sure to install them.

When tightening bolts (8), tighten the opposing side bolts evenly to 1.0Nm(10kgfcm). Then
tighten them to the regulated torque 2.0Nm(20kgfcm).
Before assembling the new wave generator (7), apply 9ml grease to the reducer inside, the bearing
(part B) of the wave generator (7). Refer to Fig. 4.3. (g) in Section 4.3.
Attach the new wave generator (7), according to Fig.4.18 (c), match the reducer phase.
クロスローラ
Cross roller サーキュラ
Circular
ベアリング スプライン
bearing
spline
C
B
C
断面 C-C
Section
C-C
B
詳細 AA
Detail
Section
B-B
断面 B-B
(タップ(a))
(tap
(a))
A
EEコネクタ
EE
connector
Tap
for bolt (M3 x 8)
図4.18(d)の
in
Fig.
4.18 (b)
ボルト(M3x8)用のタップ
Tap (a) for reducer
：減速機取付用のタップ(a)
Match the phase of the J6 flange and the tap (a)
J6フランジと減速機取付用のタップ(a)の位相を
of the reducer
as the aboved figure
上図のように合わせること。
Fig. 4.18 (c) Installation phase of the J6-axis reducer
15
16
17
18
According to Fig.4.18 (d) and Section 4.22, clean the sealant surface, then apply sealant on the J6-axis
reducer (9).
According to Fig.4.18 (b), (c), match the phase of the J6-axis reducer (9) and the J6 casing (5).
During pass the cable through the J6 casing side, attach the J5 casing (6) to the J6-axis reducer.
According to Fig.4.18 (b), fix it with bolts (1), (2), (3), (4). When tightening bolts (1), (2), (3), (4),
tighten the opposing side bolts evenly to 1.0Nm(10kgfcm). Then tighten them to regulated
torque2.0Nm (20kgfcm).
According to Fig.4.16 (a) in Section 4.16, attach the gear unit and the brake. In this time, be careful to
the following.

Before inserting the gear assembly, according to Fig.4.16 (e) in Section 4.1.6, apply 2ml grease
to the opposite side gear can be seen from the gear assembly insert position.

Be sure to install the O-ring (7 in Fig.4.16 (a)).
According to the reversed sequence of the procedure 4 to 7, attach the clamp J6-1 and the J6-axis
motor, wire the cable in the J6 casing, then attach the J6 casing cover. In this time, be careful to the
following.

When assembling the clamp J6-1, pass the cable tie which fix cables through clamp J6-1. Then
attach it.
- 101 -
4. REPLACING PARTS
B-84195EN/02

19
When attaching the J6-axis motor, refer to procedure 11 in Section 4.17. In addition, before
inserting the motor, according to Fig.4.17 (c) in Section 4.17, apply 6ml grease to the motor
inserting position.

Tighten the J6-axis motor connector (M6M) to 0.11Nm(1.1kgfcm).

(If the camera cable is specified) After connecting the camera cable connector, wind insulation
tape 2 round or motor to cover the connector whole referring to Fig. 5.3.1 (l) in Subsection 5.3.1.

When assembling the J3 arm cover, be careful not to sandwich the protection sheet and cables.
Perform single axis mastering referring to Section 6.4.
Apply LOCTITE 518 on the dotted line.
部にロックタイト518を塗布のこと。
Fig. 4.18 (d) Applying of LOCTITE
- 102 -
4. REPLACING PARTS
B-84195EN/02
4.19
REPLACING J6-AXIS SENSOR
REPLACING PROCEDURE
1
To remove the parts attached to the J6-axis reducer, set a dial gauge at the J6-axis, and prepare for
single axis mastering after replacement. Refer to Section 6.4.
Move the robot to J6=0°.Then move the robot so that the J6 casing cover and the J6 flange can be
removed. (recommended posture：J3=0°,J4=0°,J5=0°,J6=0°, other axes are arbitrary)
Turn off controller power.
Remove the J6 casing cover referring to Fig.4.17 (a) in Section 4.17.
Cut cable ties (5-A), (5-B). Then remove the all relay connectors (M6BK, EE1, EE2, TS6, CAM-E or
FS-E) and the all connectors (M6M, M6P) connected to the J6-axis motor. Refer to Fig.5.3.5 (a) in
Subsection 5.3.5.
Remove the clamp J6-1, then pull out cables of the clamp J6-1 in the pipe. Refer to Fig.4.16 (a) in
Section 4.16. Do not pullout cable forcibly during the relay pipe is caught in the pipe.
Remove seal bolts (1).
Remove bolts (2). Then remove the flange cover (4) and the O-ring (5), (6). (Taps for the seal bolts
(1) are removal taps for the flange cover (4) removal. By using these taps, remove the flange cover
(4).)
2
3
4
5
6
7
8
10
14
13
12
11
9
5
8
4
7
3
6
2
1
Fig. 4.19 (a) Replacing the J6-axis sensor
Parts name
1
2
3
4
5
6
7
8
9
10
11
12
13
14
SEAL BOLT
BOLT
SEAL WASHER
FLANGE COVER
O RING
O RING
BOLT
J6 FLANGE
BOLT
CLAMP J6-2
J6 SPACER
BOLT
J6 SENSOR
J6 SENSOR FRANGE
Specifications
A97L-0218-0417#030404BC
A97L-0218-0496#M3X10BC
A30L-0001-0048#3M
A290-7702-X549
A98L-0001-0347#S85
A98L-0001-0347#S63
A6-BA-3X35
A290-7702-X524 etc.
A6-BA-2.5X6
A290-7702-X544
A290-7702-X528
A6-BA-4X14
A97L-0318-0701
A290-7702-X410
- 103 -
Q’ty
2
4
4
1
1
1
16
1
3
1
3
16
1
1
Locking
Torque N-m (kgf-cm)
2.0Nm (20kgfcm)
2.0Nm (20kgfcm)
4.5Nm (46kgfcm)
4. REPLACING PARTS
9
10
11
12
13
14
15
B-84195EN/02
Remove bolts (7). During pulling out the J6 casing part cables, remove the J6 flange (8). Do not pull
out cables forcibly during the relay connectors are caught in the hollow hole.
Cut the cable tie (6-A), then remove the relay connector (TS-J6). Refer to Fig.5.3.6 (a) in Subsection
5.3.6.
Remove bolts (9). Then remove the clamp J6-2 (10).
Remove the J6 spacer (11).
Remove bolts (12). Then remove the J6-axis sensor (13).
Replace the J6-axis sensor (13) by new one. Then fit the sensor so that not to damage the faucet joint
of the J6-axis sensor flange (14) and prevent the J6-axis sensor (13) becomes in a tilted status.
In this times, confirm the tap hole of the J6-axis sensor flange (14), then match the cable phase of the
J6-axis sensor (13). (Refer to Fig.4.16 (b))
According to the tightening procedure in Fig.4.19 (b), attach the J6-axis sensor (13) with bolts (12).
In this time, be careful to the following.

Tighten bolts after conforming the J6-axis sensor (13) adhered to the J6-axis sensor flange (14).
Do not attract by tightening bolts in this work.

When tightening four bolts temporarily at first, tighten little by little so that the load is applied
evenly to the J6-axis sensor (13) whole.
WARNING
If assembling is performed incorrectly, safety function may lost, and it may cause
injury of the personnel.
16
Attach the J6 spacer (11) during being careful to the installation position. (Refer to Fig.4.16 (b))
Be
careful to the assembling position
J6スペーサ(3本)の組み付け位置に
of
the J6 spacer (3 pcs)
注意すること。
3
7
14
11
10
6
15
1
2
5
16
9
12
8
13
Confirm
the tap position of the sensor
センサフランジの
flange,
then
match the phase of the
4
タップ位置を確認し、
sensor
cable
Tap
position
of
the
sensor
flange
センサのケーブルの位相を
センサフランジのタップ位置
合わせてください。
Tightening
procedure
締結手順
1 To prevent
the sensor from being assembled in a tilted position,tighten the four bolts 1 to 4 little by little and
1. センサが傾いた状態で組み付かないようにするため、センサ全体で均一に
evenly ボルトの負荷がかかるよう、
so that the bolt load is evenly placed
whole fastening parts. (*)
1 からto4the
の4本のボルトを少しずつ均等に仮締めします。(*)
2 Temporarily
tighten the remaining
in the order of 5 to 16.
2. 残りのボルトを
5 から 16bolts
の順に仮締めします。
3 Tighten
specified torque in the order of 1 to 16 to 2.2Nm(22kgfcm).
3. 1with
からhalf
16the
の順に2.2Nm(22kgfcm)で締めます。
4 Tighten
with
the
specified
torque in the order of 1 to 16 to 4.5Nm(46kgfcm).
4. 1 から 16 の順に規定トルク4.5Nm(46kgfcm)で締めます。
Tighten bolts after conforming the sensor adhered to the sensor flange.
Do(*)
notセンサがセンサフランジに着座していることを確認してからボルトを締めるようにし、
attract by tightening bolts in this work.
ボルトで引きつけながら着座させないようにしてください。
Fig.4.19 (b) Tightening order of bolts (J6-axis senor installation)
- 104 -
4. REPLACING PARTS
B-84195EN/02
17
18
19
20
During passing cables to the J6 casing side, attach the clamp J6-2 (10). Then fix it with bolts (9).
Connect the relay connector (TS-J6). Then fix the cables on the clamp J6-2 with the cable (6-A). Refer
to Fig. 5.3.6 (a) in Subsection 5.3.6.
Fit the sensor so that not to damage the faucet joint of the J6-axis sensor (13) and prevent the J6 flange
(8) becomes in a tilted status. In this time, according to Fig.4.19 (c), confirm the EE connector position,
match the J6 flange phase.
According to the tightening procedure in Fig.4.19 (c), attach the J6 flange (8) with bolts (7). In this
time, be careful to the following.

During keeping the J6 casing and the J6 flange horizontal insert until clearance becomes 1mm.
Then tighten bolts. (Refer to Fig.4.19 (d)) Do not attract the J6 flange by tightening bolts.

When tightening four bolts temporarily at first, tighten little by little so that the load is applied
evenly to the J6 flange (8) whole.
WARNING
If assembling is performed incorrectly, safety function may lost , and it may
cause injury of the personnel.
21
22
23
Attach the flange cover (4) with bolts (2). Then attach the seal bolts (1). In this time, be careful to the
following.

Be sure to install the O-ring (5), (6).

For the sealant performance, replace the seal bolts (1) by new article and use it. If you cannot
prepare, remove the sealant, wind it with seal tap and reuse it.
According to the reversed sequence of procedure 4 to 6, attach the clamp J6-1. Wire the cables in the
J6 casing. Then attach the J6casing cover. In this time, be careful to the following.

When assembling the clamp J6-1, pass the cable tie which fix cables to the clamp J6-1. Then
attach it.

(If the camera cable is specified) After connecting the camera cable connector, wind insulation
tape 2 round or motor to cover the connector whole referring to Fig. 5.3.1 (l) in Subsection 5.3.1.

Tighten the J6-axis motor connector (M6M) with torque of 0.11Nm (1.1kgfcm).

When assembling the J6 casing cover, do not sandwich the protection sheet and cables.
Perform single axis mastering. Refer to Section 6.4.
- 105 -
4. REPLACING PARTS
B-84195EN/02
3
7
14
11
10
6
15
1
2
5
16
9
12
13
4
EE
connector
EEコネクタ
8
Tightening
締結手順procedure
1 1. To
prevent the J6 flange from being assembled in a tilted position,tighten the four bolts 1 to 4 little by little
J6フランジが傾いた状態で組み付かないようにするため、締結部品全体で均一に
and evenly so that the bolt load is evenly placed to the whole fastening parts. (*)
ボルトの負荷がかかるよう、 1 から 4 の4本のボルトを少しずつ均等に仮締めします。(*)
2 Temporarily tighten the remaining bolts in the order of 5 to 16.
2.
5 specified
から 16torque
の順に仮締めします。
3 残りのボルトを
Tighten with half the
in the order of 1 to 16 to 1.0Nm(10kgfcm).
から with
16 の順に1.0Nm(10kgfcm)で締めます。
4 3. 1
Tighten
the specified torque in the order of 1 to 16 to 2.0Nm(20kgfcm).
4. 1 から 16 の順に規定トルク2.0Nm(20kgfcm)で締めます。
(*) During keeping the J6 casing and the J6 flange parallel, insert the J6 flange
untilJ6ケーシングとJ6フランジを平行に保ったまま、隙間が1mmになるまで挿入した後、
the clearance becomes
(*)
1mm.ボルトを締めるようにしてください。(図4.19(d)参照)
Then tighten bolts (Referto Fig.4.19 (d))
Do not
attract part by tightning bolts
ボルトでJ6フランジを引きつけないようにしてください。
Fig. 4.19 (c) Tightening order of bolts (J6 flange installation)
Inser the J6
flange keeping the
J6ケーシングとJ6フランジを
J6 flange parallel
to the J6 casing
平行に保ったまま挿入する
1
Fig. 4.19 (d) Inserting method of the J6 flange
- 106 -
4. REPLACING PARTS
B-84195EN/02
4.20
REPLACING LED UNIT
REPLACING PROCEDURE
1
2
3
4
Remove the J2 base cover referring to Fig. 4.2 (a) in Section 4.2.
Remove the relay connector (IND1) of the LED unit.
Remove the LED unit referring to Fig. 4.2 (b) in Section 4.2.
Replace the LED by new one. Then assemble it in reversed sequence. In this time, be careful to the
following.

When assembling the LED unit, be careful that the cables do not ride on the LED.

When assembling the J2 base cover, do not sandwich the cables.
4.21
REPLACING TOOL I/F BOARD
REPLACING PROCEDURE
1
2
3
Set the Quick Master Reference Position. Refer to the QUICK MASTERING section of the
mechanical unit operator’s manual (B-84194EN). (All the axes are set to 0º before shipment.
Turn off controller power.
According to the beginning of Chapter 4, take measures against static electricity.
CAUTION
Be sure to take measures against static electricity before removing the J3 casing
cover. If you touch the tool I/F board without measures, the tool I/F might break.
4
5
6
7
8
9
10
11
12
13
14
Remove the J3 casing cover referring to Fig.4.10 (a) in Section 4.10.
According to Fig. 5.3.3 (a) in Subsection 5.3.3, cut the cable tie (3-C). Then peel off the J3 cover from
the clamp J4-1.
To reuse the sheet J3 motor, be careful to the following.

Carefully peel off the sheet J3 cover during being careful not to break it and no dirt adhere to it.
 When reusing it, if the sheet J3 motor is broken or cannot past e due to dirty, replace it by new
one.
According to Fig. 5.3.3 (b) in Subsection 5.3.3, cut cable ties (3-A), then remove the all relay connector
(M456P3, M4M3, M5M3, M6M3, TS4, TS-J4, CAM-C or FS-C).
According to Fig. 4.10 (b) in Section 4.10, remove the tool I/F board cover (5).
According to Fig. 5.3.3 (b) in Subsection 5.3.3, remove all connectors (CRS54, CRS55) connected to
the tool I/F board.
According to Fig.4.10 (b) in Section 4.10, remove spacer bolts (6). Then remove theool I/F board (7).
Attach the new tool I/F board (7) using spacer bolts (6) with regulated torque 0.9Nm(9kgfcm). (Refer
to Fig.4.10 (b) in Section 4.10)
According to Fig. 5.3.3 (b) in Subsection 5.3.3, connect the connectors (CRS54, CRS55) to the tool
I/F board.
According to Fig.5.3.3 (b) in Subsection 5.3.3, pass the cable tie (3-A) which fix cables on the tool I/F
board (5), Then using the screws (4), attach the tool I/F board cover with torque of 0.9Nm (9kgfcm).
(See Fig. 4.10 (b) in Section 4.10)
According to the reversed sequence of procedure 4 to 6, wire the cables in the J3 casing, then attach
the J3 casing cover. In this time, be careful to the following.

(If the camera cable is specified) After connecting the camera cable connector, wind insulation
tape 2 round or motor to cover the connector whole referring to Fig. 5.3.1 (l) in Subsection 5.3.1.

When assembling the J3 casing cover, be careful not to sandwich the protection sheet and cables.
Perform quick mastering. Refer to the QUICK MASTERING section of the mechanical unit operator’s
Manual (B-84194EN).
- 107 -
4. REPLACING PARTS
4.22
B-84195EN/02
SEALANT APPLICATION
Washing and degreasing the surfaces to be sealed
1
2
3
4
After removing the reducer, the surfaces that were sealed with LOCTITE 518 must be cleaned and all
old LOCTITE 518 must be removed. Apply LOCTITE Gasket Remover to the surface to be cleaned.
Allow 10 minutes to soften the old LOCTITE 518. After the LOCTITE has softened it can be
removed using a scraper.
Blow air onto the surface to be sealed to remove dust from the threaded holes.
Sufficiently degrease the reducer’s surface to be sealed and the arm’s surface to be sealed, using a
cloth dampened with solvent. Do not spray solvent directly onto the surface.
Polish the surfaces of the reducer to be sealed with an oil stone, and degrease them with removal and
cleaner again.
CAUTION
Oil may drip from inside of the reducer. Check that there is no oil drip after
finishing degreasing.
Applying Sealant
5
6
Make sure that the reducer and the surface to which it mounts are dry. If they are still wet with oil and
grease remover, wipe them dry. Make sure to use a clean cloth surface to avoid reapplying the wiped
grease. Make sure that no oil and grease remover is left on the threaded holes or anywhere. If some is
left on the surface, it may prevent stiffening of the sealant.
Apply sealant (LOCTITE 518) to the sealing surfaces.
CAUTION
Refer to the each relevant axis reducer replacement description as the sealant
required locations differ from one axis to another. Confirm the sealant surface is
clean and dry. Otherwise, you cannot apply grease correctly.
Assembly
7
8
9
To prevent dust from sticking on the surface to which sealant is applied, mount the reducer as quickly
as possible after sealant application. Pay attention not to touch the applied sealant. If the sealant is
accidently removed, apply the sealant again.
After assembling parts, secure the sealed surface, attaching with bolts and washers promptly.
After assembling the reducer, wipe off any excessive overflowing sealant with a cloth or spatula. Do
not use oil and grease remover.
CAUTION
Greasing or operating the axis before the sealants cure may cause grease to
leak. Make sure to wait at least one hour, and then start greasing or axis
operation.
- 108 -
5. REPLACING CABLES
B-84195EN/02
5
REPLACING CABLES
If a cable is broken or damaged or shows signs of wear, replace it according to the procedures in this chapter.
Precautions to be observed when handling the Pulsecoder cable
The Pulsecoder cable is provided with a marking tie, as shown below, to warn against disconnecting the
cable during transportation, installation, or maintenance.
Once the cable with the marking tie is disconnected, mastering is required. Therefore, do not
disconnect the cable except for when the motor, the Pulsecoder, the reducer sensor, tool I/F board or cable
replacement are required.
BATTERY BACKUP
DON'T
DISCONNECT
コネクタ取外不可
Fig. 5 (a) marking label
If there is a break in or any other damage to a cable, replace the cable according to the procedure described
in this chapter. If the connector of a motor cable is detached, the data about the absolute position of the
robot is lost. Once any of these cables is replaced, perform quick mastering while referencing Mastering
Chapter of the mechanical unit Operator’s Manual (B-84194EN). If the data is lost because of a break in a
cable, also perform mastering to calibrate the robot into the previous absolute position.
- 109 -
5. REPLACING CABLES
5.1
B-84195EN/02
CABLE WIRING
Followings are the routing of the robot cables. Refer to PIPING AND WIRING TO THE END EFFECTOR
of MECHANICAL UNIT OPERATOR’S MANUAL (B-84194EN) for details of option connectors.
K141
K141
(J4,J5,J6軸パワー)
(J4,J5,J6-axis
power)
K142
K142
(J4,J5,J6軸パワー,
EE)
(J4,J5,J6-axis
power,EE)
K241(sensor)
K241
(センサ)
K306
K316 K316
K306orまたは
(camera
or force力センサ)
sensor)
(カメラ または
K131
K131
(J3-axis power)
(J3軸パワー)
K132
K132
(J4,J5,J6軸パワー)
(J4,J5,J6-axis power)
K133
K133 (J3-axis Pulsecoder)
(J3軸パルスコーダ)
K134 (J4,J5,J6-axis
K134
Pulsecoder,EE)
(J4,J5,J6軸パルスコーダ, EE)
K231 (sensor)
K231
K304 or K314
(センサ)
(camera
force sensor)
K304
または or
K314
(カメラ または 力センサ)
K161
K161 (EE)
K261
(EE) (sensor)
K261 or K318
K308
(センサ) or force sensor)
(camera
K308 または K318
(カメラ または 力センサ)
K151
K151
(J5軸パワー)
(J5-axis
power)
K152
K152
(J6軸パワー)
(J6-axis
power)
K153
K153 (J5-axis Pulsecoder)
(J5軸パルスコーダ)
K154
K154(J6-axis Pulsecoder,EE)
K251
(sensor)
(J6軸パルスコーダ,
EE)
K307
K251or K317
(センサ)or force sensor)
(camera
K307 または K317
K115
K115
(J1,J2-axis
brake)
(J1,J2軸ブレーキ)
K001
(power,
EE)EE)
(パワー,Pulsecoder,
パルスコーダ,
K201 (sensor)
(センサ)
K301
or K311
K301 または
K311
(camera
or force
sensor)
(カメラ または 力センサ)
K121
(カメラ または 力センサ)
K121
(J3-axis
power)
(J3軸パワー)
K122
K122
(J4,J5,J6-axis
power)
(J4,J5,J6軸パワー)
K123(J3,J4,J5,J6-axis
K123
(J3,J4,J5,J6軸パルスコーダ,
EE)
Pulsecoder,
EE)
K221
K221 (sensor)
(センサ)
K303 or K313
K303 または K313
(camera
or force力センサ)
sensor)
(カメラ または
Fig. 5.1 (a) Routing of the robot cables (backside connector panel)
- 110 -
5. REPLACING CABLES
B-84195EN/02
K141
K141
(J4,J5,J6-axis
power)
(J4,J5,J6軸パワー)
K142
K142
(J4,J5,J6軸パワー,
EE)
(J4,J5,J6-axis
power,EE)
K241(sensor)
K241
(センサ)
K306
or K316
K306 または K316
(camera or force sensor)
(カメラ または 力センサ)
K308 または K318
(カメラ または 力センサ)
K131
K131
(J3-axis
power)
(J3軸パワー)
K132
K132
(J4,J5,J6軸パワー)
(J4,J5,J6-axis
power)
K133(J3-axis Pulsecoder)
K133
(J3軸パルスコーダ)
K134
(J4,J5,J6-axis
K134
Pulsecoder,EE)
(J4,J5,J6軸パルスコーダ, EE)
K231
K231(sensor)
K304
or K314
(センサ)
(camera
or force
sensor)
K304 または
K314
K151
K151
(J5-axis
power)
(J5軸パワー)
K152
K152
(J6-axis
power)
(J6軸パワー)
K153
K153(J5-axis Pulsecoder)
(J5軸パルスコーダ)
K154
(J6-axis Pulsecoder,EE)
K154(sensor)
K251
(J6軸パルスコーダ,
EE)
K307
or K317
K251
(camera or force sensor)
(カメラ または 力センサ)
K115
K115
(J1,J2-axis brake)
(J1,J2軸ブレーキ)
K001
K002
(power,
EE)EE)
(パワー,Pulsecoder,
パルスコーダ,
K201
K201 (sensor)
K301
or K311
(センサ)
K301 または
K311
(camera
or force
sensor)
(カメラ または 力センサ)
K161
K161(EE)
(EE) (sensor)
K261
K261or K318
K308
(センサ)or force sensor)
(camera
(センサ)
K307 または K317
(カメラ または 力センサ)
K121
K121
(J3-axis power)
(J3軸パワー)
K122
K122
(J4,J5,J6-axis
power)
(J4,J5,J6軸パワー)
K123
K123(J3,J4,J5,J6-axis Pulsecoder, EE)
K221
(sensor)
(J3,J4,J5,J6軸パルスコーダ,
EE)
K221or K313
K303
(センサ)
(camera
or force sensor)
K303 または K313
(カメラ または 力センサ)
Fig. 5.1 (b) Routing of the robot cables (bottom side connector panel)
- 111 -
5. REPLACING CABLES
5.2
B-84195EN/02
CABLE FORMING
Fig. 5.2 (a) to (c) show the cable externals chart.
M1M
M2M Relay in the J2 base
J2ベース内で中継
M1BK
M1BK
M12BK1 K115
4005-T924
DON'T
DISCONNECT
コネクタ
取外 不 可
K001 :bottom side connectr plate
K002 : backside connector plate
K001：背面分線盤
K002：底面分線盤
M2P
BATTERY BACKUP
DON'T
DISCONNECT
コ ネクタ 取 外 不可
M3BK
M3M3 K133
4005-T926
Clamp
クランプ
J3-2
J3-2
M4M3
Clamp
クランプ
J3-1
J3-1
Clamp
クランプ
J3-1
J3-1
Clamp
クランプ
J3-2
J3-2
Clamp
クランプ
J2-2
J2-2
M5M3
M5M3
K132
Clamp
クランプ
J2-1
J2-1
M2P
M4M3
M3M
in the J3 casing
J3ケーシング内で中継
K133 Relay
M3M3
M3M1 K121
2008-T754
M3M2
M456M2
K122
M1P
K131
M3BK
M6M3 K141
4005-T930
M1P
BATTERY BACKUP
Clamp
クランプ
J2-1
J2-1 Clamp
クランプ
J2-2
J2-2
M6M3
RMP K001
1702-D001
M456M1
K121
M456M1 K122
2008-T755
M3M1
Clamp
クランプ
J1-2
J1-2
Clamp
クランプ
J2-2
J2-2
M3M
Clamp
クランプ
J2-1
J2-1
Clamp
クランプ
J1-1
J1-1
Relay
under the J2 arm
J2アーム下部で中継
M2BK
M3M2 K131
2008-T756
M2BK
K115
M456M2 K132
4005-T928
M12BK1
M2M
M1M
When replacing cables, clamp the cable at the position specified in Fig. 5.2 (a) to (c) using a clamp or a
cable tie. If fail to clamp cables in specific position, it will cause the cable slack or cable disconnection by
improper pulling force. Refer to the Fig. 5.2 (a) to (c) for the cable clamp.
K141
BT456
M3P
Clamp
クランプ
J3-1
J3-1
Clamp
クランプ
J3-2
J3-2
Clamp
クランプ
J2-2
J2-2
TS-J3
TS4 K241
2008-T760
Fig. 5.2 (a) Cable externals chart of mechanical unit (basic cable) (1/2)
- 112 -
TS-J4
TS4
K231
TS-J3
TS3
TS-J2
TS3 K231
4005-T938
K221
TS-J2
TS-J1
TS2 K221
4005-T937
TS2
TS-J1
TS1
K201
M456P3 K142
4005-T931
K142
CRS55
Clamp
クランプ
J2-1
J2-1
Clamp
クランプ
J1-2
J1-2
M3P
CRS54
BT456
M456P3
M3456P2 K134
4005-T927
BT123 K134
TS1 K201
4005-T936
Clamp
クランプ
J1-1
J1-1
コネクタ 取外 不可
CRS55
K123
BATTERY BACKUP
DON' T
DI SCONNECT
CRS54
IND1
コネ ク タ 取 外 不 可
BT123
IND1
BATTERY B ACKUP
DON'T
DI SCONNECT
M3456P1 K123
4005-T925
M3456P1
DON'T
DISCONNECT
M3456P2
BATTERY BACKUP
コネクタ 取 外 不 可
K241
TS-J4
5. REPLACING CABLES
B-84195EN/02
Relay
in the J3 casing
J3ケーシング内で中継
M4BK
M4BK
M4M3
M4M3
M4M
M4M
Relay in the J3 arm
M5M
M5BK
M5BK
M6M
BATTERY BACKUP
DON'T
DISCONNECT
コ ネ クタ 取 外 不可
Clamp
クランプ
J5-2
J5-2
Relay in the J6 casing
J6ケーシング内で中継
M5P
Clamp
クランプ
J6-1
J6-1
M6P
Clamp
クランプ
J6-2
J6-2
EE1 K161
4005-T935
EE
K261
TS-J5
TS-J5
TS-J6
TS-J6
K161
TS6
TS5
K251
TS-J4
TS-J4
EE2
J5-1
Clamp
クランプ
J4-2
J4-2
TS4 K241
2008-T760
EE
Clamp
クランプ
クランプ Clamp
J5-1
J5-2
J5-2
EE2
K154
Clamp
クランプ
J4-1
J4-1
K241
M6P4 K154
4005-T934
コネ クタ 取 外 不 可
TS5 K251
4005-T939
BATTERY BACKUP
DON'T
DISCONNECT
M6P4
EE1
BATTERY BACKUP
DON'T
DISCONNECT
コネ クタ 取 外 不 可
TS6 K261
1702-D005
K153
M5P
コ ネ クタ 取外 不 可
M6BK
M6BK
Clamp
クランプ
J5-1
J5-1
M6P
M4P
M5P4 K153
2008-T758
BATTERY BACKUP
DON'T
DISCONNECT
M6M
M6M4 K152
1702-D006
K152
M5P4
K142
M5M
M456P3 K142
4005-T931
M456P3
コ ネク タ 取外 不可
M4P
BATTERY BACKUP
DON'T
DISCONNECT
BATTERY BACKUP
DON'T
DISCONNECT
コネ ク タ 取 外 不 可
M5M4 K151
4005-T932
M5M4
M6M4
K141
K151
Clamp
クランプ
Clamp
クランプ J4-2
J4-2
J4-1
J4-1
M6M3 K141
4005-T930
M6M3
M5M3
M5M3
J3アーム内で中継
Fig. 5.2 (b) Cable externals chart of mechanical unit (basic cable) (2/2)
Relay
in the J2 base
J2ベース内で中継
Clamp
クランプ
J1-2
J1-2
Clamp
クランプ
J2-1
J2-1
Clamp
クランプ
J2-2
J2-2
Relay in the J3 casing
J3ケーシング内で中継
Clamp
クランプ
J4-1
J4-1
Clamp
クランプ
J3-1
J3-1
Clamp
クランプ
J3-2
J3-2
Relay
in the J3 arm
J3アーム内で中継
Clamp
クランプ
J5-1
J5-1
Clamp
クランプ
J4-2
J4-2
Relay
in the J6 casing
J6ケーシング内で中継
Clamp
クランプ
J6-1
J6-1
Clamp
クランプ
J5-2
J5-2
Clamp
クランプ
J6-2
J6-2
K301
K304
CAM-E K308
1702-D004
CAM-E
CAM-D K307
2008-T766
CAM-D
K306
K310
K311
K312
K313
FS-E K314
1702-D008
FS-E
FS-D K313
2008-T770
FS-D
FS-C K312
2008-T769
FS-C
FS-B K311
2008-T768
FS-B
FS-A K310
2008-T767
FS-A
FS1 K309
1702-D007
K309
K314
Fig. 5.2 (c) Cable externals chart of mechanical unit (option cable)
- 113 -
CAM
K308
K307
FS2
K303
CAM-C K306
2008-T765
CAM-C
CAM-B K304
2008-T763
CAM-B
CAM-A K303
2008-T762
CAM-A
CAM1 K301
1702-D003
CAM2
Clamp
クランプ
J1-1
J1-1
Relay under
the
J2 arm
J2アーム下部で中継
FS
5. REPLACING CABLES
5.3
B-84195EN/02
CABLE AND AIR TUBE REPLACEMENT
This section describes a procedure for periodically replacing all the (full-option) mechanical unit cables.
See Section 5.1 for the configuration of the mechanical unit cables.
You must perform mastering after cable replacement. Refer to Chapter 6 or Chapter 8 THE OPERATOR’S
MANUAL (B-84194EN) in advance. (If Pulsecoder cable is not replaced, mastering is not necessary.) In
replacing cables, arrange the cable ties.
5.3.1
Replacing Cable K001,K002,K201,K301,K309
(connector panel to J2 base)
Replacing procedure
1
2
3
4
5
6
7
8
9
10
Set the Quick Master Reference Position. Refer to the QUICK MASTERING section of the
mechanical unit operator’s manual (B-84194EN). (All the axes are set to 0º before shipment.)
Move the robot to J1=0°. Then move the robot to the posture that the J2 base cover and the connector
panel can be removed when laying down the robot.
(recommended posture: J1=0°,J2=0°J3=249°, other axes are arbitrary) (Refer to Fig.4.3 (a) in
Section 4.3)
Turn off controller power. Then remove the robot connection cable from the controller.
Remove the J2 base cover referring to Fig. 4.2 (a) in Section 4.2.
Remove the relay connector (IND1) of the LED unit.
Remove the LED unit referring to Fig. 4.2 (b) in Section 4.2.
Remove the J1-axis motor connector (M1M,M1P,M1BK) and the J2-axis motor connector
(M2M,M2P,M2BK).
Pull out cables from between the J1-axis motor and the J2-axis motor. According to Fig.5.3.1 (a), cut
the cable tie (1-A),(1-B),(1-D) which fix braided tube (1-A). Then remove the braided tube.
Remove the all relay connectors (M12BK1,M3M1,M456M1,M3456P1,TS2,CAM-A or FS-A)
referring to Fig.5.3.1 (a).(In case of the camera cable connector, remove the insulation tape, then
remove the connector.)
Remove the robot from floor plate. Then turn it sideways referring to Fig. 4.4 (a) in Section 4.4.
WARNING
When removing the robot floor plate and turning it sideways, be sure to perform
these work with two people. If it was done by one people, it may cause injury.
11
12
13
14
15
16
17
18
19
20
Remove the J1 base cover referring to Fig. 4.4 (b), (c) in Section 4.4.
Remove three locations of the double-sided tape of the sheet J1-1 which cover the cable. Refer to Fig.
5.3.1 (b), (c). The sheet J1-1 will be reused. So be careful to the following.

Carefully peel off the sheet J1-1 during being careful not to break it and no dirt adhere to it.

If the sheet J1-1 is broken or no adhesive strength due to dirt, replace it by new one.
Cut the cable tie (1-F) which fix the cable on the clamp J1-1. Refer to Fig. 5.3.1 (b),(c).
Remove the relay connector (TS-J1) referring to Fig. 5.3.1 (b),(c).
Remove the connector panel referring to Fig. 5.3.1 (d),(e). (In case of the bottom side connector panel,
remove the cover plate.)
Remove the earth line referring to Fig. 5.3.1 (b),(c).
Remove the bolts which fix the clamp J1-2, then cut the cable tie (1-E) which fix the cable on the
clamp J1-2. Refer to Fig. 5.3.1 (a).
Pull out the cable in J2 base to the J1 base side. Do not pull out the cables forcibly with the relay
connector is caught in the pipe.
Remove the bolts, then remove the plate, the gasket and the camera connector or the force sensor
connector. Refer to Fig. 5.3.1 (f), (g)
(In case of bottom side connector panel) Cut the cable tie (1-G), then remove the braided tube (1-C)
referring to Fig.5.3.1 (i),(j).
- 114 -
5. REPLACING CABLES
B-84195EN/02
21
22
23
Remove the clamp J1-1 referring Fig. 4.4 (d) in Section 4.4.
Replace the cables. Then assemble them in the reversed sequence. In this time, be careful to the
following.

When assembling the clamp J1-1 or the clamp J1-2, pass the cable through the cable ties, then
assemble them.

(In case of the camera cable) After connecting the camera cable connector, wrap the insulation
tap 2 round so that the whole of the connector is covered. Refer to Fig.5.3.1 (k).

When assembling the LED unit, be careful the cables does not ride on the LED.

When assembling the J1 base cover or the J2 base cover, be careful not to sandwich the protection
sheet and cables.
Perform quick mastering. Refer to the QUICK MASTERING of the mechanical unit operator’s
Manual (B-84194EN) and Section 6.4.
ケーブルタイ(1-D)
Cable
tie (1-D)
Cable
tie (1-E)
ケーブルタイ(1-E)
Fix
the yellow tape part.
黄色テープの箇所を固定すること
Cable
tie (1-E)
ケーブルタイ(1-E)
Braided
tube (1-B)
編組チューブ(1-B)
A98L-0040-0363#19L210R0
A98L-0040-0363#19L210R0(2)
(2)
Section
A-A
断面
A-A
Connector
コネクタ
M12BK1, M3M1, M456M1, M3456P1,
M12BK1,M3M1,M456M1,M3456P1,
TS2, CAM-A or FS=A, IND1
IND 1
TS2,CAM-AまたはFS-A,
Cable tie (1-A)
ケーブルタイ(1-A)
Cable
tie (1-C)
ケーブルタイ(1-C)
Clamp J1-2
クランプ J1-2
A290-7702-X321
A290-7702-X321
Bolt
ボルト
A6-BA-4X10
(2)
Section
B-B
断面 B-B
(Before
closing
(J1/J2シート閉じる前)
the J1/J2 sheet)
J1/J2 sheet
A290-7702-X325
J1/J2 シート
After
fixiing the cables,
A290-7702-X325
ケーブル固定後、
close
i with cable ties.
ケーブルタイにて閉じること(上図参照)
(Refer
to the aboved figure)
A6-BA-4X10 (2)
Ｃ
A
A
Camera
cable (black
カメラケーブル
(黒))
Signal line
信号線(青X白)
(blue
x white)
Sensor
センサ cable
)
(black
ケーブル(黒)
B
Braided
tube (1-A)
編組チューブ(1-A)
A98L-0040-0363#19L210R0
(2)
A98L-0040-0363#19L210R0 (2)
Cable
tie (1-E)
ケーブルタイ1-(E)
断面 B-B
B-B
Ｃ Section
B
Power
line
パワー線
(0.2SQ
x white)
(0.2SQred
赤X白)
Power
line
パワー線
(0.5SQ
x white)
(0.5SQred
赤X白)
Section
断面 C-C
C-C
Sensor
センサcable
(black
)
ケーブル(黒)
Power
line
パワー線
(0.2SQ
red赤X白)
x white)
(0.2SQ
Power
line
パワー線
(0.5SQ
red x赤X白)
white)
(0.5SQ
(When the camera
cable is specified)
(カメラケーブル指定時)
Cable tie (1-B)
ケーブルタイ(1-B)
Use編組チューブは信号線
one braided tube for/ signal
line/sensor cable, camera cable
センサケーブル / カメラケーブルもしくは
or force
sensor cable. Use the other braided tube for power line.
力センサケーブルで1つ、動力線で1つ使用すること
Fig. 5.3.1 (a) Replacing the J2 base cables
- 115 -
Force sensor cable
(blue
x white)
力センサケーブル(青X白)
Force
sensor cable (black)
力センサケーブル(黒)
Signal line
信号線
(blue
x white)
(青X白)
Section
C-C
断面 C-C
(When the force sensor
(力センサケーブル指定時)
cable is specified)
5. REPLACING CABLES
B-84195EN/02
Power line 0.5SQ
Sensor cable (black)
センサケーブル(黒)
Sensor cable (black)
センサケーブル(黒)
パワー線0.5SQ(赤X白)
(red x white)
Signal
line (blue x white)
信号線(青X白)
Signal
line (blue x white)
信号線(青X白)
Camera cable (black)
カメラケーブル (黒)
Power line 0.2SQ
(red
x white)
パワー線0.2SQ(赤X白)
Force sensor cable (blue x white)
Force sensor cable
力センサケーブル(黒)
(black)
Power line 0.2SQ
(red x white)
パワー線0.2SQ(赤X白)
Power line 0.5SQ
パワー線0.5SQ(赤X白)
(red x white)
力センサケーブル(青X白)
Section
A-A
断面 A-A
Section
A-A
断面 A-A
(When
the camera cable is specified) (When
the force sensor cable is specified)
(カメラケーブル指定時)
(力センサケーブル指定時)
Close
sheet J1-1 with double-sided tape
シートthe
J1-1に貼付されている両面テープで
attached
to the sheet J1-1.
シート J1-1を閉じること
Cable
tie (1-F)
ケーブルタイ(1-F)
Fix
the yellow tape
黄色テープの箇所を
position
固定すること
Clamp filter
クランプフィルタ
Clamp J1-1
クランプ
J1-1
A290-7702-X211
A290-7702-X211
Bolt
ボルト
A6-BA-3X8
A6-BA-3X8
A
A
Cable
tie (1-F)
ケーブルタイ(1-F)
Cable tie (1-F)
ケーブルタイ(1-F)
Connect the TS-J1
TS-J1を接続すること
Cable tie (1-F)
ケーブルタイ(1-F)
Do not fix the
J1センサのケーブルは
J1 sensor cable
固定しないこと
J1
sensor cable
Ｊ１センサケーブル
Cable tie (1-F)
ケーブルタイ(1-F)
B
B
Cable tie (1-F)
ケーブルタイ(1-F)
Sheet
シート J1-1
J1-1
A290-7702-X220
A290-7702-X220
When assembling the J1 base cover,
J1ベースカバーを取り付ける際、
be careful not to sandwich the sheet J1-1.
シート J1-1を挟み込まないように注意すること
Earth
line (gray) for signal line
信号線のアース線（灰）
Earth
line (gray) for power line
パワー線のアース線（灰）
Section
B-B
断面 B-B
Protection earth line
保護アース線（黄X緑）
(yellow x green)
Bolt
ボルト
A97L-0218-0606#M4X6
A97L-0218-0606#M4X6(3)(3)
Fig. 5.3.1 (b) Replacing the J1 base cable (back side connector panel)
- 116 -
5. REPLACING CABLES
B-84195EN/02
Sensor cable (black)
センサケーブル(黒)
Power line 0.5SQ
パワー線0.5SQ(赤X白)
(red x white)
Signal line
(blue x white)
信号線(青X白)
Power line 0.5SQ
パワー線0.5SQ(赤X白)
Sensor cable (black)
センサケーブル(黒)
(red x white)
Signal 信号線(青X白)
line (blue x white)
Power line 0.2SQ
パワー線0.2SQ(赤X白)
Force
sensor cable (black)
力センサケーブル
(黒)
(red x white)
Power line 0.2SQ
パワー線0.2SQ(赤X白)
Force 力センサケーブル(青X白)
sensor cable (blue x white)
(red
x white)
Camera cable (black)
カメラケーブル
(黒)
Section
A-A
断面 A-A
Section
A-A
断面 A-A
(When the
camera cable is specified) (When the(力センサケーブル指定時)
force sensor cable is specified)
(カメラケーブル指定時)
Close
sheet J1-1 with double-sided tape
シートthe
J1-1に貼付されている両面テープで
attached
to the sheet J1-1.
シート J1-1を閉じること
Cable
tie (1-F)
ケーブルタイ(1-F)
Fix
the yellow tape position
黄色テープの箇所を固定すること
Clamp filter
クランプフィルタ
Cable tie (1-F)
ケーブルタイ(1-F)
A
Cable
tie (1-F)
ケーブルタイ(1-F)
A
Clamp J1-1
J1-1
シート
A290-7702-X211
A290-7702-X211
Bolt
ボルト
A6-BA-3X8
A6-BA-3X8
Connect the TS-J1
TS-J1を接続すること
J1
sensor cable
J１センサケーブル
Cable tie (1-F)
ケーブルタイ(1-F)
B
Sheet J1-1
シート
J1-1
A290-7702-X220
A290-7702-X220
When
assembling
the J1 base cover,
J1ベースカバーを取り付ける際、
be
careful
not to sandwich the sheet J1-1.
シート
J1-1を挟み込まないように注意すること
B
Protection earth
保護アース線（黄X緑）
(yellow
x green)
Earth line
for signal line (gray)
信号線のアース線（灰）
Earthパワー線のアース線（灰）
line for power line (gray)
Section
B-B
断面 B-B
Bolt
ボルト
A97L-0218-0606#M4X6
(3)(3)
A97L-0218-0606#M4X6
Fig. 5.3.1 (c) Replacing the J1 base cable (bottom side connector panel)
1
2
3
Fig. 5.3.1 (d) Removal of the connector panel (back side connector panel)
Parts name
1
2
3
BOLT
CON.PLATE
GASKET
Specifications
A97L-0218-0496#M4X12BC
A290-7702-X207
A290-7702-X213
Q’ty
4
1
1
- 117 -
Locking
Torque N-m
(kgf-cm)
4.5Nm(46kgfcm)
5. REPLACING CABLES
B-84195EN/02
1
2
3
Fig. 5.3.1 (e) Removal of the connector panel (bottom side connector panel)
Parts name
1
2
3
Specifications
BOLT
COVER.PLATE
GASKET
A97L-0218-0496#M4X12BC
A290-7702-X208
A290-7702-X213
4 3
2
Q’ty
4
1
1
4.5Nm(46kgfcm)
4 3 2
1
(In case of back side
(背面分線盤指定時)
connector panel)
Torque N-m
(kgf-cm)
Locking
1
(In case of bottom side
(底面分線盤指定時)
connector panel)
Fig. 5.3.1 (f) Removal of the camera connector
Parts name
1
2
3
4
BOLT
J1 CAM PLATE
CABLE K301
GASKET
Specifications
A97L-0218-0546#030808BC
A290-7702-X215
A05B-1702-D003
A290-7702-X218
Q’ty
4
1
1
1
- 118 -
Locking
Torque N-m
(kgf-cm)
1.6Nm(16kgfcm)
5. REPLACING CABLES
B-84195EN/02
3
2
3 2
1
1
(In case of back side
(背面分線盤指定時)
connector panel)
(In case of bottom side
(底面分線盤指定時)
connector panel)
Fig. 5.3.1 (g) Removal of the force sensor connector
Parts name
Specifications
Q’ty
1
BOLT
A97L-0218-0546#030808BC
4
2
3
CABLE K309
GASKET
A05B-1702-D007
A290-7702-X218
1
1
Locking
1.6Nm(16kgfcm)
Seal bolt
シールボルト
A97L-0218-0546E030808BC
A97L-0218-0546#030808BC(4)(4)
Tightening
締結トルクtorque
1.6Nm
(16kgfcm)
1.6Nm(16kgfcm)
(When
the camera cable is specified)
(カメラケーブル指定時)
Gasket
ガスケット
A290-7702-X218 (1)
Cable
K301K301
ケーブル
A05B-1702-D003
(1)
A05B-1702-D003(1)
Torque N-m
(kgf-cm)
A290-7702-X218(1)
J1
plate
J1camera
カメラプレート
A290-7702-X215
(1)
A290-7702-X215(1)
Signal line
(blue x white)
信号線(青X白)
Signal
line (black)
信号線(黒)
Connect the TS1
コネクタTS1を接続すること
Cable
K201K201
ケーブル
A660-4005-T936
(1)
A660-4005-T936(1)
Clamp
filter
クランプフィルタ
A45L-0001-0493#A(1)
A45L-0001-0493#A(1)
ConnectorTS-J1
TS-J1
コネクタ
Power
line (black)
パワー線(黒)
Cable
K001K001
ケーブル
A05B-1702-D001
(1)
A05B-1702-D001(1)
Power
line (red x white)
パワー線(赤X白)
(When
the force sensor cable is specified)
(力センサケーブル指定時)
Gasket
ガスケット
A290-7702-X218
A290-7702-X218(1)
Cable K309K309
ケーブル
A05B-1702-D007 (1)
A05B-1702-D007(1)
Signal line
(blue x white)
信号線(青X白)
Signal
line (black)
信号線(黒)
Connect the TS1
コネクタTS1を接続すること
Cable
K201 K201
ケーブル
A660-4005-T936
(1)
A660-4005-T936(1)
Clamp
filter
クランプフィルタ
A45L-0001-0493#A(1)
Power
line (black)
パワー線(黒)
Cable
K009 K001
ケーブル
A05B-1702-D009
(1)
A05B-1702-D009(1)
A45L-0001-0493#A(1)
ConnectorTS-J1
TS-J1
コネクタ
Power
line (red x white)
パワー線(赤X白)
Fig. 5.3.1 (h) J1 base clamp (back side connector panel)
- 119 -
Seal シールボルト
bolt
A97L-0218-0546E030808BC
(4)
A97L-0218-0546#030808BC(4)
締結トルク
Tightening
torque
1.6Nm(16kgfcm)
1.6Nm
(16kgfcm)
Key
position
キー位置
5. REPLACING CABLES
B-84195EN/02
Cable tie (1-G)
ケーブルタイ(1-G)
Fix the braided tube with cable ties
ケーブルタイで編組チューブを固定のこと
Powerパワー線(赤X白)
line (red x white)
Connect the TS1
コネクタTS1を接続すること
Braided tube (1-C)
編組チューブ(1-C)
A98L-0040-0363#19L120R0
A98L-0040-0363#19L120R0
Wrap the
power line of K002 with braided
K002の動力線を編組チューブで包むこと
tubes. ※アース線は包まないこと
*Do not wrap the earth line.
Power
line (black)
パワー線(黒)
Cable
tie (1-G)
ケーブルタイ(1-G)
Fix the
braided tube with cable
ケーブルタイで編組チューブを
ties 固定のこと
Connector
TS-J1
コネクタ TS-J1
10 10
10
10
クランプフィルタ
Clamp
filter
A45L-0001-0493#A(1)
A45L-0001-0493#A(1)
Cable
K201
ケーブル
K201
A660-4005-T936 (1)
A660-4005-T936(1)
10 10
Cable
tie (1-G)
ケーブルタイ(1-G)
Fix
the braided tube with
ケーブルタイで編組チューブを
cable
ties
固定のこと
Braided tube (1-C)
(Cable K301)
(ケーブル
K301)
編組チューブ(1-C)
Signal
line (black) A98L-0040-0363#19L120R0
信号線(黒)
A98L-0040-0363#19L120R0
Wrap
the signal line of K002,
K002の信号線,
K201,
K301を
K201
and K301 with
braided
tubes.
編組チューブで包むこと
*Do
not wrap the earth line.
※アース線は包まないこと
Cable
K002
ケーブル K002
A05B-1702-D002
(1) ケーブルタイ(1-G)
Cable tie (1-G)
A05B-1702-D002(1)
Fix the braided tube with
ケーブルタイで編組チューブを
固定のこと
cable ties
Signal line (blue
x white)
信号線(青X白)
Gasket
ガスケット
A290-7702-X218
(1)
A290-7702-X218(1)
J1 J1
camera
plate
カメラプレート
A290-7702-X215
(1)
A290-7702-X215(1)
Seal bolt
シールボルト
A97L-0218-0546#030808BC
(4)
A97L-0218-0546#030808BC(4)
Tightening
torque
締結トルク
1.6Nm
(16kgfcm)
1.6Nm(16kgfcm)
(When the force
(カメラケーブル指定時)
sensor
cable is specified)
Fig. 5.3.1 (i) J1 base clamp (bottom side connector panel) (1/2)
Cable
tie (1-G)
ケーブルタイ(1-G)
Fix
the braided tube with cable ties
ケーブルタイで編組チューブを固定のこと
Power line
(red
x white)
パワー線(赤X白)
Connect the TS1
コネクタTS1を接続すること
Braided tube (1-C)
編組チューブ(1-C)
A98L-0040-0363#19L120R0
Wrap A98L-0040-0363#19L120R0
the power line of K002 with braided
K002の動力線を編組チューブで包むこと
*Do not wrap the earth line.
Power
line tubes.※アース線は包まないこと
パワー線(黒)
(black)
Connector
TS-J1
コネクタ TS-J1
Cable tie (1-G)
ケーブルタイ(1-G)
Fix the braided tube with
ケーブルタイで編組チューブを
cable ties
固定のこと
Clamp
filter
クランプフィルタ
A45L-0001-0493#A(1)
A45L-0001-0493#A(1)
Cable
K201
ケーブル
K201
A660-4005-T936
A660-4005-T936(1)(1)
10
10
10 10
Cable tie (1-G)
(Cable K309)
(ケーブル
K309)
Signal
line
信号線(青X白)
(blue x white)
10 10
Signal
line
信号線(黒)
(black)
ケーブルタイ(1-G)
Fix the braided tube with
ケーブルタイで編組チューブを
cable ties
固定のこと
Cable
K009K009
ケーブル
A05B-1702-D009
(1)
A05B-1702-D009(1)
Braided tube (1-C)
編組チューブ(1-C)
A98L-0040-0363#19L120R0
A98L-0040-0363#19L120R0
Wrap
the signal line ofK009,
K009の信号線,
K201, K309を
K201
and K309 with braided
tubes.
*Do 編組チューブで包むこと
not wrap the earth line.
※アース線は包まないこと
Cable tie (1-G)
ケーブルタイ(1-G)
Fix the braided tube with
ケーブルタイで編組チューブを
固定のこと
cable ties
Gasket
ガスケット
A290-7702-X218
(1)
A290-7702-X218(1)
Seal bolt
シールボルト
A97L-0218-0546#030808BC
(4)
A97L-0218-0546#030808BC(4)
Tightening
torque
締結トルク
1.6Nm
(16kgfcm)
1.6Nm(16kgfcm)
(When the force
sensor
cable is specified)
(力センサケーブル指定時)
Fig. 5.3.1 (j) J1 base clamp (bottom side connector panel) (2/2)
- 120 -
5. REPLACING CABLES
B-84195EN/02
55mm以上
55
Camera cable
カメラケーブル
Insulation
tape
絶縁テープ
Wind the insulation tape
コネクタを全て覆うように
2 round so that the whole of[
絶縁テープを2周以上巻くこと。
the
connector is covered.
Wire rod part
：線材部分
Connector part
：コネクタ部分
Fig. 5.3.1 (k) Insulation tape of the camera cable connector
5.3.2
Replacing Cable K115,K121,K122,K123,K221,K303,K310
(J2 base to J2 arm lower side)
Replacing procedure
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
To remove the J1 -axis motor, set a dial gauge at the J1-axis, and prepare for single axis mastering
after replacement. Refer to Subsection 6.4.
Set the Quick Master Reference Position. Refer to the QUICK MASTERING section of the
mechanical unit operator’s manual (B-84194EN). (All the axes are set to 0º before shipment.)
Move the robot to J2=0°, and move the robot to the posture so that the J2 base cover and the J2 arm
cover (root side)can be removed. (recommended posture: J2=0°, J3=0°, other axes are arbitrary)
Turn off controller power.
Remove the J2 arm cover (root side) and the gasket, then remove the battery cable connector. Refer
to Section 2.1.
Remove the J2 cable cover referring to Fig. 4.7. (a) in Section 4.7.
Cut the cable tie (2-A) referring to Fig. 5.3.2 (a).
Cut the cable tie (2-B) referring to Fig. 5.3.2 (b).
Remove the all relay connectors (M3M2, M456M2, M3456P2, TS3, TS-J2, CAM-B or FS-B)
referring to Fig. 5.3.2 (a). (In case of the camera cable, firstly remove the insulation tape. Then remove
the connector.)
Remove the clamp J2-2A referring Fig. 4.6 (a) in Section 4.6.
Remove the J2 base cover referring Fig. 4.2 (a) in Section 4.2.
Remove the relay connector (IND1) of the LED unit.
Remove the LED unit and the J1-axis motor referring to Fig. 4.2 (b) in Section 4.2. (Removing the
gear from the motor is not required.)
Cut the cable ties (1-A), (1-B), (1-C) which fix the braided tube (1-B), then remove the braided tube
(1-B). Refer to Fig. 5.3.1 (a).
Remove the all relay connectors (M12BK1,M3M1,M456M1,M3456P1,TS2,CAM-A or FS-A)
referring to Fig.5.3.1 (a). (In case of the camera cable, firstly remove the insulation tape. Then remove
the connector.)
Remove the bolts, then remove the clamp J2-1 referring to Fig. 5.3.2 (c).
Pull out the J2 arm lower side cable to the J2 base side. Do not pull out cables forcibly when the relay
connectors are caught in the pipe.
Cut the cable tie (2-D) which fix the cable on the clamp J2-1. Then remove the J1/J2 sheet. Refer to
Fig. 5.3.2 (d).
- 121 -
5. REPLACING CABLES
19
20
B-84195EN/02
Replace cables. Then attach those in the reversed sequence. In this time, be careful to the following.

When assembling the clamp J2-2A, pass the cable tie which fix cables thorough the J2-2A, then
assemble it.

(In case of the camera cable) Connect the camera cable connector. Wrap the insulation tape to
the connector 2 rounds or more so that whole of the connector is covered. Refer to Fig.5.3.1 (l).

When mounting the J1-axis motor, refer to Section 4.2.

When assembling the LED unit, be careful the cables does not ride on the LED.

When assembling the J2 arm cover (root side) or the J2 base cover, be careful not to sandwich
the cables.
Perform quick mastering and perform single axis mastering of J1-axis. Refer to the QUICK
MASTERING section of the mechanical unit operator’s Manual (B-84194EN) and Section 6.4 of this
manual.
Cable
tie (2-A)
ケーブルタイ(2-A)
3本のケーブルを縛ること
Bind
three cables
Cable
tie (2-A)
ケーブルタイ(2-A)
Bind
all cables
全てのケーブルを縛ること
Cable
tie (2-A)
ケーブルタイ(2-A)
Bind
two
cables
2本のケーブルを縛ること
Cable tie (2-A)
ケーブルタイ(2-A)
全てのケーブルを縛ること
Bind all cables
Connect
the connector TS-J2
コネクタTS-J2とJ2軸センサコネクタを
and
the J2-axis sensor connector
接続すること
Fig. 5.3.2 (a) Replacing the J2 arm lower side cable (1/2)
- 122 -
5. REPLACING CABLES
B-84195EN/02
Clamp J2-2A
クランプ
J2-2A
A290-7702-X327
A290-7702-X327
Bolt
ボルト
A6-BA-3X8 (4)
A6-BA-3X8(4)
Cable
tie (2-B)
ケーブルタイ(2-B)
Fix
the yellow tape position
黄色テープの箇所を固定すること
Cable tie (2-B)
ケーブルタイ(2-B)
Bind two tubes.
2本のチューブを縛ること
Signal
line
信号線(青X白)
(blue x white)
Sensor
cable J2
センサケーブルJ2
N
Cable
tie (2-B)
ケーブルタイ(2-B)
Cable tie (2-B)
ケーブルタイ(2-B)
Fix the cable M3M2M3M2,
X327の穴でケーブル
M456M2を固定すること
and M456M2.
続きの作業については
Refer to the Fig.5.3.2 (a)
図5.3.2(a)を参照のこと
for continued work
Camera
cable (black)
カメラケーブル
(黒)
Power line 0.5SQ
パワー線0.5SQ(赤X白)
(red x white)
センサケーブル(黒)
Sensor cable (black)
Power
line 0.2SQ
パワー線0.2SQ(赤X白)
(red x white)
Section
O-O
断面 O-O
Connector
M3M2, M456M2,
M3456PS,TS3, CAM-B
コネクタ
or FS-B
M3M2,
M456M2, M3456P2, TS3,
Connect the aboved
CAM-BまたはFS-B
connectors
上記のコネクタを接続すること
コネクタの並びについては
Refer to the section Q-Q
断面
Q-Qを参照すること
about
the connector layout
Q
(When the camera
(カメラケーブル指定時)
Cable tie (2-B)
ケーブルタイ(2-B)
Fix the connector
コネクタとケーブルを
and the cables
固定すること
O
Q
cable is specified)
Force sensor cable
(blue力センサケーブル
x white)
(青X白)
Power line 0.5SQ
パワー線0.5SQ(赤X白)
(red x white)
J2-axis
sensor cable
J2軸センサケーブル
Cable
tie (2-B)
ケーブルタイ(2-B)
N
J2-axis
sensor connector
J2軸センサコネクタ
O
Clamp J2-2B
クランプ J2-2B
A290-7702-X328
A290-7702-X328
Bolt
ボルト
A6-BA-3X8
(2)
A6-BA-3X8(2)
Cable tie (2-B)
ケーブルタイ(2-B)
Fix the cable M3M2
and
X327の穴でケーブル
M3M2,M456M2
M456M2 with hole of the X327
を固定すること
続きの作業については
Refer to Fig. 5.3.2 (a)
図5.3.2(a)を参照のこと
for the continued work
Force sensor cable
力センサケーブル(黒)
(black)
Signal
line
信号線(青X白)
(blue x white)
Sensor cable (black)
センサケーブル(黒)
Power
line 0.2SQ
パワー線0.2SQ(赤X白)
(red x white)
Section
断面O-O
O-O
Section
N-N
断面
N-N
(When the force
(力センサケーブル指定時)
sensor cable is specified)
Connector
M3456P2
コネクタ
M3456P2
Connector
コネクタM3M2
M3M2
Connector TS-J2
コネクタ TS-J2
Refer
to Fig. 5.3.2 (a)
続きの作業については
for
the continued work
図5.3.2(a)を参照のこと
Connector
M456M2
コネクタ
M456M2
Connector
CAM-B
コネクタ CAM-B
Section
断面 Q-Q
Q-Q
Section
P-P
断面 P-P
P
Connector
TS3
コネクタ TS3
(When the camera
(カメラケーブル指定時)
cable
is specified)
Connector
BT456
コネクタ BT456
Connector
BT123
コネクタ BT123
Connector
コネクタ TS3
TS3
Connector
コネクタM3M2
M3M2
Connector
M456M2
コネクタ
M456M2
P
Connector
コネクタM3456P2
M3456P2
Connector FS-B
コネクタ FS-B
Section
Q-Q
断面 Q-Q
(When the force
(力センサケーブル指定時)
sensor cable is specified)
Fig. 5.3.2 (b) Replacing the J2 arm lower side cable (2/2)
2
1
Fig. 5.3.2 (c) Removal of the clamp J2-1
Parts name
1
2
BOLT
CLAMP J2-1
Specifications
A6-BA-4X10
A290-7702-X322
Q’ty
2
1
- 123 -
Locking
Torque N-m
(kgf-cm)
5. REPLACING CABLES
B-84195EN/02
Cable
clamp position of J2-1
J2-1のケーブルクランプ位置
X322X322
clamp
position
クランプ位置
Cable K123
Connector
M3456P2
ケーブル K123
コネクタ
M3456P2
A660-4005-T925
A660-4005-T925
Signal line信号線(青X白)
(blue x white)
Cable
K303
or K310
ケーブル
K303またはK310
Connector
CAM-B
A660-2008-T762
or A660-2008-T767 コネクタ
A660-2008-T762またはA660-2008-T767
CAM-B
or FS-B
Camera
cable (黒)または
(black) or
カメラケーブル
またはFS-B
力センサケーブル(黒、青X白)
Force
sensor cabel (black, blue x white)
Cable
K221 K221
ケーブル
A660-4005-T937
A660-4005-T937
Sensor
cable (black)
センサケーブル(黒)
Cable K122
ケーブル K122
A660-2008-T755
A660-2008-T755
Power lineパワー線0.2AQ(赤X白)
0.2SQ (red x white)
Connector
コネクタM3456P1
M3456P1
Connector
コネクタ BT123
BT123
Connector
CAM-A
コネクタ CAM-A
or FS-A
またはFS-A
Connector
コネクタ BT456
BT456
Connector
コネクタ
TS3TS3
Connector
TS2
コネクタ TS2
Connector
コネクタ TS-J2
Connector
コネクタ
M456M2
M456M2
Connector
コネクタM456M1
M456M1
Cable K121
ケーブル K121
A660-2008-T754
Connector
M3M2
A660-2008-T754
コネクタ M3M2
Power lineパワー線0.5SQ(赤X白)
0.5SQ (red x white)
Connector
M3M1
コネクタ M3M1
Clamp
J2-1
クランプ
J2-1
A290-7702-X322(1)
A290-7702-X322
(1)
24
Cable
K123
ケーブル
K123
A660-4005-T925
A660-4005-T925(1)(1)
Signal
line (blue x white)
信号線(青X白)
Connector
コネクタ
M3456P1
M3456P1
Cable
K221
ケーブル
K221
A660-4005-T937
A660-4005-T937(1)(1)
Sensor
cable (black)
センサケーブル(黒)
Cable
K303
ケーブル
K303
A660-2008-T762(1)
A660-2008-T762
(1)
カメラケーブル
(黒)
Camera cable (black)
(A290-7702-X325)
Section
A-A
断面 A-A
A
A
Cable K122
ケーブル
K122
A660-2008-T755(1)
A660-2008-T755 (1)
パワー線0.2SQ(赤X白)
Power line 0.2SQ (red x white)
Cable
K121K121
ケーブル
A660-2008-T754(1)
A660-2008-T754
(1)
パワー線0.5SQ(赤X白)
Power
line 0.5SQ
(red x white)
Connector
コネクタ
M456M1,
M456M1,M3M1
M3M1
Connector
コネクタ
TS2,
CAM-A
TS2,CAM-A
or またはFS-A
FS-A
Cable
tie (2-C)
ケーブルタイ(2-C)
(When the camera
(カメラケーブル指定時)
cable
is specified)
J1/J2
sheet
J1/J2
シート
A290-7702-X325
(1)
A290-7702-X325(1)
クランプJ2-1とケーブルとJ1/J2シートを固定後、
Fix
the clamp J2-1, the cable,
ケーブルタイにてJ1/J2シートを閉じること（下図参照）
and
the J1/J2/ sheet.
Then close the J1/J2 sheet with cable ties.
(Refer to the following figure)
Cable
K123
ケーブル
K123
A660-4005-T925
A660-4005-T925(1)(1)
Signal
line (blue x white)
信号線(青X白)
Cable K221
ケーブル K221
A660-4005-T937
(1)
A660-4005-T937(1)
Sensor
cable (black)
センサケーブル(黒)
Cable K310
ケーブル K310
A660-2008-T767
(1)
A660-2008-T767(1)
Force
sensor cable (black)
力センサケーブル(黒)
Cable
K310
ケーブル
K310
A660-2008-T767
A660-2008-T767
力センサケーブル(青X白)
Force
sensor cable (blue x white)
(A290-7702-X325)
Cable
K122
ケーブル
K122
A660-2008-T755
(1)
A660-2008-T755(1)
Power
line 0.2SQ (red x white)
パワー線0.2SQ(赤X白)
Section
A-A
断面 A-A
Cableケーブル
K121 K121
A660-2008-T754
(1)
A660-2008-T754(1)
パワー線0.5SQ(赤X白)
Power
line 0.5SQ (red x white)
(When the force
Braided tube (1-B)
(力センサケーブル指定時)
編組チューブ(1-B)
A98L-0040-0363#19L120R0
(1)
sensor
cable is specified)
WrapA98L-0040-0363#19L120R0(1)
the cable K123, K221 K303
ケーブル K123、K221、K303または
or K310
with
the
braided
tube.
K310を編組チューブで包むこと
(Cable
tie (1-C)
(ケーブルタイ(1-C))
(Fix(ケーブルタイで編組チューブを固定のこと)
the braided tube with cable ties)
(A290-7702-X325)
10
20
Braided tube (1-B)
編組チューブ(1-B)
A98L-0040-0363#19L120R0
(1)
A98L-0040-0363#19L120R0(1)
Wrap
the cable K121, K122 with the braided
ケーブル K121, K122を編組チューブで包むこと
tube.
Cable
tie (2-C)
ケーブルタイ(2-C)
Fixation method
of the J1/J2 sheet and braided tubes.
J1/J2シート及び編組チューブ固定方法
Fig.5.3.2 (d) Cable clamp of the clamp J2-1
- 124 -
5. REPLACING CABLES
B-84195EN/02
5.3.3
Replacing Cable K131,K132,K13,K134,K231,K304,K311
(J2 arm lower side to J3 casing)
Replacing procedure
1
2
3
4
5
6
7
8
9
Set the Quick Master Reference Position. Refer to the QUICK MASTERING section of the
mechanical unit operator’s manual (B-84194EN). (All the axes are set to 0º before shipment.)
Move the robot to J3=0°. Then move the robot to the posture that the J2 arm cover (root side and tip
side) and the J3 casing cover can be removed.(recommended posture: J3=0°, other axes are arbitrary.)
Turn off controller power.
Remove the J2 arm cover (root side) referring to Section 2.1.
Remove the J2 cable cover referring Fig. 4.7 (a) in Section 4.7.
Cut the cable tie (2-A) referring to Fig. 5.3.2 (a).
Cut the cable tie (2-B) referring to Fig. 5.3.2 (b).
Remove the all relay connectors (M3M2, M456M2, M3456P2, TS3, CAM-B or FS-B) referring to
Fig.5.3.2 (b). (In case of the camera cable, remove the insulation tape. Then remove the connectors.)
According to the beginning of Chapter 4, take measures against static electricity.
CAUTION
Be sure to take measures against static electricity before removing the J3 casing
cover. If you touch the tool I/F board without measures, the tool I/F might break.
10
11
12
13
14
15
16
17
18
19
20
21
22
Remove the J3 casing cover referring Fig.4.10 (a) in Section 4.10.
Cut the cable tie (3-C), then peel off the sheet J3 cover from the clamp J4-1 referring to Fig.5.3.3(a).
The sheet J3 cover will be reused. So be careful to the following.

Carefully peel off the sheet J3 cover during being careful not to break it and no dirt adhere to it.

When reusing it, if the sheet J3 cover is broken or cannot paste due to dirty, replace it by new
one.
Cut the cable ties (3-A) and (3-B) which fix the cables on the tool I/F board and the clamp J3-2. Refer
to Fig.5.3.3 (b).
Remove all relay connectors (M456P3,M4M3,M5M3,M6M3,TS4, TS-J4, CAM-C or FS-C) and the
all connectors (CRS54,CRS55) connected to the tool I/F board. Refer to Fig.5.3.3 (b).
(In case of the camera cable, remove the insulation tape. Then remove the connectors.)
Remove the J2 arm cover (tip side) referring to Fig. 4.8 (a) in Section 4.8.
Peel off the sheet J3 motor referring to Fig.5.3.3 (c). To reuse the sheet J3 motor, be careful to the
following.

Carefully peel of the sheet J3 motor so that not to break it and not to it’s tape surface get dirty.

If the sheet J3 motor is broken or it have cannot be adhere due to dirt, replace it by new one.
Remove the Pulsecoder connector(M3P) of the J3-axis motor and the relay connector (M3M3)
referring to Fig.5.3.3 (c).
Remove the clamp J3-1A . Then pull out the J2 arm root side cables to the J2 arm tip side. Refer to
Fig.5.3.3 (d). Do not pull out cables forcibly during the relay connectors are caught at the J2 arm or
the metal plate.
According to Fig.5.3.3 (e), remove the clamp J3-1B, then pull out J3 casing side cables to the J2 arm
side. Do not pull out cables forcibly during the relay connectors are caught in the pipe.
Cut the cable tie (3-D) which fix the clamp J3-1A referring to Fig.5.3.3 (c).
Cut the cable tie (3-E) which fix the clamp J3-1B, braided tubes, the sheet J3-1, then remove those
parts. Refer to Fig .5.3.3 (f).
Remove the tool I/F board cover and the clamp J3-2. Pass the cable tie which fix cable through two
part, then reassemble it. When assembling the tool I/F board cover, tighten it with them with tightening
torque 0.9Nm(9kgfcm). (Refer to Fig.4.10 (b) in Section 4.10)
Replace cable. Then assemble those by the reversed sequence. In this time, be careful to the following.

(In case of the camera cable) After connecting the camera cable connector, wrap the insulation
tap 2 round or more so that the whole of the connector is covered. Refer to Fig.5.3.1 (l).
- 125 -
5. REPLACING CABLES
B-84195EN/02

23
When assembling the J2 arm cover (root side and tip side) or the J3 casing cover, be careful not
to sandwich the protection sheet and cables.
Perform quick mastering. Refer to the QUICK MASTERING of the mechanical unit operator’s
Manual (B-84194EN).
Cable tie (3-C)
ケーブルタイ(3-Ｃ)
Fix the sheet J3 cover
シートJ3カバーと
and the J3-axis sensor
J3軸センサケーブルを
cable
固定すること
Attach
貼り付け
Sheet
J3 cover
シートJ3カバー
A290-7702-X424
(Clamp
J4-1)
(クランプ
J4-1)
(A290-7702-X420)
(290-7702-X420)
A290-7702-X424
Fig. 5.3.3 (a) Replacing the J3 casing cables (1/2)
Force
sensor cable (black)
力センサケーブル(黒)
Signal line
(blue x white)
信号線(青X白)
Camera cable (black)
カメラケーブル (黒)
Signal line
信号線(青X白)
(blue
x white)
Force
sensor cable (blue x white)
力センサケーブル(青X白)
Power
line (red x white)
パワー線(赤X白)
Power
line (red x white)
パワー線(赤X白)
Sensor
cable (black)
センサケーブル(黒)
Sensor cable (black)
センサケーブル(黒)
Section
R-R
断面 R-R
Section
R-R
断面 R-R
3:1
3:1
(When the force
(力センサケーブル指定時)
sensor cable is specified)
(When the camera
(カメラケーブル指定時)
cable is specified)
Clamp J3-2
クランプ J3-2
A290-7702-X419
A290-7702-X419
Bolt
ボルト
A6-BA3X8
(3)
Connector
TS-J3
コネクタ TS-J3
A6-BA-3X8(3)
J3-axis sensor cable
J3軸センサケーブル
Cable
tie (3-B)
ケーブルタイ(3-B)
Fix
the yellow tape position.
黄色テープの
Cable tie (3-B)
ケーブルタイ(3-B)
箇所を固定すること
Cable
tie (3-A)
ケーブルタイ(3-A)
R
R
Connector
コネクタCRS54
CRS54
Connect
i to the
ツールI/Fボードに
tool
I/F board
接続すること
Connect
connector TS4
コネクタthe
TS4を接続すること
Connect the connector FS-C
コネクタ
FS-CまたはCAM-Cを接続すること
or
the CAM-C.
Cable tie (3-A)
ケーブルタイ(3-A)
ToolツールI/Fボードカバー
I/F board cover
Cable
tie (3-A)
A290-7702-X417
ケーブルタイ(3-A)
A290-7702-X417
Fix
only
the
power
line
bolt
"パワー線(赤X白)"のみ Spacer
スペーサボルト
(red
x white)
A97L-0218-0745#10
(3)
固定すること
A97L-0218-0745#10(3)
Screw
スクリュー
A6-SW2NA-3X6S (3)
Cable tie (3-A)
J4-axis
sensor cable
J4軸センサケーブル
Connector
コネクタ
M456P3, M4M3, M5M3, M6M3
M456P3,M4M3,M5M3,M6M3
Connect the aboved connectors
上記のコネクタを接続すること
ケーブルタイ(3-A)
Connect the J4 sensor cable
コネクタ
TS-J4 TS-J4
of the connector
J4センサのケーブルと
and the white connector.
白色のコネクタを接続すること
Connector
CRS55
コネクタ CRS55
Connect
it to the tool I/F board
ツールI/Fボードに接続すること
Cable tie (3-A)
ケーブルタイ(3-A)
Fix only the signal line (blue x white)
"信号線(青X白)"のみ固定すること
Fig. 5.3.3 (b) Replacing the J3 casing cables (2/2)
- 126 -
A6-SW2NA-3X6S(3)
5. REPLACING CABLES
B-84195EN/02
Cable
clamp position of the J3-1A
J3-1Aのケーブルクランプ位置
A05B-1702-H201-K3
or
A05B-1702-H201-K3または
A05B-1702-H202-K3
A05B-1702-H202-K3
A05B-1702-B202(CRX-10iA/L)
X330
position
X330 clamp
クランプ位置
Green
緑
Connector
コネクタ M3M3
M3M3
(T301 or T302)
Green
緑
A05B-1702-B201
(CRX-10iA)
A05B-1702-B201(CRX-10iA)
Extra
length part
余長部分
(A290-7702-X331)
(Signal
line)
(信号線)
(T301 または T302)
Clamp J3-1A
クランプ
J3-1A
A290-7702-X330
A290-7702-X330
Bolt
ボルト
A6-BA-3X8 (2)
A6-BA-3X8(2)
A05B-1702-B201
(CRX-10iA)
A05B-1702-B201(CRX-10iA)
X330clamp
クランプ位置
X330
position
A05B-1702-B201 (CRX-10iA)
A05B-1702-B201(CRX-10iA)
Referto
the right figure for extra part works
余長部分の作業については右の図を参照すること
A05B-1702-B201 (CRX-10iA)
(Power line)
(パワー線)
A05B-1702-B201(CRX-10iA)
Insert the extra part to this
余長部分をこの位置に入れること
position
(A2909-7702-X331)
(A290-7702-X331)
Pass the cales through
モータ固定前に
J3 hollow hole
J3中空穴にケーブルを通し、
before motor fixation.
X331を固定すること
Refer to the following figure
チューブの固定については
for tube fixation
下図を参照のこと
Sheet J3 motor
シート J3 モータ
A290-7702-X335
A290-7702-X335
Then fix the X331.
モータに張り付けること
Attach
to the motor.
(T301 または T302)
続きの作業については
(T301
ボルトor T302)
Bolt
A6-BA-3X8(2)
A6-BA-3X8 (2)
Connect the connector
コネクタM3M3を接続すること
M3M3
For continued
works,
下図を参照のこと
refer to the lower
figure.
Connector
M3P
コネクタ M3P
(A290-7702-X330)
(V301)
(V301)
Cable
K133
ケーブル
K133
A660-4005-T926
A660-4005-T926
Cable tie (3-D)
ケーブルタイ（3-D)
Fix the green tape position
緑色テープの箇所を固定すること
Attach it on the motor
モータに張り付けること
(Power
line)
(パワー線)
(Signal
line)
(信号線)
Fig. 5.3.3 (c) Replacing the J2 arm upper side cables
1
2
Fig. 5.3.3 (d) Removal of the clamp J3-1A
Parts name
1
2
BOLT
CLAMP J3-1A
Specifications
A6-BA-3X8
A290-7702-X330
Q’ty
2
1
- 127 -
Locking
Torque N-m
(kgf-cm)
5. REPLACING CABLES
B-84195EN/02
1
2
Fig. 5.3.3 (e) Removal of the clamp J3-1B
Parts name
1
2
BOLT
CLAMP J3-1B
Specifications
A6-BA-3X8
A290-7702-X331
Q’ty
2
1
- 128 -
Locking
Torque N-m
(kgf-cm)
5. REPLACING CABLES
B-84195EN/02
Cable
clamp position of the J3-1B
J3-1Bのケーブルクランプ位置
Cable K134
ケーブル K134
A660-4005-T927
A660-4005-T927
signal
line (blue x white)
X331
clamp position
X331 クランプ位置
Connector
M3456P2
コネクタ M3456P2
Connector
コネクタ M456P3
M456P3
Connector
CRS55
コネクタ CRS55
信号線(青X白)
Cable
K304
or cable K311
ケーブル
K304または、ケーブル
K311
A660-2008-T763
or A660-2008-T768
Connector
A660-2008-T763または、A660-2008-T768
コネクタ CAM-C
CAM-C
Camera
cable (black)
or
カメラケーブル
(黒)または、
or FS-C
または、FS-C
Force
sensor
cable
(black,
blue
x
white)
力センサケーブル（黒、青X白）
Connector CAM-B
orコネクタ
FS-B CAM-B
Connector
M3P
コネクタ M3P
Connector
コネクタ CRS54
CRS54
または、FS-B
Connector
TS3
コネクタ TS3
Connector
コネクタ TS4TS4
Cable
K231
ケーブル
K231
A660-4005-T938
A660-4005-T938
センサケーブル(黒)
sensor
cable (black)
Connector
コネクタ TS-J3
TS-J3
Connector
コネクタTS-J4
TS-J4
Connector
M456M2
コネクタ M456M2
Connector
コネクタM4M3
M4M3
Cable K132
ケーブル
K132
A660-4005-T928
A660-4005-T928
Power line 0.2SQ (red x white)
パワー線0.2SQ(赤X白)
Connector
コネクタM5M3
M5M3
Binding position
縛る位置
Connector
M6M3
コネクタ
M6M3
Connector
コネクタM3M3
M3M3
Cable
K131
ケーブル
K131
A660-2008-T756
A660-2008-T756
Power
line 0.5SQ (red x white)
パワー線0.5SQ(赤X白)
Connector
M3M2
コネクタ M3M2
(A290-7702-X333)
(A290-7702-X333)
C
Cable K134
ケーブル K134 (1)
A660-4005-T927
A660-4005-T927(1)
signal
line (blue x white)
Clamp
クランプJ3-1B
J3-1B
A290-7702-X331(1)
A290-7702-X331(1)
Connector
コネクタ
M3456P2
M3456P2
信号線(青X白)
Cable K304
ケーブル K304
A660-2008-T763
(1)
A660-2008-T763(1)
camera
cable (black)
カメラケーブル
(黒)
A
Cable
K231K231
ケーブル
A660-4005-T938(1)
A660-4005-T938
(1)
センサケーブル(黒)
sensor cable (black)
Cable tie (3-E)
ケーブルタイ（3-E)
Bind
the cable
K131 andK132を縛ること
K132
ケーブル
K131とケーブル
Cable tie (3-E)
ケーブルタイ（3-Ｅ)
Cable
K132
ケーブル
K132
A660-4005-T928(1)
A660-4005-T928
(1)
パワー線(赤X白)
power
line (red x white)
Cable
K131
ケーブル
K131
A660-2008-T756
(1)
A660-2008-T756(1)
パワー線(灰)
power
line (gray)
Connector
M3M3
コネクタ M3M3
Section
C-C
断面 C-C
C
(When
the camera cable is specified)
(カメラケーブル指定時)
Sheet
J3-1
シート
J3-1
A290-7702-X333
(1)
A290-7702-X333(1)
FixクランプJ3-1BとケーブルとシートJ3-1を固定後、
the clamp J3-1B, cables and thesheet J3-1.
ケーブルタイにてシートJ3-1を閉じること（下図参照）
Then
close the sheet J3-1 with cable ties.
(See the following figure)
(A290-7702-X333)
Cable K134
ケーブル K134
A660-4005-T927
(1)
A660-4005-T927(1)
signal
line (blue x white)
信号線(青X白)
Cable K311
ケーブル K311
A660-2008-T768
(1)
A660-2008-T768(1)
force
sensor cable (black)
Connector
TS3,
コネクタ
TS3,CAM-B
CAM-B or
or FS-B
またはFS-B
Connector
コネクタ
M456M2,
M3M2
M456M2,
M3M2
力センサケーブル(黒)
Cable
K311
ケーブル
K311
A660-2008-T768
A660-2008-T768 (1)
force
sensor cable (blue x white)
力センサケーブル(青X白)
Cable K231
ケーブル K231
A660-4005-T938
A660-4005-T938(1)(1)
sensor
cable (black)
センサケーブル(黒)
Cable K132
ケーブル
K132
A660-4005-T928 (1)
A660-4005-T928(1)
パワー線(赤X白)
power line (red x white)
Section
C-C
断面 C-C
(When
the
force
(力センサケーブル指定時)
sensor cable is specified)
Cable
tie (3-E)
ケーブルタイ(3-E)
Braided tube
編組チューブ
A98L-0040-0363#19L780R0(1)
A98L-0040-0363#19L780R0(1)
Wrap the cable K134,K231,K304 or K311 with braided tube
ケーブル K134、K231、K304またはK311を編組チューブで包むこと
240
70
5
20
20
A
20
Cable
tie (3-E)
ケーブルタイ（3-E)
Fix
the braided tube
ケーブルタイで
With
cable
ties
編組チューブを固定のこと
Braided tube
編組チューブ
A98L-0040-0363#19L800R0(1)
A98L-0040-0363#19L800R0(1)
Wrap
the cable K131 and K132
K131、K132を
withケーブル
braided tube
編組チューブで包むこと
Fixation method of the sheet J3-1 and braided tube
シートJ3-1及び編組チューブ固定方法
Fig. 5.3.3 (f) Cable clap of the clamp J3-1B
- 129 -
Cable
tie (3-E)
ケーブルタイ（3-E)
Fix
the braided tube
ケーブルタイで
With
cable
ties
編組チューブを固定のこと
5. REPLACING CABLES
5.3.4
B-84195EN/02
Replacing Cable K141,K142,K241,K306,K312
(J3 casing to J3 arm)
Replacing procedure
1
2
3
4
5
6
7
8
To remove the J4 unit, set a dial gauge at the J4-axis, and prepare for single axis mastering after
replacement. Refer to Section 6.4.
Set the Quick Master Reference Position. Refer to the QUICK MASTERING sections of the
mechanical unit Operator’s Manual (B-84194EN). (All the axes are set to 0º before shipment.)
Move the robot to J4=0°, and move the robot to the posture so that the J3 casing cover, the J3 arm
cover and the wrist unit can be removed. (recommended posture：J3=0°,J4=0°, other axes are arbitrary)
Turn off controller power.
According to Fig.4.11 (a) in Section 4.11, remove the J3 arm cover.
According to Fig.5.3.4 (a), cut the cable tie (4-B) which fix the cables on the J5-2 and the cable tie (4C) which fix the sheet J5-1. To reuse the sheet J5-1, be careful to the following.

Carefully cut the cable tie (4-C) during being careful not to break the sheet J5-1.

If the sheet J5-1 is broken when it is reused, replace it by new one.
According to Fig.5.3.4 (a), remove the all relay connectors (M5M4, M6M4, M5P4, M6P4,TS5, CAMD or FS-D).(In case of the camera cable connector, remove the insulation tape. Then remove the
connector.)
According to the beginning of Chapter 4, take measures against static electricity.
CAUTION
Be sure to take measures against static electricity before removing the J3 casing
cover. If you touch the tool I/F board without measures, the tool I/F might break.
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
Remove the J3 casing cover referring to Fig.4.10 (a) in Section 4.10.
According to Fig.5.3.3 (a), cut the cable tie (3-C). Then peel of the sheet J3 cover from the clamp J41. To reuse the sheet J3 cover, be careful to the following.

Carefully peel off the sheet J3 cover during being careful not to break it and no dirt adhere to it.

When reusing it, if the sheet J3 cover is broken or cannot paste due to dirty, replace it by new
one.
According to Fig.5.3.3 (b), cut the cable tie (3-A) which fix cables on the tool I/F board.
According to Fig.5.3.3 (b), remove the all relay connectors (M456P3, M4M3,M5M3,M6M3,TS4, TSJ4, CAM-C or FS-C). (In case of the camera cable connector, remove the insulation tape. Then remove
the connector.)
According to Fig. 4.11 (b) in Section 4.11, remove the J4-axis cover.
According to Fig. 4.12 (a) in Section 4.12, remove the J3 arm unit.
According to Fig. 4.12 (b) in Section 4.12, remove the J4 unit from the J3 arm unit. In this time, Pull
out cable in the J3 arm to the J4 unit side. Do not pull out cables forcibly during the relay connectors
are caught at the J5 motor unit or the J3 arm.
According to Fig.5.3.4 (b), peel off the sheet J4 motor. Then remove the all connectors (M4M, M4BK,
M4P) connected to the J4-axis motor. To reuse the sheet J4 motor, be careful to the following.

Carefully peel off the sheet J4 motor during being careful not to break it and no dirt adhere to it.
According to Fig.5.3.4 (b), cut cable ties (4-E), (4-F).
According to Fig.5.3.4 (c), remove the clamp J4-2.
Pull out the J4-axis sensor side cables to the J4-axis motor side. Do not pull out cables forcibly during
the relay connectors are caught in the pipe.
According to Fig.5.3.4 (b), (d),(e), cut the cable tie (4-G). Then remove the braided tubes.
Replace the cables. According to Fig. 5.3.4 (d), (e), fix the clamp J4-2 and the braided tube with the
cable tie (4-G).
According to Fig.5.3.4 (b), make the cables fixed on the clamp J4-2 pass from the J4-axis motor side
to the J4-axis sensor side. Do not pull out cables forcibly during the relay connectors are caught in the
pipe.
According to Fig.5.3.4 (c), attach the clamp J4-2.
- 130 -
5. REPLACING CABLES
B-84195EN/02
24
25
According to Fig.5.3.4 (b), fix the cables on the clamp J4-1 with the cable tie (4-E).
According to Fig.5.3.4 (b), connect the connectors(M4M,M4BK,M4P) to the J4-axis motor, fix the
cables with the cable tie (4-F). Then paste the sheet J4 motor. In this time, be careful to the following.

Tighten the J4-axis motor connector (M4M,M4BK) to 0.11Nm (1.1kgfcm).

If the sheet J4 motor is broken or cannot paste due to dirty, replace it by new one.
While passing the cable to the J3 arm tip side, according to procedure 35 and Fig. 4.12 (b) in Section
4.12, attach the J4 unit on the J3 arm unit. Do not pull out cables forcibly during the relay connectors
are caught at the J5 motor unit or the J3 arm.
According to procedure 36 and Fig.4.12 (a) in Section 4.12, attach the J3 arm unit.
Remove the tool I/F board cover. Pass the cable tie (3-A) which fix cables through the parts. Then
retighten it to regulated torque 0.9Nm (9kgfcm). (See Fig.4.10 (b) in Section 4.10)
According to the reversed sequence of procedure 5 to 13, assemble parts such as cover, and wire the
cables. In this time, be careful to the following.

(In case of the camera cable) After connecting the camera cable connector, wrap the insulation
tap 2 round so that the whole of the connector is covered. Refer to Fig.5.3.1 (l).

When assembling the J3 casing cover and the J3 arm cover, be careful not to sandwich the
protection sheet and cables.
Perform single axis mastering of J4-axis after you perform quick mastering. Refer to the QUICK
MASTERING of the mechanical unit operator’s Manual (B-84194EN) and Section 6.4.
26
27
28
29
30
ケーブルタイ(4-C)
Cable
tie (4-C)
シートthe
J5-1の穴を通すこと
Pass
hole of the sheet J5-1
Fix the cables with cable ties.
ケーブルタイで
Then attach the sheet
J5-1 (X546)
ケーブル固定後、
*Refer to the rightシート
figureJ5-1 (X546)を
Cable tie (4-B)
ケーブルタイ(4-B)
ケーブルタイで編組チューブを固定のこと
Fix the braided tube with the cable tie.
(A290-7702-X546)
Section
W-W
断面 W-W
(2 locations)
(2箇所)
取り付けること
※右図参照
(H201-K4)
or (H202-K4)
(H201-K4)または(H202-K4)
W
Clamp
クランプJ5-2
J5-2
A290-7702-X540
A290-7702-X540
Bolt
ボルト
A6-BA-3X8(2)
A6-BA-3X8
(2)
Sheet
シート J5-1
J5-1
A290-7702-X546
A290-7702-X546
W
Cable
tie (4-C)
ケーブルタイ(4-C)
Fixthe sheet J5-1
クランプJ5-2の切り欠きで
with
notch
of teh clamp J5-2
シート J5-1を固定すること
Connector
コネクタ
M5M4,
TS5,
M5M4, M6M4,
M6M4,TS5,
CAM-DまたはFS-D,
M5P4,
M6P4
CAM-D
or FS-D, M5P4,
M6P4
上記のコネクタを接続すること
Connect
the aboved connectors.
Sheet J5-1 attach
シート J5-1取付図
U
U
Cable tie (4-A)
ケーブルタイ(4-A)
Cable K307
ケーブル K307
A660-2008-T766
A660-2008-T766
Camera
cable (black)
カメラケーブル
(黒)
Cable tie (4-D)
ケーブルタイ(4-D)
(A290-7702-X539)
Bolt
ボルト
A6-BA-3X8
(2)
A6-BA-3X8(2)
Cable
K251 K251
ケーブル
A660-4005-T939
A660-4005-T939
Sensor
cable (black)
センサケーブル(黒)
V
Cable K313
Cable K152
ケーブル K152
Cable K152
ケーブル K313
A660-2008-T770
A05B-1702-D006
ケーブル K152
A05B-1702-D006
A660-2008-T770
A05B-1702-D006
Force
sensor cable (black)
A05B-1702-D006
Powerパワー線(赤X白)
line (red x
力センサケーブル(黒)
Power
line (red x white)
パワー線(赤X白)
Cable K313
ケーブル K313
A660-2008-T770
A660-2008-T770
Force sensor cable
力センサケーブル(青X白)
Cable K154
(blue x white)
Cable K154
A660-4005-T934
ケーブル K154
ケーブル K154
A660-4005-T934
Cable
K251 K251
Signal
line
A660-4005-T934
ケーブル
A660-4005-T934
Signal
line
信号線(青X白)
A660-4005-T939
A660-4005-T939
信号線(青X白)
(blue
x white)
Section
V-V (blue x white)
センサケーブル(黒)
断面 V-V
Section V-V
Sensor
cable (black)
4:1
(When
the camera
(カメラケーブル指定時)
cable is specified)
V
Connector
M5P
コネクタ M5P
Connector
M5BK
コネクタ
M5BK
Connector
コネクタ M5M
M5M
Section
断面U-U
U-U
Cable
tie (4-D)
ケーブルタイ(4-D)
Fix
it so that no to touch the motor
モータに接触しないように留めること
Cable
tie (4-A)
ケーブルタイ(4-A)
Fix
the yellow tape position
黄色テープの箇所を固定すること
Fig. 5.3.4 (a) Replacing the J3 arm cables
- 131 -
断面 V-V
4:1
(When
the force sensor
(力センサケーブル指定時)
cable is specified)
5. REPLACING CABLES
B-84195EN/02
Power
line (red x white)
パワー線(赤X白)
Signal line
(blue x white)
信号線(青X白)
Signal 信号線(青X白)
line (blue x white)
Sensor cable (black)
センサケーブル(黒)
Sensor cable
センサケーブル
J4J4
Power line (red x white)
パワー線(赤X白)
Sensor
cable J4 J4
センサケーブル
Camera
cable (black)
カメラケーブル
(黒)
Sensor
cable (black)
センサケーブル(黒)
Force sensor cable (blue x white)
力センサケーブル(青X白)
Section
T-T
断面 T-T
Align
the sheet J4 motor edge
シートJ4モータの端と
and
the J4 motor edge.
J4モータの端を揃えて貼ること
Force sensor cable (black)
力センサケーブル(黒)
Section
T-T
断面 T-T
2:1
2:1 sensor
(When the force
(力センサケーブル指定時)
cable is specified)
(When
the camera
(カメラケーブル指定時)
cable is specified)
S
T
Cable tie (4-E)
ケーブルタイ(4-E)
Fix yellow tape
黄色テープの箇所を
position
固定すること
Section
断面 R-R
R-R
Paste
2 points with
シートJ4モータに
double-sided
tape
貼付されている
attached
to the sheet
両面テープで2箇所
J4
motor
貼り付けること
Connector
コネクタM4BK
M4BK
Sheet J4 motor attach
シート J4モータ取付図
Connector M4M
T
コネクタ M4M
After attaching the connectors
J4モータへのコネクタ取付後、
on theJ4-axis motor,
シートJ4モータを貼り付けること(上図参照)
paster the sheet J4 motor
(refer to the aboved figure)
Cable tie (4-F)
ケーブルタイ(4-F)
Sheet
J4-1J4-1
シート
A290-7702-X422
A290-7702-X422
After
fixing
the cable,
ケーブル固定後、
close
it with the cable tie
ケーブルタイにて
(refer
to the lower figure)
閉じること(下図参照)
(Adhesive
tape)
(接着テープ)
Sheet J4 motor
シートJ4モータ
A290-7702-X425
A290-7702-X425
R
R
View
斜視S S
Connector M4P
コネクタ M4P
Clamp J4-1
CLAMP J4-1
A290-7702-X420
A290-7702-X420
Bolt
ボルト
A6-BA-2.5X6
(4)
A6-BA-2.5X6(4)
Cable tie (4-G)
ケーブルタイ(4-G)
Cable tie (4-E)
ケーブルタイ(4-E)
Sheet J4 attach
シート J4取付図
Clamp
J4-2
クランプ
J4-2
A290-7702-X421
A290-7702-X421
Bolt
ボルト
A6-BA-3X8
(2)
A6-BA-3X8(2)
Fig. 5.3.4 (b) Replacing the J4 unit cables
2
1
Fig. 5.3.4 (c) Removal of the clamp J4-2
Parts name
1
2
BOLT
CLAMP J4-2
Specifications
A6-BA-3X8
A290-7702-X421
Q’ty
2
1
- 132 -
Locking
Torque N-m
(kgf-cm)
5. REPLACING CABLES
B-84195EN/02
(A290-7702-X423)
SheetJ4-2
シート J4-2
A290-7702-X423 (1)
A290-7702-X423(1)
E
Cable tie (4-G)
ケーブルタイ(4-G)
Fix
the clamp J4-2 and the cables and the sheet J4-2
Cable K141
ケーブル
K141
A660-4005-T930 (1)
A660-4005-T930(1)
0.2SQ power line (red x white)
0.2SQパワー線(赤X白)
クランプJ4-2とケーブルとシートJ4-2を固定
Make the cable tie head
ケーブルタイの頭の位置を
to this position
図の位置にすること
Cable K241
ケーブル K241(1)
A660-2008-T760
A660-2008-T760(1)
Torque
sensor cable (black)
Cable
tie (4-G)
ケーブルタイ(4-G)
トルクセンサケーブル(黒)
Cable
K306 K306
ケーブル
A660-2008-T765 (1)
A660-2008-T765(1)
Camera cable (black)
カメラケーブル (黒)
Cable K142
ケーブル K142
A660-4005-T931
A660-4005-T931
Signal
line (blue x white)
信号線(青X白)
Section E-E
断面 E-E
Clamp J4-2
クランプ J4-2
A290-7702-X421 (1)
E
A290-7702-X421(1)
(When the camera
(カメラケーブル指定時)
cable
is specified)
(A290-7702-X423)
Cable 141
ケーブル
K141
A660-4005-T930 (1)
A660-4005-T930(1)
0.2SQ power line (red x white)
0.2SQパワー線(赤X白)
Make the cable tie head
ケーブルタイの頭の位置を
to this position
図の位置にすること
Cable
K241 K241
ケーブル
A660-2008-T760 (1)
A660-2008-T760(1)
Torque sensor cable (black)
トルクセンサケーブル(黒)
Cable
K312 K312
ケーブル
A660-2008-T769 (1)
A660-2008-T769(1)
Force sensor cable (black)
Cable
K142 K142
ケーブル
A660-4005-T931
A660-4005-T931
Signal line (blue x white)
力センサケーブル(黒)
信号線(青X白)
Cable
312 K312
ケーブル
A660-2008-T769
A660-2008-T769
Force sensor cable (blue x white)
Section E-E
断面 E-E
(When the force sensor
(力センサケーブル指定時)
cable is specified)
力センサケーブル(青X白)
Fig. 5.3.4 (d) Cable clamp of the clamp J4-2 (1/2)
Braided tube
ConnectorM4BK
M4BK
コネクタ
Cable tie (4-G)
ケーブルタイ(4-G)
Fix
the braided tube with the cable tie
編組チューブ
A98L-0040-0363E06L290R0 (1)
A98L-0040-0363#06L290R0(1)
Wrap the cable K141 with braided tube
ケーブル K141を編組チューブで包むこと
Connector
コネクタ M4M
M4M
ケーブルタイで編組チューブを固定のこと
20
Connector
コネクタ M4P
M4P
Connector
コネクタ
M5M4,
M5M4,M6M4
M6M4
30
Cable
tie (4-F)
ケーブルタイ(4-F)
Close the sheet J4-2)
シートJ4-2を閉じること
コネクタConnector
TS5, CAM or FS5, M5P4, M6P4
TS5, CAM5またはFS5, M5P4, M6P4
Braided
tube
編組チューブ
A98L-0040-0363#12L290R0 (1)
A98L-0040-0363#12L290R0(1)
Wrap the cable K142, K241, K306 or K312 with braided tube
CABLE K142、K241、K306またはK312を編組チューブで包むこと
Cable
tie (4-G)
ケーブルタイ(4-G)
Fix the clamp J4-2 and two tubes with notch of he clamp
クランプJ4-2の切り欠きで
J4-2
クランプJ4-2と2本のチューブを固定すること
Fig. 5.3.4 (e) Cable clamp of the clamp J4-2 (2/2)
- 133 -
5. REPLACING CABLES
5.3.5
B-84195EN/02
Replacing cable K152, K154, K251, K307, K313
(J3 arm part to J6 casing part)
Replacing procedure
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
To remove the J6-axis motor, set a dial gauge at the J6-axis, and prepare for single axis mastering after
replacement. Refer to Section 6.4.
Set the Quick Master Reference Position. Refer to the QUICK MASTERING section of the
mechanical unit operator’s manual (B-84194EN). (All the axes are set to 0º before shipment.)
Move the robot to J5=0°,J6=0°. Move the robot to the posture so that the J3 arm cover and the J6
casing cover can be removed. (recommended posture：J4=0°,J5=0°,J6=0°, other axes are arbitrary)
Turn off controller power.
Remove the J3 arm cover referring to Fig.4.11 (a) in Section 4.11.
Cut the cable tie (4-A), (4-B) which fix cables on the clamp J5-2 and the cable tie (4-C) which fix the
sheet J5-1. Refer to Fig. 5.3.4 (a). To reuse the sheet J5-1, be careful to the following.

Carefully cut the cable tie (4-C) while being careful not to break the sheet J5-1.

If the sheet J5-1 is broken when it is reused, replace it by new one.
Remove the all relay connectors (M5M4, M6M4, M5P4, M6P4,TS5, CAM-D or FS-D) referring to
Fig.5.3.4 (a). (In case of the camera cable connector, remove the insulation tape. Then remove the
connector.)
Remove the clamp J5-2 referring to Fig. 4.14 (a) in Section 4.14.
Remove the J6 casing cover referring to Fig. 4.17 (a) in Section 4.17.
Cut the cable tie (5-A) which fix cables and the cable tie (5-B) which fix cables on the clamp J6-1.
Refer to Fig. 5.3.5 (a).
Remove the all relay connectors (M6BK, EE1,EE2,TS6,CAM-E or FS-E) and the all connectors
(M6M,M6P) connected to the J6-axis motor. Refer to Fig.5.3.5 (a).
(In case of the camera cable, remove the insulation tape, then remove the connector.)
Remove the clamp J6-1 as referring to Fig. 4.16 (a) in Section 4.16.
Remove the J6-axis motor referring to Fig.4.17 (b) in Section 4.17. (Remove the gear from the motor
is not necessary.)
Remove the clamp J5-3 referring to Fig. 5.3.5 (b).
Pull out the J3 arm side cables to the J6 casing side. Do not pull out cables forcibly during the relay
connectors are caught in the pipe.
Cut the cable tie (5-C) which fix cables on the clamp J5-3 referring to Fig.5.3.5 (c).
Replace cables. Fix the cable on the clamp J5-3 with the cable tie (5-C) referring to Fig.5.3.5 (c).
Pass the cables fixed on the clamp J5-3 from the J6 casing side to the J3 arm side. Do not pull out
cables forcibly during the relay connectors are caught in the pipe.
Attach the clamp J5-3 referring to Fig. 5.3.5 (b).
Attach the J6-axis motor referring to procedure 11 and Fig. 4.17 (b) in Section 4.17.
Attach parts in reversed sequence of procedure 5 to 12. In this time, be careful to the following.

Tighten the J6-axis motor connector (M6M) with torque of 0.11Nm(1.1kgfcm).

When assembling the clamp J5-2 and the clamp J6-1, pass the cable tie which fix cables through
the clamp J5-2 and the clamp J6-1, then assemble it.

(In case of the camera cable) After connecting the camera cable connector, wrap the insulation
tap 2 round so that the whole of the connector is covered. Refer to Fig.5.3.1 (l).

When assembling the J6 casing cover and the J3 arm cover, do not sandwich the protection sheet
and cables.
Perform quick mastering and perform single axis mastering of J6-axis. Refer to the QUICK
MASTERING section of the mechanical unit operator’s Manual (B-84194EN) and Section 6.4 of this
manual.
- 134 -
5. REPLACING CABLES
B-84195EN/02
Clamp J6-1
クランプ J6-1
A290-7702-X543
A290-7702-X543
Bolt
ボルト
A6-BA-3X8 (2)
(Cable tie (5-B))
(ケーブルタイ(5-B))
A6-BA-3X8 (2)
Green緑
Cable
tie (5-B)
ケーブルタイ(5-B)
Cable
tie (5-B)
ケーブルタイ(5-B)
Fix
the yellow
黄色テープの箇所を
tape
position.
固定すること
Signal line信号線(青X白)
(blue x white)
Z
Z
Y
Sensor
cable (black)
センサケーブル(黒)
Y
Camera
cable (black)
カメラケーブル
(黒)
Section
Z-Z
断面 Z-Z
Connector
M6M
コネクタ M6M
5:1
(When the camera cable is
(カメラケーブル指定時)
specified)
Connector
M6P
コネクタ M6P
Connector
コネクタ
M6BK,
EE1, EE2,
EE2,TS6
TS6CAM-E
CAM-E または
or FS-EFS-E
M6BK, EE1,
Connect
the aboved connectors
上記のコネクタを接続すること
Cable tie (5-A)
ケーブルタイ(5-A)
Fix only cables with cable ties.
ケーブルタイでケーブルのみ固定のこと
Signal line信号線(青X白)
(blue x white)
Cable
tie (5-B)
ケーブルタイ(5-B)
Fix the
cable and the clamp J6-1
ケーブルタイでケーブルと
with クランプJ6-1を固定のこと
cable ties
Sensor
cable (black)
センサケーブル(黒)
Force sensor
cable (blue x white)
力センサケーブル(青X白)
Force力センサケーブル(黒)
sensor cable (black)
Section
Z-Z
断面 Z-Z
5:1
(When
the force sensor
(力センサケーブル指定時)
cable is specified)
Clamp J5-3
クランプJ5-3
A290-7702-X541
A290-7702-X541
J5-axis sensor cable
J5軸センサのケーブル
Connect
TS-J5
コネクタ the
TS-J5を接続すること
Section
Y-Y
断面 Y-Y
Brake cable
ブレーキケーブル
2:1
Fig. 5.3.5 (a) Replacing the J6 casing cables
2
1
Fig. 5.3.5 (b) Removal of the clamp J5-3
Parts name
1
2
BOLT
CLAMP J5-3
Specifications
A6-BA-3X8
A290-7702-X541
Q’ty
2
1
- 135 -
Locking
Torque N-m
(kgf-cm)
5. REPLACING CABLES
Cable
307 K307
ケーブル
A660-2008-T766 (1)
A660-2008-T766(1)
Camera cable (black)
カメラケーブル (黒)
B-84195EN/02
Clamp J5-3
クランプ J5-3
A290-7702-X541 (1)
Cable
251 K251
ケーブル
A660-4005-T939
(1)
A660-4005-T939(1)
Sensor
cable (black)
センサケーブル(黒)
A290-7702-X541(1)
Connector
CAM-D or FS-D
コネクタ CAM-DまたはFS-D
F
Make
the cable tie
Connector
TS5
ケーブルタイの
コネクタ TS5
head
position
頭の位置を
to
this
position.
図の位置にすること
Cable
K152K152
ケーブル
A05B-1702-D006
(1)
A05B-1702-D006(1)
Power
line (red x white)
パワー線(赤X白)
Section
断面F-F
F-F
Yellow
黄
Green
Yellow
黄
緑
Connector M6P4
コネクタ M6P4
Cable K154
ケーブル K154 (1)
A660-4005-T934
A660-4005-T934(1)
Signal
line (blue x white)
F
Connector
M6M4
コネクタ M6M4
信号線(青X白)
Cable tie (5-C)
ケーブルタイ(5-C)
Use SHT18R
(When
the camera cable is specified)
(カメラケーブル指定時)
SHT18Rを使用すること
Cable 313
ケーブル K313(1)
A660-2008-T770
A660-2008-T770(1)
Force
sensor cable (black)
力センサケーブル(黒)
Cable K313
ケーブル K313
A660-2008-T770
A660-2008-T770
Force sensor cable 0.2SQ (blue x white)
力センサケーブル0.2SQ(青X白)
Cable K251
ケーブル K251
A660-4005-T939 (1)
A660-4005-T939(1)
Sensor cable (black)
センサケーブル(黒)
Make the cable tie
Section
断面F-F
F-F
ケーブルタイの
head position
頭の位置を
to this position.
図の位置にすること
Cable K152
ケーブル K152(1)
A05B-1702-D006
Cable K154
ケーブル
K154
A05B-1702-D006(1)
power
line (red x white)
A660-4005-T934 (1)
A660-4005-T934(1) パワー線(赤X白)
signal line (blue x white)
信号線(青X白)
(When
the force sensor cable is specified)
(力センサケーブル指定時)
Fig.5.3.5 (c) Cable clamp of the clamp J5-3
5.3.6
Replacing Cable K161,K261,K308,K314
(J6 casing to wrist flange)
Replacing procedure
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
To remove the J6 flange, set a dial gauge at the J6-axis, and prepare for single axis mastering after
replacement. Refer to Section 6.4.
Move the robot to J6=0°, and move the robot to the posture so that the J6 casing cover and the J6
flange can be removed. (recommended posture ：J4=0°,J5=0°,J6=0°, Other axes are arbitrary.)
Turn off controller power.
Remove the J6 casing cover referring to Fig. 4.17 (a) in Section 4.17.
Cut the cable tie (5-A) which fix cables and the cable tie (5-B) which fix cables to the clamp J6-1.
Refer to Fig. 5.3.5 (a).
Remove all relay connectors (M6BK, EE1, EE2, TS6, CAM-E or FS-E) referring to Fig.5.3.5 (a).
(Firstly remove the insulation tape of the camera connector. Then remove the connector.)
Remove the clamp J6-1 referring to Fig. 4.16 (a) in Section 4.16.
Remove the J6 flange cover and the J6 flange referring to Fig.4.19 (a) in Section 4.19. (Taps for the
seal bolt are removal taps for the J6 flange cover. Remove the J6 flange cover using these taps.)
Cut the cable tie (6-A) which fix the able on the clamp J6-2 and the cable tie (6-B) which fix the
braided tube. Then remove the braided tube. Refer to Fig.5.3.6 (a).
Remove the relay connector (TS-J6) referring to Fig. 5.3.6 (a).
Remove the clamp J6-2 referring to Fig. 4.19 (a) in Section 4.19.
Pull out the J6 casing part cable to the wrist flange side. Do not pull out it forcibly during the relay
connector is caught in the pipe.
Cut the cable tie (6-C) which fix the cable on the clamp J6-3. Refer to Fig. 5.3.6 (b).
Remove the J6 flange connector referring to Fig.5.3.6 (c), (d), (e). (When removing or assembling the
EE connector nut, use the box wrench to prevent wrist flange is damaged.)
Remove the clamp J6-3 referring to Fig. 5.3.6 (f).
- 136 -
5. REPLACING CABLES
B-84195EN/02
16 Replace the cables and assemble them in the reversed sequence. In this time, be careful to the following.

When assembling the clamp J6-3 and the clamp J6-1, pass the cable tie which fix cables through
the clamp J5-2 and the clamp J6-1. Then assemble it.

The nut for EE connector assembling to the J6 flange is attached to the cable K161. Remove it
from the cable K161, then assemble it again. (See Fig. 5.3.6 (c))

When assembling the connector to the J6 flange, pay attention to the key phase referring to Fig.
5.3.6 (b).

(In case of the camera cable) After connecting the camera cable connector, wrap the insulation
tap 2 round or more so that the whole of the connector is covered. Refer to Fig.5.3.1 (l).

When tightening the bolt (7) in Fig. 4.19 (a) of Section 4.19, tighten it with referring to Fig.4.19
(c) in Section 4.19.

For keeping the seal performance, replace the seal bolts (1) in Fig.4.19(a) of Section 4.19 by new
articles. If you cannot prepare those, remove the sealant and seal those with seal tape.

When assembling the J6 casing cover, be careful not to pinch the protection sheet or cables.
17 Perform single axis mastering of J6-axis. Refer to Section 6.4.
Braided
tube
編組チューブ
Clamp J6-2
クランプ J6-2
A290-7702-X544
A290-7702-X544
Bolt
A6-BA-2.5X6
ボルト (3)
A98L-0040-0363#06L100R0
A98L-0040-0363#06L100R0
A6-BA-2.5X6 (3)
AA
Cable K261
CABLE K261
A05B-1702-D005
Sensor
cable (black)
A05B-1702-D005
センサケーブル(黒)
Cable tie (6-B)
ケーブルタイ(6-B)
AA
J6
sensor cable
J6センサのケーブル
Connect
connector TS-J6.
コネクタthe
TS-J6を接続すること
Cable tie (6-A)
ケーブルタイ(6-A)
Signal
line (blue x white)
信号線(青X白)
Signal
line (blue x white)
信号線(青X白)
Sensor
cable (black)
センサケーブル(黒)
Sensor
cable (black)
センサケーブル(黒)
Force
sensor cable (blue x white)
力センサケーブル(青X白)
Force
sensor cable (black)
力センサケーブル(黒)
Camera
cable (black)
カメラケーブル
(黒)
Section AA-AA
断面 AA-AA
5:1
(when force sensor cable is specified)
Section AA-AA
断面 AA-AA
5:1
(when
camera cable is specified)
(カメラケーブル指定時)
(力センサケーブル指定時)
Fig. 5.3.6 (a) Replacing the wrist flange part cables（1/2）
- 137 -
5. REPLACING CABLES
B-84195EN/02
Cable K308
ケーブル K308
A05B-1702-D004
A05B-1702-D004
Camera
cable (black)
カメラケーブル
(黒)
J6
plate
J6camera
カメラプレート
A290-7702-X536
A290-7702-X536
Cap
キャップ
A63L-0002-0275#C1
A63L-0002-0275#C1
Clamp
J6-3
クランプ
J6-3
A290-7702-X545
A290-7702-X545
Bolt
ボルト
A6-BA-3X8
(2)(2)
A6-BA-3X8
Cable
tie (6-C)
ケーブルタイ(6-C)
Key
phase
キーの位相
Cable
K161K161
ケーブル
A660-4005-T935
A660-4005-T935
Signal
line (blue x white)
信号線(青X白)
Cap
キャップ
A63L-0002-0378
A63L-0002-0378
Key
phase
キー位置
詳細 X
X
Detail
5:1
X
AB
Nut (attachment of the cable K161)
ナット(ケーブル
1.5Nm
(15kgfcm) K161のアタッチメント)
1.5Nm(15kgfcm)
Apply LOCTITE 243
ロックタイト243を塗布のこと
詳細AB
AB
Detail
(when(カメラケーブル指定時)
camera cable is specified)
Clamp J6-3
クランプ J6-3
A290-7702-X545
A290-7702-X545
Bolt
ボルト
A6-BA-3X8
(2)(2)
A6-BA-3X8
Cable
tie (6-C)
ケーブルタイ(6-C)
Cable K161
ケーブル K161
A660-4005-T935
A660-4005-T935
Signal line (blue x white)
信号線(青X白)
Cap
キャップ
A63L-0002-0378
A63L-0002-0378
AC
Cable K314
A05B-1702-D008
ケーブル K314
Force
sensor cable
A05B-1702-D008
力センサケーブル(青X白、黒)
(blue
x white. black)
キャップ
Cap
A63L-0002-0115#07
Key phase
キーの位相
Detail
詳細 AC
AC
4:1
Nut
(attachment ofK161のアタッチメント)
the cable K161)
ナット(ケーブル
1.5Nm
(15kgfcm)
1.5Nm(15kgfcm)
Apply
LOCTITE 243
ロックタイト243を塗布のこと
A63L-0002-0115#07
(when(力センサケーブル指定時)
force sensor cable is specified)
Fig. 5.3.6 (b) Replacing the wrist flange part cables（2/2）
1
1'
2
Fig. 5.3.6 (c) Removal of the EE connector
Parts name
1
1’
2
CABLE K161
NUT(*)
J6 FLANGE
Specifications
Q’ty
Locking
Torque N-m
(kgf-cm)
A660-4005-T935
(size：width across flats10mm)
A290-7702-X524
1
1
2
LOCTITE 243
1.5Nm(15kgfcm)
(*) It is included in the cable K161.
- 138 -
5. REPLACING CABLES
B-84195EN/02
4
5
3
2
1
Fig. 5.3.6 (d) Removal of the camera connector
Parts name
1
2
3
4
5
PLATED BOLT
J6 CAM PLATE
CABLE K308
O RING
J6 FLANGE
Specifications
Q’ty
A97L-0218-0496#M3X8BC
A290-7702-X536
A05B-1702-D004
A98L-0001-0347#S24
A290-7702-X524
4
Locking
Torque N-m
(kgf-cm)
4
1
1
1
1
3
2
1
Fig. 5.3.6 (e) Removal of the force sensor connector
Parts name
1
2
3
4
PLATED BOLT
CABLE K314
O RING
J6 FLANGE
Specifications
A97L-0218-0496#M3X8BC
A05B-1702-D008
A98L-0001-0347#S24
A290-7702-X524
- 139 -
Q’ty
4
1
1
1
Locking
Torque N-m
(kgf-cm)
5. REPLACING CABLES
B-84195EN/02
1
2
3
Fig.5.3.6 (f) Removal of the clamp J6-3
Parts name
1
2
3
BOLT
CLAMP J6-3
J6 FLANGE
5.3.7
Specifications
A6-BA-3X8
A290-7702-X545
A290-7702-X524
Q’ty
Locking
Torque N-m
(kgf-cm)
2
1
1
Replacing cable K133,K151,K153
(J3-axis, J5-axis motor cable)
Replacing procedure of cable K133
1
2
3
4
5
Remove the J3-axis motor referring to procedure 1 to 6 of Section 4.8.
Remove the all connectors (M3M, M3BK) connected to the J3-axis motor.
Replace the cable by new one. Connect the connector (M3M, M3BK) to the J3-axis motor.
Attach the J3-axis motor and the J2 arm cover referring to procedure 14 to 17 of Section 4.8.
Perform single axis mastering. Refer to Section 6.4.
Replacing procedure of cable K151, K153
1
2
3
4
5
6
7
8
Remove the J5 motor unit referring to procedure 1 to 10 in Section 4.14.
Remove all connectors (M5M, M5BK, M5P) connected to the J5-axis motor.
Remove the clamp J5-1 referring Fig. 5.3.7 (a).
Cut the cable tie (4-D) which fix the cable on the clamp J5-1. Refer to Fig. 5.3.4 (a).
Replace cables by new one. Then fix them on the clamp J5-1 with cable ties (4-D) referring to Fig.
5.3.4 (a).
Attach the clamp J5-1 which fix cables referring to Fig. 5.3.7 (a).
Attach the J5 motor unit, wire cables in the J3 arm then attach the J3 arm cover. Refer to procedure
18 to 23 in Section 4.14.
Perform quick mastering and perform single axis mastering of J5-axis. Refer to the QUICK
MASTERING section of the mechanical unit operator’s Manual (B-84194EN) and Section 6.4 of this
manual.
- 140 -
5. REPLACING CABLES
B-84195EN/02
2
1
Fig. 5.3.7 (a) Removal of the clamp J5-1
Parts name
1
2
BOLT
CLAMP J5-1
Specifications
A6-BA-3X8
A290-7702-X539
Q’ty
2
1
- 141 -
Locking
Torque N-m
(kgf-cm)
6. MASTERING
6
B-84195EN/02
MASTERING
Mastering associates the angle of each robot axis with the pulse count value supplied from the absolute
Pulsecoder connected to the corresponding axis motor. To be specific, mastering is an operation for
obtaining the pulse count value; corresponding to the zero position.
6.1
OVERVIEW
The current position of the robot is determined according to the pulse count value supplied from the
Pulsecoder on each axis.
Mastering is factory-performed. It is unnecessary to perform mastering in daily operations. However,
mastering is required under the following conditions:
Motor replacement
Pulsecoder replacement
Reducer replacement
Cable replacement
Batteries for pulse count backup in the mechanical unit have gone dead.
WARNING
Robot data (including mastering data) and Pulsecoder data are backed up by
their respective backup batteries. Data will be lost if the batteries are gone
dead. Replace the batteries in the controller and mechanical units periodically.
Alarm will alert decreasing the battery voltage.
Once mastering has been performed, positioning (calibration) is necessary. Positioning is an operation
which recognizes the current robot position based on the newly mastered robot pulse counts.
CAUTION
1 If mastering is performed incorrectly, the robot may behave unexpectedly. This is
very dangerous. For the reason, the Master/Cal screen is designed to appear
only when the $MASTER_ENB system variable is 1 or 2. After performing
positioning, press F5 [DONE] on the Master/Cal screen. The $MASTER_ENB
system variable is then reset to 0 automatically. And the Master/Cal screen will
disappear.
2 Before performing mastering, it is recommended that you back up the current
mastering data.
- 142 -
6. MASTERING
B-84195EN/02
6.2
RESETTING ALARMS AND PREPARING FOR
MASTERING
Before performing mastering because a motor has been replaced, it is necessary to reset the relevant alarm
and display the positioning menu.
Alarm displayed
“SRVO-062 BZAL” or “SRVO-075 Pulse not established”
Procedure
1
Display the positioning menu by following steps 1 to 6.
1
Press the [MENU] key.
2
Press [0 NEXT] and select [6 SYSTEM].
3
Press F1 [TYPE], and select [SYSTEM Variable] from the menu.
4
Place the cursor on $MASTER_ENB, then key in “1” and press [ENTER] key.
5
Press F1 [TYPE], and select [Master/Cal] from the menu.
6
Select the desired mastering type from the [Master/Cal] menu.
2
To reset the “SRVO-062 BZAL” alarm, follow steps 1 to 5.
1
Press the [MENU] key.
2
Select [0 NEXT] and select [6 SYSTEM].
3
Press F1 [TYPE], and select [SYSTEM Variable] from the menu.
4
Place the cursor on F3 RES_PCA, then press F4 [YES].
5
Turn off the controller power and on again
3
To reset the “SRVO-075 Pulse not established” alarm, follow steps 1 to 2.
1
After cycling controller power, the message “SRVO-075 Pulse not established” appears again.
2
Move the axis for which the message mentioned above has appeared in either direction till the
alarm disappears when you press the [RESET] key.
If“SRVO-062 BZAL” alarm or “SRVO-068 DTERR” alarm occurred, and you cannot release the alarm,
Please check there is no faulty wiring or disconnected part.
- 143 -
6. MASTERING
6.3
B-84195EN/02
ALL-AXES VISION MASTERING
CAUTION
Explanation in this section is for the following models. In case of other models
please contact your local FANUC representative.
Mechanical unit
specification No.
Model name
FANUC Robot CRX-10iA
FANUC Robot CRX-10iA/L
FANUC Robot CRX-20iA/L
A05B-1702-B201, B203
A05B-1702-B202, B204
A05B-1702-B212
Refer to the following Table 6.3 (a). And confirm all the necessary parts are ready for all-axis vision
mastering. To perform the all-axes vision mastering, software version 7DF5/09 (V9.40P/09) or later is
required. If the software version is 7DF5/08 or before, update the software version to 7DF5/09 (V9.40P/09)
or later.
Upper Specifications
A05B-1702-K081
ALL-AXIS VISION
MASTERING BRACKET
A05B-1702-K082
BASE PLATE FOR
ALL-AXIS VISION MASTERING
A05B-1702-K083
STAND FOR ALL-AXIS VISION
MASTERONG
A05B-1702-K084
Calibration grid for ALL-AXIS
VISION MASTERING
A05B-1426-K001
SC130EF2
A05B-1405-K511
8mm LENS
Table 6.3 (a) All-axe vision mastering fixture
Part name
Specifications
Q’ty
BRACKET A
BRACKET B
BRACKET C
CAMERA COVER A
CAMERA COVER B
CAMERA COVER C
PIN
MOUNT
CAMERA CABLE
BOLT
BOLT
BOLT
BOLT
BOLT
BASE PLATE
ADAPTER
PIN
PIN
PIN
BOLT
BOLT
STAND
PLATE
PIN
DOT PLATE
PIN
PIN
BOLT
A290-7702-X941
A290-7702-X942
A290-7702-X943
A290-7702-X948
A290-7702-X949
A290-7702-X950
A290-7139-X913
A98L-0001-0573#TY8F1
A660-2008-T341#L10R03
A6-BA-3X8
A6-BA-3X22
A6-BA-4X10
A6-BA-4X16
A6-BA-6X16
A290-7702-X945
A290-7702-X946
A290-7139-X913
A290-7139-X914
JB-PH-H7A-8X16S45C
A6-BA-8X20
A6-BA-8X25
A290-7702-X940
A290-7702-X944
A290-7139-X914
A290-7702-V901
A290-7139-X913
A290-7139-X914
A6-BA-8X20
1
1
1
1
1
1
1
2
1
8
3
2
8
4
1
1
1
1
2
4
4
1
1
1
1
1
1
4
CAMERA
A97L-0318-0644
1
LENS
A97L-0218-0712#219HB
1
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6. MASTERING
B-84195EN/02
A290-7139-X913 and A290-7139-X914 are similar in shape. Be careful to misassembling referring to Fig.
6.3 (a).
A
B
SECTION A-A
A290-7139-X913
SECTION B-B
A
A290-7139-X914
B
Fig. 6.3 (a) Shape of the A290-7139-X913 the A290-7139-X914
6.3.1
Bracket Assembling
Assemble the bracket referring to Fig.6.3.1 (a).
Mount
(A98L-0001-0573#TY8F1)
マウント(A98L-0001-0573#TY8F1)
Bolt ボルト(M4X10)
(M4 x 10)
Camera
cable
カメラケーブル
(A660-2008-T341#L10R03)
(A660-2008-T341#L10R03)
Camera
(A97L-0318-0644)
カメラ(A97L-0318-0644)
Camera
cover C (A290-7702-X950)
カメラカバーC(A290-7702-X950)
Bolt
(M3 x 8)
ボルト(M3X8)
2 pcs
2本
A
Bolt (M4 x 16)
4 ボルト(M4X16)
pcs
4本
30°
Fix
the cable with cable ties
ケーブルタイで
ケーブルを固定してください
Bracket
(A290-7702-X941)
ブラケットA(A290-7702-X941)
Bolt (M3 x 22)
ボルト(M3X22)
Tightening
torque
締付トルク0.5Nm
0.5Nm
3本
3 pcs
Bolt (M4 x 16)
ボルト(M4X16)
4 pcs
4本
A
Bolt (M3 x 8)
ボルト(M3X8)
2 pcs
2本
Bolt
(M3 x 8)
ボルト(M3X8)
CameraカメラカバーA(A290-7702-X948)
cover A (A290-7702-X948)
Camera
cover B (A290-7702-X949)
カメラカバーB(A290-7702-X949)
Lens
(A97L-0218-0712#219HB)
レンズ(A97L-0218-0712#219HB)
SECTION A-A
Fig. 6.3.1 (a) Bracket assembly
- 145 -
Bracket
B (A290-7702-X942)
ブラケットB(A290-7702-X942)
Bracket
C (A290-7702-X943)
ブラケットC(A290-7702-X943)
6. MASTERING
6.3.2
B-84195EN/02
Cable assembling
Be sure to turn off robot controller power before the work. Inserting and/or removing the camera cable
while the robot controller is powered up may cause fatal damage to the controller.

Connect the camera cable (A660-2008-T341#L10R03) to the CRJ3 port in the robot controller (refer
to Fig. 6.3.2 (a)).

If another camera or multiplexer is connected to the CRJ3 port, disconnect those cable temporarily.
After the all-axis vision calibration procedure is completed, place the original cable back in place.
CRJ3
Camera cable
カメラケーブル
Fig.6.3.2 (a) Cable assembling
6.3.3
Setting and Adjustment of Camera
Setting the camera
1
Assemble the wrist camera and the calibration grid assembled in Fig. 6.3.1 (a). Refer to Fig. 6.3.3 (a).
プレート(A290-7702-X944)
Plate (A290-7702-X944)
ボルト(M6X16) 4本で固定
Fix it with four bolts (M6 x16)
ピン(A290-7139-X913)
Pin (A290-7139-X913)
ピン(A290-7139-X914)
Pin (A290-7139-X914)
Wrist camera
手首カメラ(図6.3.1(a)で組立)
(assembled in Fig.6.3.1 (a))
スタンド(A290-7702-X940)
Stand
(A290-7702-X940)
Bolt (M8
x 20)
ボルト(M8X20)
Calibration grid
ドットプレート(A290-7702-V901)
(A290-7702-V901)
Pin
(A290-7139-X913)
ピン(A290-7139-X913)
ピン(A290-7139-X914)
Pin (A290-7139-X914)
Fig. 6.3.3 (a) Assembling the stand
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6. MASTERING
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2
3
4
5
6
Press the [MENU] key on the teach pendant. Select the “UTILITIES” from the pull-down menu.
Press the F1 [TYPE], select “2 iRCalibration” from the screen menu.
Select “All-Axis Vision Mastering”.
Press the F2 (DISP_IMG). The iPendant configuration turns into "Double" panel and the runtime
monitor screen will be displayed on the right-hand screen.
Loosen the two screws on the lens as shown, and set the aperture level up to “16” as shown Fig. 6.3.3
(b).
Screws
Point A
This white line indicates the
aperture level. In this picture
, the line indicates “16”.
Fig. 6.3.3 (b) Aperture of lens
7
8
Move the cursor to the “2 Exposure Time”, and press the F4 (LIVE). The live image of the camera is
displayed on the runtime monitor.
Adjust exposure time to display the live camera image with appropriate brightness referring to Fig.
6.3.3 (c).
Target mark image with too
short exposure time
Target mark image with
appropriate exposure time
Target mark image with too
long exposure time
Fig. 6.3.3 (c) Adjustment of the exposure time
9
10
11
If the camera image looks dark on the condition that exposure time is 100msec, set the aperture level
down in the center of “16” and “8” (Paint A in the picture) or “8”, and retry to adjust the exposure
time. If the image looks dark nevertheless, increase environmental brightness.
Temporary, set the aperture level down to “1.4”. After changing the aperture, the camera image looks
brighter. Adjust exposure time to display the live camera image with appropriate brightness again.
Adjust the focus ring so that the camera image on the screen is clearly displayed. Then slide only focus
ring with aperture ring held.
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6. MASTERING
12
13
14
B-84195EN/02
Move the aperture handle to the position (“16”, Point A or “8”) and set exposure time adjusted by Step
9) in this chapter.
Tighten up the two screws on the lens
Press the F4 (LIVE), and stop the live image.
6.3.4
Base plate installation
In case of these models, putting the robot on the base plate (A290-7702-X945) when performing the allaxis vision mastering. As shown in Fig. 6.3.4 (a). There are 2 types hole for the base plate fixation. (Hole
A and B for the base plate fixation) Be sure to fix the plate which type 4 holes. Use appended four bolts
(A6-BA-8X20) for fixation. The dimension of the hole A for base plate fixation is same to fixation hole for
robot main body. So you can install it on the robot installed trestle.
240
200
20
120
100
20
45°
240
210
Robot
front
ロボット正面方向
O1
70
Hole A for the base
plate fixation
Φ9 through
ベースプレート固定用穴A
C’bore Φ15 depth 9
OEqually
9 貫通 spaced
ザグリ径 O15 深さ9
周上等配
Hole B for the base
plate fixation
ベースプレート固定用穴B
Φ9 through
O9 貫通
C’bore Φ15 depth 9
ザグリ径 O15 深さ9
Fig. 6.3.4 (a) Base plate installation
6.3.5
Execute All-Axis Vision Mastering
In this chapter, you execute all-axis vision mastering. If the operation all-axis vision mastering screen is
not displayed, display operation all-axis mastering screen referring to step from 2 to 5 of Section 6.3.4. If
Gravity Compensation is on, set payload parameters referring to Subsection 6.3.7, there is the information
about payload of the wrist camera.
1
2
3
Move the cursor to the “3 Cal. Camera pos” from the screen menu.
Press F3 [CAL] while holding down the Shift key, and the camera calibration will start. If the camera
calibration has been done already, the following message appears: “Cal.Camera pos?” If you would
like to redo the camera calibration, respond to the message with F4 (YES).
*
In the following operation step, the robot will move. Please consider appropriate safety.
And in order to prevent the camera cable interfering with the camera field of view, please pay
attention to the cable forming.
If the mastering date is lost from the controller caused by parts replacement, or the mastering data is
different from actual data, perform zero-position mastering referring to Chapter 8 of mechanical unit
operator’s manual (B-84194EN) before performing all-axis vision mastering
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6. MASTERING
B-84195EN/02
4
Remove the calibration grid and the wrist camera from the stand. Referring to fig. 6.3.5 (a), first set
the base plate, the adaptor (A290-7702-X946), the calibration grid and the wrist camera on the base
plate.In this case, you can change the robot position in order to make installation easier.
Pin (A290-7139-X913)
ピン(A290-7139-X913)
Wrist camera
(assemble in Fig. 6.3.1 (a))
手首カメラ(図6.1.1で組立)
Fix it withボルト(M6X16)
four bolts (M6
x 16)
4本で固定
Fix it with four bolts and washers
Pin (A290-7139-X914)
ピン(A290-7139-X914)
ロボットに添付されているボルトとワッシャで
of the robot appendix.
4箇所固定してください
Base
plate
ベースプレート(A290-7702-X945)
(A290-7702-X945)
ピン(A290-7139-X914)
Pin (A290-7139-X914)
ドットプレート(A290-7702-V901)
Calibration grid
ボルト(M8X20) 4本で固定
(A290-7702-V901)
Fix it with four bolts (M8 x 20)
Pinピン(JB-PH-H7A-8X16S45C)
(JB-PH-H7A-6X16S45C)
Adaptor (A290-7702-X946)
アダプタ(A290-7702-X946)
Fix
it with four bolts (M8 x 25)
ボルト(M8X25) 4本で固定
Pin
(A290-7139-X913)
ピン(A290-7139-X913)
Pin (A290-7139-X913)
ピン(A290-7139-X913)
Fig. 6.3.5 (a) Fixture assembling
5
6
7
8
Move the cursor to the “4 Move to start pos”. Check that the wrist camera pin (A290-7139-X913) is
not inserted to the robot. Do not operate the robot with the pin inserted as the robot and pins will
interfere with each other.
Press F3 [MOVE TO] while holding down the Shift key, and the robot moves to starting position.
Move the cursor to the “5 Measure”. If camera calibration has been uncompleted, you can’t move the
cursor to the “5 Measure”. Retry the operation from step 1 in this chapter.
Press F3 [MEASURE] while holding down the Shift key, and the robot starts on all-axis vision
mastering.
*
If measurement halted, mastering data will not change.
*
If the measurement halted because the camera image is too dark to measure, you can resume to
measure after readjusting exposure time. After moving the cursor to the “2 Exposure Time” and
changing the time length, move the cursor to the “5 Measure”, and hold down [SHIFT] key and
press F3 [MEASURE] . The following message will be displayed like Fig.6.3.5 (b) on the screen.
If you select F4 [RESUME], you can skip the measurement position already finished. To start
over to measure, select F5 [RESTART].
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6. MASTERING
*
B-84195EN/02
If measurement is stopped by method such as HOLD, you can restart the measurement by same
procedure.
Are you sure to resume?
RESUME RESTART
Fig. 6.2.5 (b) Resume to measure
9
10
The measurement state change “Done” after measurement finished.
Move the cursor to the “6 Update Master CT”. If the measurement hasn’t been finished yet, you can’t
move the cursor to the “6 Update Master CT”. Retry the operation from step 5) in this chapter.
Press F3 [DETAIL]. The measurement result of all-axis vision mastering is displayed on the screen
(Fig. 6.3.5 (c)). Figure in parentheses means standard range. Check weather these results fall within
standard range referring to Table 6.3.5 (a). If there is no problem, go to the next step.
11
UTILITIES iRCalibration
All-Axis Vision Mastering
1/6
Update Master CT
Robot Group:
1
1 Compensation Angles [deg]
J1:
0.300
J2:
-0.254
J3:
0.172
J4:
-0.239
J5:
-0.082
J6:
0.326
2 Residual Error [mm]:
0.58 ( 1.50)
3 VTCP Error [mm]
X: 0.10 (± 1.50)
Z: 0.10 (± 1.00)
4 Grid Pattern Error [mm]
X: 0.20 (± 1.00)
Z: -0.54 (± 1.50)
5 Residual Error 2 [mm]: 0.58 ( 1.50)
6 VTCP Error 2 [mm]
X: 0.10 (± 1.50)
Z: 0.10 (± 1.00)
[ TYPE ]
UPDATE
Fig. 6.2.5 (c) Update mastering data on the screen
Table 6.3.5 (a) Details of the update screen items
No.
1
Items
2
Compensation
Angles
Residual Error
3
VTCP Error
4
Grid Pattern Error
Explanation
Compensation angles from the previous mastering
data.
An index of precision if the mastering data is updated
with the results of measurement and identification. If
this value is much larger than the threshold, range,
the measurement might have not been done properly.
It is an error of TCP for Vision measurement. It is a
difference between the identified value and the design
value. If this value is much larger than the threshold ,
assembly of the bracket might have not been proper
or position of the calibration grid on the stand might
have not been proper.
It is an error of grid position. It is a difference between
the identified value and the design value. If this value
is much higher than the standard range, assembly of
the grid might have not been proper.
- 150 -
If result figure is larger than
its standard range
Retry the operation referring to
Item "VTCP Error" or "Grid
Pattern Error"
No problem if “Residual Error”
is within the threshold. If VTCP
Error is too larger than its
standard range, Restart
operation from Subsection
6.2.1.
No problem if “Residual Error”
is within the threshold. If VTCP
Error is too larger than its
standard range, retry from
Subsection 6.2.3. Check
weather calibration grid is set
upside down.
6. MASTERING
B-84195EN/02
No.
Items
5
Residual Error 2
6
VTCP Error 2
12
If result figure is larger than
its standard range
Explanation
This figure is foreign to this model, so that this figure
is display as [****] on the screen.
This figure is foreign to this model, so that this figure
is display as [****] on the screen.
Hold down the [SHIFT] key and press F3 [UPDATE] . Mastering data will be updated.
That rests all-axes vision mastering.
6.3.6
Removal of the fixture
Turn off the controller before disconnecting the camera cable from the controller. You can change the robot
position in order to remove fixtures easily.
Inserting and/or removing the camera cable whilst the robot controller is powered up may cause fatal
damage to the controller.
6.3.7
Payload value for wrist camera installation
If you execute all-axis vision mastering in the case that Gravity Compensation is on, set payload parameters
referring to Table 6.3.7 (a).
Table 6.3.7 (a) Values for payload setting
Setting items
PAYLOAD [kg]
PAYLOAD CENTER X [cm]
PAYLOAD CENTER Y [cm]
PAYLOAD CENTER Z [cm]
PAYLOAD INERTIA X [kgfcms2]
PAYLOAD INERTIA Y [kgfcms2]
PAYLOAD INERTIA Z [kgfcms2]
6.4
Values
1.84
-8.42
0.08
3.74
0.003
0.007
0.005
SINGLE AXIS MASTERING (FOR PARTS REPLACING)
Single axis mastering is performed for one axis at a time. The mastering position for each axis can be
specified by the user. Perform single axis mastering when parts are replaced.
NOTE
There is a possibility that you cannot perform the procedure in this section due to
the backlash or the motor failure. In that case, contact your local FANUC
representative.
- 151 -
6. MASTERING
B-84195EN/02
SINGLE AXIS MASTER
J1
J2
J3
J4
J5
J6
E1
E2
E3
ACTUAL POS
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
AUTO
(MSTR POS)
0.000)
(
(
0.000)
0.000)
(
(
0.000)
(
0.000)
(
0.000)
(
0.000)
(
0.000)
(
0.000)
J OINT 10%
1/9
(SEL)
[ST]
(0)
[2]
(0)
[2]
(0)
[2]
(0)
[2]
(0)
[2]
(0)
[0]
(0)
[0]
(0)
[0]
(0)
[0]
EXEC
Table 6.4 (a) Items set in single axis mastering
Item
Current position
(ACTUAL AXIS)
Mastering position
(MSTR POS)
SEL
ST
Description
The current position of the robot is displayed for each axis in degree units.
A mastering position is specified for an axis to be subjected to single axis mastering. It would
be convenient if it is set to 0 degree position.
This item is set to 1 for an axis to be subjected to single axis mastering. Usually, it is 0.
This item indicates whether single axis mastering has been completed for the corresponding
axis. It cannot be changed directly by the user.
The value of the item is reflected in $EACHMST_DON (1 to 9).
0 : Mastering data has been lost. Single axis mastering is necessary.
1 : Mastering data has been lost. (Mastering has been performed only for the other
interactive axes.) Single axis mastering is necessary.
2 : Mastering has been completed.
Procedure of Single axis mastering
1
2
3
4
Press the [MENU] key to display the screen menu.
Select [0 NEXT] and press [6 SYSTEM].
Press F1 [TYPE]. Then select [Variables] from the menu.
Prepare a mark (witness mark, scribe mark, point for check or temporarily set dial gauge)for single
axis mastering before parts replacing, then record all axis position of this posture.
*
The reproducibility after replacing parts varies depending on the mark’s accuracy.
*
When you can use a dial gauge, set the dial gauge as shown in the figure, then record the scale
reading of the dial gauge and the angle of the axis.
Fig. 6.4 (a) Setting of the dial gauge
5
Move the robot to the posture when the parts are replaced, so replace the parts.
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6. MASTERING
B-84195EN/02
6
7
8
9
After replacing parts, move the robot the marked position in step 5. At this time, move the axis except
the replaced axis correctly, match the replaced axis to the marked positon (in case of the dial gauge :
scale reading).
Clear an alarm that occurs as described in Section 6.2. Then prepare for the mastering.
Select [6 SYSTEM].
Select [Master/Cal]. The positioning screen will be displayed.
SYSTEM Master/Cal
AUTO JOINT 10 %
TORQUE = [ON ]
1 FIXTURE POSITION MASTER
2 ZERO POSITION MASTER
3 QUICK MASTER
4 QUICK MASTER FOR SINGLE AXIS
5 SINGLE AXIS MASTER
6 SET QUICK MASTER REF
7 CALIBRATE
Press 'ENTER' or number key to select.
[ TYPE ]
10
LOAD
RES_PCA
DONE
Select [5 SINGLE AXIS MASTER]. The following screen will be displayed.
SINGLE AXIS MASTER
J1
J2
J3
J4
J5
J6
E1
E2
E3
ACTUAL POS
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
AUTO
(MSTR POS)
(
0.000)
(
0.000)
(
0.000)
0.000)
(
(
0.000)
0.000)
(
(
0.000)
(
0.000)
(
0.000)
JO INT 10%
1/9
(SEL)
[ST]
(0)
[2]
(0)
[2]
(0)
[2]
(0)
[2]
(0)
[2]
(0)
[0]
(0)
[0]
(0)
[0]
(0)
[0]
EXEC
11
12
13
Move the cursor to the [SEL] column for the unmastered axis and press the numeric key [1]. Setting
of [SEL] is available for one or more axes.
Input the position data (recorded position in step 5) of the axis mastering is done.
Press F5 [EXEC]. Mastering is performed. So, [SEL] is reset to 0, and [ST] is re-set to 2 or 1.
SINGLE AXIS MASTER
J1
J2
J3
J4
J5
J6
E1
E2
E3
ACTUAL POS
0.000
0.000
0.000
0.000
0.000
90.000
0.000
0.000
0.000
AUTO
(MSTR POS)
(
0.000)
0.000)
(
(
0.000)
0.000)
(
(
0.000)
0.000)
(
(
0.000)
(
0.000)
(
0.000)
JOINT 10%
6/9
(SEL)
[ST]
(0)
[2]
(0)
[2]
(0)
[2]
(0)
[2]
(0)
[2]
(1)
[0]
(0)
[0]
(0)
[0]
(0)
[0]
EXEC
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6. MASTERING
14
B-84195EN/02
When single axis mastering is completed, press the [PREV] key to resume the previous screen.
SYSTEM Master/Cal
AUTO JOINT 10 %
TORQUE = [ON ]
1 FIXTURE POSITION MASTER
2 ZERO POSITION MASTER
3 QUICK MASTER
4 QUICK MASTER FOR SINGLE AXIS
5 SINGLE AXIS MASTER
6 SET QUICK MASTER REF
7 CALIBRATE
Press 'ENTER' or number key to select.
[ TYPE ]
15
16
LOAD
RES_PCA
DONE
Select [7 CALIBRATE], then press F4 [YES]. Positioning is performed. Alternatively, turn off the
controller power and on again. Positioning is performed.
After positioning is completed, press F5 [DONE].
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6. MASTERING
B-84195EN/02
6.5
VERFYING MASTERING
1
How to verify that the robot is mastered properly:
Usually, positioning is performed automatically when the power is turned on. To check whether
mastering has been performed correctly, examine if the current displayed position matches the
actual robot position by using one or more of the procedures described below:
(1) Reproduce a particular point in a program. Check whether the point agrees with the specified
position.
(2) Set all axes of the robot to their 0-degree (0 rad) positions. Check that the zero-degree position
marks indicated in Section 8.3 of the MECHANICAL UNIT OPERATOR’S MANUAL (B84194EN) are aligned. There is no need to use a visual aid.
(3) Using fixtures, set the robot to the mastering position in the same way as when performing
mastering. Check that the displayed current position agrees with the actual mastering position.
If the displayed and actual positions do not match, the counter value for a Pulsecoder may have been
invalidated as a result of an alarm described in 2. Alternatively, the mastering data in system variable
$DMR_GRP.$MASTER_COUN may have been overwritten as a result of an operation error or some
other reason.
Compare the data with the values indicated on the supplied data sheet. This system variable is
overwritten whenever mastering is performed. Whenever mastering is performed, record the value of
the system variable on the data sheet.
2
Alarm type displayed during mastering and their solution method:
(1) BZAL alarm
This alarm is displayed if the Pulsecoder's backup battery voltage decreases to 0 V while the
power to the controller is disconnected. Furthermore, if the Pulsecoder connector is removed for
cable replacement, etc. this alarm is displayed as the voltage decreases to 0. Check to see if the
alarm will disappear by performing a pulse reset (See Section 6.2.). Then, cycle controller power
and check if the alarm disappears or not.
The battery may be drained if the alarm is still displayed. Perform a pulse reset, and turn off and
on the controller power after replacing the battery. Note that, if this alarm is displayed, all the
original data held by the Pulsecoder will be lost. Mastering is required.
(2) BLAL alarm
This alarm is displayed if the voltage of the Pulsecoder's backup battery has fallen to a level
where backup is no longer possible. If this alarm is displayed, replace the battery with a new one
immediately while keeping the power turned on. Check whether the current position data is valid,
using the procedure described in 1 in this Section.
(3) Alarm notifications like CKAL, RCAL, PHAL, CSAL, DTERR, CRCERR, STBERR, and
SPHAL may indicate trouble with Pulsecoder; contact your local FANUC representative.
- 155 -
APPENDIX
APPENDIX
B-84195EN/02
A
MAINTENANCE PARTS
Name
Table A (a) List of basic cable (basic cable)
Specifications
Remarks
K001
A05B-1702-D001
K002
A05B-1702-D002
K009
A05B-1702-D009
K010
A05B-1702-D010
K115
K121
K122
A660-4005-T924
A660-2008-T754
A660-2008-T755
K123
A660-4005-T925
K131
K132
K133
A660-2008-T756
A660-4005-T928
A660-4005-T926
K134
A660-4005-T927
K141
K142
K151
K152
K153
K154
K161
K201
K221
K231
K241
K251
K261
A660-4005-T930
A660-4005-T931
A660-4005-T932
A05B-1702-D006
A660-2008-T758
A660-4005-T934
A660-4005-T935
A660-4005-T936
A660-4005-T937
A660-4005-T938
A660-2008-T760
A660-4005-T939
A05B-1702-D005
Name
K301
K303
K304
K306
K307
K308
K309
K310
K311
K312
K313
K314
A. MAINTENANCE PARTS
Robot connection cable
(camera, back side connector panel)
Robot connection cable
(camera, bottom side connector panel)
Robot connection cable
(force sensor, back side connector panel)
Robot connection cable
(camera, bottom side connector panel)
J1,J2 brake
Relay of J3 power (J2 base to J2 arm lower side)
Relay of J4,J5,J6 power (J2 base to J2 arm lower side)
Relay of J3,J4,J5,J6 Pulsecoder
Battery connection cable
Relay of J3 power (J2 arm lower side to J3 casing)
Relay of J4,J5,J6 power (J2 arm lower side to J3 casing)
J3 power
J3 Pulsecoder,
Relay of J4,J5,J6 Pulsecoder,
Tool I/F board connection cable
J4 power, relay of J5,J6 power
J4 Pulsecoder, relay of J5,J6 Pulsecoder
J5 power
J6 power
J5 Pulsecoder
J6 Pulsecoder, relay of end effector
End effector
J1-axis sensor
J2-axis sensor
J3-axis sensor
J4-axis sensor
J5-axis sensor
J6-axis sensor
Table A (b) List of basic cable (option cable)
Specifications
Function
A05B-1702-D003
A660-2008-T762
A660-2008-T763
A660-2008-T765
A660-2008-T766
A05B-1702-D004
A05B-1702-D007
A660-2008-T767
A660-2008-T768
A660-2008-T769
A660-2008-T770
A05B-1702-D008
Relay of camera (connector panel to J2 base)
Relay of camera (J2 base to J2 arm lower side)
Relay of camera (J2 arm lower side to J3 casing)
Relay of camera (J3 casing to J3 arm)
Relay of camera (J3 arm to J6 casing)
Camera
Relay of force sensor (connector panel to J2 base )
Relay of force sensor (J2 base to J2 arm lower side)
Relay of force sensor (J2 arm lower side to J3 casing)
Relay of force sensor (J3 casing to J3 arm)
Relay of force sensor (J3 arm to J6 casing)
Force sensor
- 159 -
A. MAINTENANCE PARTS
APPENDIX
B-84195EN/02
Table A (c) Motor
Axis
J1, J2, J3
J4, J5
J6
Specifications
Remarks
βiS1/6000LV-B BRAKE(DC24V)
βiS0.3/6000LV-B BRAKE(DC24V)
βiS0.3/6000LV-B
A06B-2127-B303
A06B-2123-B303
A06B-2123-B003
Output (kW)
0.45
0.1
0.1
Table A (d) Reducer
Name
Specifications
Remarks
CRX-10iA, CRX-10iA/L
J1, J2-axis reducer
A97L-0318-0292#80
CRX-10iA, CRX-10iA/L
J3-axis reducer
A97L-0318-0293#80
CRX-10iA, CRX-10iA/L
J4, J5, J6-axis reducer A97L-0318-0294#50
CRX-10iA, CRX-10iA/L (For food specification)
J1, J2-axis reducer
A97L-0318-0292#80FL3
CRX-10iA, CRX-10iA/L (For food specification)
J3-axis reducer
A97L-0318-0293#80FL3
CRX-10iA, CRX-10iA/L (For food specification)
J4, J5, J6-axis reducer A97L-0318-0294#50FL3
CRX-20iA/L
J1, J2-axis reducer
A97L-0318-0292#120
CRX-20iA/L
J3-axis reducer
A97L-0318-0293#120
CRX-20iA/L
J4-axis reducer
A97L-0318-0315#80
CRX-20iA/L
J5-axis reducer
A97L-0318-0294#100
CRX-20iA/L
J6-axis reducer
A97L-0318-0294#80
Table A (e) Gear
Name
J1, J2-axis gear
J3-axis gear
J4-axis gear
J4-axis gear
J5-axis gear
J6-axis gear
J6-axis brake gear
Specifications
Used location
A290-7702-X204
A290-7702-X308
A290-7702-X407
A290-7702-Y407
A290-7702-X507
A290-7702-X508
A290-7702-V507
J1, J2-axis motor (2pcs/ per 1 robot)
J3-axis motor
J4-axis motor (CRX-10iA, CRX-10iA/L)
J4-axis motor (CRX-20iA/L)
J5-axis motor
J6-axis motor
J6-axis brake
Table A (f) Brake
Name
J6-axis brake
Specifications
J6-axis brake
Table A (g) Electric part
Specifications
Name
Tool I/F board
Used location
A97L-0318-0660
A20B-8102-0360
Table A (h) Battery・grease
Name
Battery
Grease
Grease
Specifications
Remarks
A98L-0031-0040#A
A98L-0040-0230#0.20KG
A98L-0040-0320#0.20KG
(2pcs/ per 1 robot)
For food specification
Table A (i) O-RING
Name
O-RING
O-RING
O-RING
O-RING
O-RING
O-RING
O-RING
O-RING
O-RING
Specifications
A98L-0001-0347#S46
A98L-0001-0347#S80
A98L-0001-0347#S90
A98L-0001-0347#S35
A98L-0001-0347#S29
A98L-0001-0347#S50
A98L-0001-0347#S26
A98L-0001-0347#S85
A98L-0001-0347#S63
Used location
J1, J2, J3-axis motor
J3 arm to J3 casing (CRX-10iA, CRX-10iA/L)
J3 arm to J3 casing (CRX-20iA/L)
J4, J5, J6-axis motor
J4 gearbox to J4 flange
J5 gear unit to J5 holder cover
J6-axis brake
J6 flange
J6 flange
- 160 -
APPENDIX
B-84195EN/02
A. MAINTENANCE PARTS
Table A (j) Sensor
Name
Specifications
J1,J2,J3-axis sensor
A97L-0318-0700
J4,J5,J6-axis sensor
A97L-0318-0701
J4-axis sensor
A97L-0318-0727
Name
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
Flange socket bolt
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
Used location
J1, J2, J3-axis (3 pcs/ per 1 robot)
J4, J5, J6-axis (CRX-10iA, CRX-10iA/L, 3 pcs/ per 1 robot)
J5, J6-axis (CRX-20iA/L, 2 pcs/ per 1 robot)
J4-axis (CRX-20iA/L, 1 pcs/ per 1 robot)
Table A (k) Bolt
Q’ty
Used location
1
J1-axis motor
1
J2-axis motor
A6-BA-5X20
5
J2 base to J1-axis reducer
5
J2 base to J2-axis reducer
14
J2 base to J1-axis reducer
A6-BA-5X30
14
J2 base to J2-axis reducer
12
J1-axis reducer to J1 sensor flange
A6-BA-5X35
12
J2-axis reducer to J2 sensor flange
16
J1-axis sensor to J1 sensor flange
A6-BA-6X25
16
J2-axis sensor to J2 sensor flange
16
J1 base to J1-axis sensor
A6-BA-6X20
16
J2 arm to J2-axis sensor
A6-BA-5X12
1
J3-axis motor
A6-BA-4X35
13
J2 arm to J3-axis reducer
A6-BA-4X25
4
J2 arm to J3-axis reducer
A6-BA-4X30
12
J3-axis reducer to J3sensor flange
16
J3 casing to J3-axis sensor
A6-BA-6X22
16
J3-axis sensor to J3 sensor flange
1
J4-axis motor
1
J5-axis motor
A97L-0218-0504#M3X10
1
J6-axis motor
12
J4 adaptor to J3 casing
12
J4-axis reducer to J4 sensor flange
(CRX-10iA, CRX-10iA/L)
A6-BA-3X25
14
J4 flange to J4-axis reducer (CRX-20iA/L)
12
J5-axis reducer to J5 sensor flange
12
J5-axis reducer to J5 sensor flange
16
J4 adaptor to J4-axis sensor
A6-BA-3X20
(CRX-10iA, CRX-10iA/L)
J4 adaptor to J4-axis sensor (CRX-20iA/L)
A6-BA-4X22
16
16
J4-axis sensor to J4 sensor flange
(CRX-10iA, CRX-10iA/L)
A6-BA-4X14
16
J5-axis sensor to J5 sensor flange
16
J6-axis sensor to J6 sensor flange
16
J4-axis sensor to J4 sensor flange (CRX-20iA/L)
A6-BA-5X18
9
J4 flange to J4-axis reducer
(CRX-10iA, CRX-10iA/L)
A6-BA-3X30
9
J3 arm to J5-axis reducer
7
J6 casing to J6-axis reducer
12
J4-axis reducer to J4 sensor flange (CRX-20iA/L)
3
J4 flange to J4-axis reducer
(CRX-10iA, CRX-10iA/L)
A6-BA-3X22
3
J3 arm to J5-axis reducer
2
J6 casing to J6-axis reducer
2
J4 flange to J4-axis reducer (CRX-20iA/L)
A6-BA-3X50
J4 flange to J3 arm (CRX-10iA, CRX-10iA/L)
A6-BA-3X12
12
4
J3 arm to J5-axis reducer
12
J4 flange to J3 arm (CRX-20iA/L)
A6-BA-3X14
16
J6 casing to J5-axis sensor
2
J6 casing to J6-axis reducer
A6-BA-3X8
2
J6 casing to J6-axis reducer
Specifications
- 161 -
A. MAINTENANCE PARTS
Name
Bolt
Seal bolt
Seal bolt
APPENDIX
Specifications
Q’ty
A6-BA-3X35
A97L-0218-0417#030404BC
A97L-0218-0546#030808BC
16
2
4
B-84195EN/02
Used location
J6 flange to J6-axis sensor
J6 flange cover
K301, K309
NOTE
When a bolt with instructions to apply LOCTITE is removed, it is recommended
to replace it with the new one.
Table A (l) Sheet
Name
Sheet
Sheet
Sheet
Sheet
Sheet
Specifications
A290-7702-X220
A290-7702-X335
A290-7702-X424
A290-7702-X425
A290-7702-X546
Used location
J1 base
J3-axis motor
J3 casing
J4-axis motor
J3 arm (J5-axis side)
- 162 -
B-84195EN/02
B
APPENDIX
B. MECHANICAL UNIT
CIRCUIT DIAGRAM
MECHANICAL UNIT CIRCUIT DIAGRAM
- 163 -
B. MECHANICAL UNIT
CIRCUIT DIAGRAM
APPENDIX
B-84195EN/02
A63L-0002-0066#R04DX
A63L-0002-0066#CR2L
A1
A2
(
X-KEY
BLACK
1
2
3
4
5
6
RMP
5
31
38
51
64
B1
B2
6PB
2022PCFA
J3U
J3V
J3W
K121
J3G
A660-2008-T754
BKC(J3)
BK(J3)
F20DX
CTM
J4V
J4G
J5V
J5G
J6V
J6G
BK(J5)
M456M1
K001(H201)
A05B-1702-D001
K002(H301)
A05B-1702-D002
A63L-0002-0066#R20DX
A63L-0002-0066#CRM
(
X-KEY
BLACK
)
A63L-0002-0205#24SB
A63L-0002-0205#2428SCFA
A63L-0002-0205#4SB
A63L-0002-0205#2428SCFA
A1 J4U
A2 J4W
A3 J5U
A4 J5W
A5 J6U
A6 J6W
A7 BK(J4)
A8 BK(J6)
A9
B1
B2
B3
B4
B5
B6
B7
B8
B9
A10
B10
A63L-0002-0205#7SB
A63L-0002-0205#2428SCFA
7PB
2428PCFA
2 RS485_T2 1 RS485_T1
4 XRS485_T2 3 XRS485_T1
SHIELD
7 24V_T
6 0V_T
TS1
5
K122
A660-2008-T755
BKC(J4-J6)
24PB
2428PCFA
5 PRQJ5
4 XPRQJ4
3 PRQJ4
2 XPRQJ3
1 PRQJ3
10 0V(J3,J4) 9 5V(J3,J4) 8 XPRQJ6
7 PRQJ6
6 XPRQJ5
15 0V_C+
14 30V_C+
13 30V_C+
12 0V(J5,J6) 11 5V(J5,J6)
19
18
17
16 0V_C+
20
24 6V(BT1,BT2) 23 0V(BT1,BT2) 22 XRS485_C+ 21 RS485_C+
M3456P1
K123
A660-4005-T925
LED UNIT
A97L-0318-0704
IND1
RDO1
RDO3
2
4
A63L-0002-0205#7SB
A63L-0002-0205#2428SCFA
K115
A660-4005-T924
M3M1
A63L-0002-0376#6SB
A63L-0002-0376#2022SCFA
18
BKC(J1)
BKC(J2)
)
RMP CONNECTOR
Han 75DDD
(2.5SQ 10A)
1 RS485_T1
2 RS485_T2
3 XRS485_T1 PE FG
4 XRS485_T2
PRQJ1
6 PRQJ2
7 PRQJ3
8 PRQJ4
9 PRQJ5
10 PRQJ6
11 RS485_C+
12 XPRQJ1 13 XPRQJ2 14 XPRQJ3 15 XPRQJ4 16 XPRQJ5 17 XPRQJ6
5V(J1,J2) 19 5V(J3,J4) 20 5V(J5,J6) 21 0V(J1,J2) 22 0V(J3,J4) 23 0V(J5,J6) 24 XRS485_C+
25 24V_T
26 0V_T
27 30V_C+
28 0V_C+
29 24V_DI/DO 30 0V_DI/DO
32
33
34
35
36 XROT
37
RDO1
39 RDO2
40 RD03
41
42
43
44 SHIELD
45 J1G
46 J2G
47 J3G
48 J4G
49 J5G
50 J6G
J1U
52 J2U
53 J3U
54 J4U
55 J5U
56 J6U
57 BKC(J1-J6)
58 J1V
59 J2V
60 J3V
61 J4V
62 J5V
63 J6V
65 J2W
66 J3W
67 J4W
68 J5W
69 J6W
70 BK(J1)
J1W
71 BK(J2) 72 BK(J3) 73 BK(J4)
74 BK(J5)
75 BK(J6)
F04DX
CTM
BK(J1)
BK(J2)
M12BK1
1
3
0V_DI/DO
RDO2
7PB
2428PCFA
2 RS485_T2 1 RS485_T1
4 XRS485_T2 3 XRS485_T1
SHIELD
7 24V_T
6 0V_T
TS2
5
K221
A660-4005-T937
K201
A660-4005-T936
A63L-0002-0205#13SB
A63L-0002-0205#2428SCFA
TS-J1
3
7
11
(
J1 CONNECTOR PANEL
CAM1 A63L-0002-0275#J3
1
CAMERA
Shield 0V(CAMERA)
BLACK
)
0V_T
A97L-0318-0700
24V_T
2 0V_T
1
6 SHIELD
5 RS485_T2 4 RS485_T1
10 0V_T
9 XRS485_T2 8 XRS485_T1
13
12 SHIELD
CAM-A
A63L-0002-0300#P1
A63L-0002-0300#J1
1
CAMERA
Shield 0V(CAMERA)
K301
A05B-1702-D003
(
BNC
K303
A660-2008-T762
)
:可動部用
MOVABLE
Fig. B (a) Circuit diagram (Camera cable) (CRX-10iA, CRX-10iA/L, CRX-20iA/L) (1/2)
- 164 -
B. MECHANICAL UNIT
CIRCUIT DIAGRAM
APPENDIX
B-84195EN/02
J1 MOTOR (βiS1/6000-B)
A63L-0002-0376#6SB
M1M
A63L-0002-0376#2022SCFA
A63L-0002-0284#A
V
W
A63L-0002-0285#A
J1V
J1W
U
G
1
2
3
4
5
6
M1BK
G
A63L-0001-0848#E10SL1
A63L-0001-0850
+ BKC(J1)
- BK(J1)
M1P
4
5
6
7
8
9 5V(J1)
10 0V(J1)
A63L-0002-0284#A
J1U
J1G
6V(BT1)
XPRQJ1
PRQJ1
0V(BT1)
J3 MOTOR (βiS1/6000-B)
M3M
A63L-0002-0284#A
M3M3 6PB
2022PCFA
J3U
J3V
J3W
J3G
BKC(J3)
BK(J3)
V
W
A63L-0002-0285#A
K133
A660-4005-T926
J3V
J3W
U
G
J3U
J3G
M3BK
G
A63L-0001-0848#E10SL1
A63L-0001-0850
+ BKC(J3)
- BK(J3)
M3P
8
9
10
1
2
3
5V(J3)
0V(J3)
4
5
6
7
6V(BT3)
XPRQJ3
PRQJ3
0V(BT3)
1
2
3
J2 MOTOR (βiS1/6000-B)
M2M
V
W
A63L-0002-0285#A
J2V
J2W
U
G
J2U
J2G
A63L-0002-0066#R06DX
A63L-0002-0066#CRM
M2BK
G
A63L-0001-0848#E10SL1
A63L-0001-0850
M2P
8
9
10
M4M3
F06DX
CTM
A1 J4U
B1 J4V
A2 J4W
B2 J4G
A3 BKC(J4-J6) B3 BK(J4)
+ BKC(J2)
- BK(J2)
4
5
6
7
5V(J2)
0V(J2)
6V(BT2)
XPRQJ2
PRQJ2
0V(BT2)
X-KEY
BLACK
A63L-0002-0066#R04DX
A63L-0002-0066#CRM
(
1
2
3
)
K141
A660-4005-T930
M5M3
F04DX
CTM
A1 J5U
A2 J5W
X-KEY
BLACK
A63L-0002-0066#R06DY
A63L-0002-0066#CRM
(
M3M2
A63L-0002-0376#6SB
A63L-0002-0376#2022SCFA
1
2
3
4
5
6
6PB
2022PCFA
J3U
J3V
J3W
J3G
BKC(J3)
BK(J3)
A1
A2
A3
A4
A5
A6
A7
A8
A9
(
X-KEY
BLACK
)
J4U
J4W
J5U
J5W
J6U
J6W
BK(J4)
BK(J6)
(
Y-KEY
BLACK
)
F20DX
CTM
B1
B2
B3
B4
B5
B6
B7
B8
B9
A10
F06DY
CTM
B1 J6V
B2 J6G
B3 BK(J6)
M6M3
A1 J6U
A2 J6W
A3 BK(J5)
K131
A660-2008-T756
M456M2
A63L-0002-0066#R20DX
A63L-0002-0066#CRM
B1 J5V
B2 J5G
)
J4V
J4G
J5V
J5G
J6V
J6G
BK(J5)
K132
A660-4005-T928
BKC(J4-J6)
B10
A63L-0002-0205#24SB
A63L-0002-0205#2428SCFA
A63L-0002-0205#24SB
A63L-0002-0205#2428SCFA
24PB
2428PCFA
5 PRQJ5
4 XPRQJ4
3 PRQJ4
2 XPRQJ3
1 PRQJ3
10 0V(J3,J4) 9 5V(J3,J4) 8 XPRQJ6
7 PRQJ6
6 XPRQJ5
15 0V_C+
14 30V_C+
13 30V_C+
12 0V(J5,J6) 11 5V(J5,J6)
17
16 0V_C+
20 6V(BT4-BT6) 19 0V(BT4-BT6) 18
24 6V(BT3)
23 0V(BT3)
22 XRS485_C+ 21 RS485_C+
M3456P2
BATTERY
BT123 A98L-0031-0011#D
A63L-0001-0812#F03SX
A63L-0001-0812#CTS
K134
A660-4005-T927
5
10
15
20
A63L-0002-0066#R04DX
A63L-0002-0066#CRM
A63L-0002-0066#CR2L
TOOL I/F BOARD
CRS54
1 6V(BT1-BT3)
2 0V(BT1-BT3)
3
X-KEY
BLACK
(
A63L-0001-0812#F03SX
A63L-0001-0812#CTS
A1 30V_C+
A2 0V_C+
A1
A2
A3
A4
A63L-0002-0205#13SB
A63L-0002-0205#2428SCFA
7PB
2428PCFA
2 RS485_T2 1 RS485_T1
4 XRS485_T2 3 XRS485_T1
SHIELD
7 24V_T
6 0V_T
A63L-0002-0205#7SB
A63L-0002-0205#2428SCFA
TS-J2
)
3 24V_T
7
6
11 0V_T
10
13
2
SHIELD
0V_T
5
A97L-0318-0700
1 0V_T
5 RS485_T2 4 RS485_T1
9 XRS485_T2 8 XRS485_T1
12 SHIELD
A63L-0002-0205#13SB
A63L-0002-0205#2428SCFA
(
BLACK
7PB
2428PCFA
2 RS485_T2 1 RS485_T1
4 XRS485_T2 3 XRS485_T1
SHIELD
7 24V_T
6 0V_T
TS-J3
3 24V_T
2
7
6 SHIELD
11 0V_T
10 0V_T
13
)
TS-J4
3
7
11
(
CAM-B
A63L-0002-0300#P1
)
BLACK
)
(
BNC
)
:可動部用
MOVABLE
- 165 -
A97L-0318-0700
1
5 RS485_T2 4 RS485_T1
9 XRS485_T2 8 XRS485_T1
12 SHIELD
A63L-0002-0300#J1
1
CAMERA
Shield 0V(CAMERA)
K304
A660-2008-T763
K241
A660-2008-T760
A97L-0318-0701
24V_T
2 0V_T
1 0V_T
6 SHIELD
5 RS485_T2 4 RS485_T1
10 0V_T
9 XRS485_T2 8 XRS485_T1
13
12 SHIELD
CAM-C
A63L-0002-0300#P1
A63L-0002-0300#J1
1
CAMERA
Shield 0V(CAMERA)
BNC
DO1
DO2
RS485_H
XRS485_H
TS4
K231
A660-4005-T938
A63L-0002-0205#13SB
A63L-0002-0205#2428SCFA
(
B1
B2
B3
B4
A63L-0002-0066#R08DX
A63L-0002-0066#CRM
A63L-0002-0066#CR2L
TS3
5
BLACK
POW_H
0V_H
DI1
DI2
)
A63L-0002-0205#7SB
A63L-0002-0205#2428SCFA
(
B1 RS485_C+
B2 XRS485_C+
CRS55
)
BATTERY
BT456 A98L-0031-0011#D
1 6V(BT4-BT6)
2 0V(BT4-BT6)
3
X-KEY
BLACK
(
24PB
2428PCFA
PRQJ5
4 XPRQJ4
3 PRQJ4
2
1
9 5V(J4)
8 XPRQJ6
6 XPRQJ5
7 PRQJ6
0V(J4)
0V_H
14 POW_H
13 POW_H
12 0V(J5,J6) 11 5V(J5,J6)
K142
A660-4005-T931
19 DO1
18 DI2
17 DI1
16 0V_H
DO2
24 6V(BT4-BT6) 23 0V(BT4-BT6) 22 XRS485_H 21 RS485_H
M456P3
K306
A660-2008-T765
B. MECHANICAL UNIT
CIRCUIT DIAGRAM
APPENDIX
B-84195EN/02
A63L-0002-0302#P
A63L-0002-0302#CA
J4 MOTOR (βiS0.3/6000-B)
M4M
PE J4G
A63L-0002-0366#P
A63L-0002-0366#CA
2
X-KEY
BLACK
A63L-0002-0066#R04DX
A63L-0002-0066#CRM
(
)
A1 J5U
A2 J5W
(
(
X-KEY
BLACK
M6M4
A1 J6U
A2 J6W
A3 BKC(J6)
(
M6M3
2
J4V
1
J4U
Y-KEY
BLACK
1 BKC(J4)
4
5
6
7
6V(BT4)
XPRQJ4
PRQJ4
0V(BT4)
1
2
3
F06DX
CTM
B1 J5V
B2 J5G
B3 BK(J5)
K151
A660-4005-T932
)
B1 J5V
B2 J5G
F06DY
CTM
B1 J6V
B2 J6G
B3 BK(J6)
K152
A05B-1702-D006
)
F06DY
CTM
B1 J6V
B2 J6G
B3 BK(J6)
A1 J6U
A2 J6W
A3 BK(J5)
(
M5M4
A63L-0002-0066#R06DY
A63L-0002-0066#CRM
F04DX
CTM
)
Y-KEY
BLACK
5V(J4)
0V(J4)
A1 J5U
A2 J5W
A3 BKC(J5)
K141
A660-4005-T930
M5M3
X-KEY
BLACK
A63L-0002-0066#R06DY
A63L-0002-0066#CRM
A63L-0002-0066#R06DX
A63L-0002-0066#CRM
F06DX
CTM
A1 J4U
B1 J4V
A2 J4W
B2 J4G
A3 BKC(J4-J6) B3 BK(J4)
BK(J4)
M4P
8
9
10
M4M3
J4W
M4BK
A63L-0001-0848#E10SL1
A63L-0001-0850
A63L-0002-0066#R06DX
A63L-0002-0066#CRM
3
)
A63L-0002-0205#6SB
A63L-0002-0205#2428SCFA
M5P4
3
6
PRQJ5
0V(J5)
2
5
0V(BT5)
5V(J5)
1
4
6PB
2428PCFA
6V(BT5)
XPRQJ5
K153
A660-2008-T758
A63L-0002-0205#24SB
A63L-0002-0205#2428SCFA
A63L-0002-0205#24SB
A63L-0002-0205#2428SCFA
5
10
15
20
A63L-0002-0205#7SB
A63L-0002-0205#2428SCFA
24PB
2428PCFA
4 XPRQJ4
3 PRQJ4
2
1
PRQJ5
9 5V(J4)
8 XPRQJ6
7 PRQJ6
6 XPRQJ5
0V(J4)
14 POW_H
13 POW_H
12 0V(J5,J6) 11 5V(J5,J6)
0V_H
K142
19 DO1
18 DI2
17 DI1
16 0V_H
DO2
A660-4005-T931
24 6V(BT4-BT6) 23 0V(BT4-BT6) 22 XRS485_H 21 RS485_H
7PB
2428PCFA
2 RS485_T2 1 RS485_T1
4 XRS485_T2 3 XRS485_T1
SHIELD
7 24V_T
6 0V_T
5
CAM-C
(
BNC
7PB
2428PCFA
2 RS485_T2 1 RS485_T1
4 XRS485_T2 3 XRS485_T1
SHIELD
7 24V_T
6 0V_T
CAM-D
A63L-0002-0300#P1
)
(
BNC
K251
A660-4005-T939
A63L-0002-0300#J1
1
CAMERA
Shield 0V(CAMERA)
K306
A660-2008-T765
K154
A660-4005-T934
TS5
5
K241
A660-2008-T760
A63L-0002-0300#J1
1
CAMERA
Shield 0V(CAMERA)
M6P4
A63L-0002-0205#7SB
A63L-0002-0205#2428SCFA
TS4
A63L-0002-0300#P1
24PB
2428PCFA
5
4
3
2
1
10
9
8 XPRQJ6
6
7 PRQJ6
15 0V_H
14 POW_H
13 POW_H
11 5V(J6)
12 0V(J6)
19 D01
18 DI2
17 DI1
16 0V_H
20 DO2
24 6V(BT6) 23 0V(BT6) 22 XRS485_H 21 RS485_H
M456P3
K307
A660-2008-T766
)
:可動部用
MOVABLE
Fig. B (b) Circuit diagram (Camera cable) (CRX-10iA, CRX-10iA/L, CRX-20iA/L) (2/2)
- 166 -
B. MECHANICAL UNIT
CIRCUIT DIAGRAM
APPENDIX
B-84195EN/02
A63L-0002-0302#P
A63L-0002-0302#CA
J5 MOTOR (βiS0.3/6000-B)
M5M
PE
A63L-0002-0366#P
A63L-0002-0366#CA
3
J5W
2
J5V
1
J5U
M5BK
2
A63L-0001-0848#E10SL1
A63L-0001-0850
J5G
BK(J5)
M5P
8
9
10
5V(J5)
0V(J5)
1 BKC(J5)
4
5
6
7
6V(BT5)
XPRQJ5
PRQJ5
0V(BT5)
1
2
3
J6 BREAK
A97L-0318-0660
M6BK
A63L-0002-0066#R04DX
A63L-0002-0066#CRM
A1 BKC(J6)
A2
A63L-0002-0302#P
A63L-0002-0302#CA
B1 BK(J6)
B2
J6 MOTOR (βiS0.3/6000)
M6M
PE J6G
A63L-0001-0848#E10SL1
A63L-0001-0850
M6P
8
9
10
5V(J6)
0V(J6)
3
J6W
2
4
5
6
7
6V(BT6)
XPRQJ6
PRQJ6
0V(BT6)
1
2
3
J6V
1
J6U
A63L-0002-0205#4SB
A63L-0002-0205#2428SCFA
EE1
POW_H
0V_H
2
4
1
3
J6 FLANGE
EE
4PB
2428PCFA
POW_H
0V_H
A63L-0002-0374#MB
5 POW_H
4 DI1
8 0V_H
3 DI2
RS485_H 2 XRS485_H
6
K161
A660-4005-T935
A63L-0002-0205#6SB
A63L-0002-0205#2428SCFA
EE2
3 DO1
6 XRS485_H
A63L-0002-0205#7SB
A63L-0002-0205#2428SCFA
2
5
DI2
RS485_H
1
4
1
7PB
2428PCFA
2 RS485_T2 1 RS485_T1
4 XRS485_T2 3 XRS485_T1
SHIELD
7 24V_T
6 0V_T
A63L-0002-0205#13SB
A63L-0002-0205#2428SCFA
TS-J5
3
7
11
(
BLACK
)
24V_T
6
10
13
CAM-E
A63L-0002-0300#P1
3
BNC
BLACK
24V_T
6
10
13
)
A97L-0318-0701
2 0V_T
1
5 RS485_T2 4 RS485_T1
SHIELD
0V_T
9 XRS485_T2 8 XRS485_T1
12 SHIELD
J6 FLANGE
CAM2 A63L-0002-0275#J3
A63L-0002-0300#J1
1
CAMERA
Shield 0V(CAMERA)
(
TS-J6
7
11
K261
A05B-1702-D005
(
A63L-0002-0205#13SB
A63L-0002-0205#2428SCFA
DO2
DO1
6PB
2428PCFA
DI1
DO2
TS6
5
7
)
:可動部用
MOVABLE
- 167 -
K308
A05B-1702-D004
1
CAMERA
Shield 0V(CAMERA)
2
SHIELD
0V_T
A97L-0318-0701
1 0V_T
5 RS485_T2 4 RS485_T1
9 XRS485_T2 8 XRS485_T1
12 SHIELD
B. MECHANICAL UNIT
CIRCUIT DIAGRAM
APPENDIX
B-84195EN/02
A63L-0002-0066#R04DX
A63L-0002-0066#CR2L
F04DX
CTM
B1 BK(J1)
B2 BK(J2)
M12BK1
A1 BKC(J1)
A2 BKC(J2)
(
X-KEY
BLACK
M3M1 6PB
2022PCFA
A63L-0002-0376#6SB
A63L-0002-0376#2022SCFA
1
2
3
4
5
6
RMP CONNECTOR
RMP
5
18
31
38
51
64
Han 75DDD
(2.5SQ 10A)
1 RS485_T1
2 RS485_T2
3 XRS485_T1 PE FG
4 XRS485_T2
PRQJ1
6 PRQJ2
7 PRQJ3
8 PRQJ4
9 PRQJ5
10 PRQJ6
11 RS485_C+
12 XPRQJ1 13 XPRQJ2 14 XPRQJ3 15 XPRQJ4 16 XPRQJ5 17 XPRQJ6
5V(J1,J2) 19 5V(J3,J4) 20 5V(J5,J6) 21 0V(J1,J2) 22 0V(J3,J4) 23 0V(J5,J6) 24 XRS485_C+
25 24V_T
26 0V_T
27 30V_C+
28 0V_C+
29 24V_DI/DO 30 0V_DI/DO
32
33
34
35
36 XROT
37
RDO1
39 RDO2
40 RD03
41
42
43
44 SHIELD
45 J1G
46 J2G
47 J3G
48 J4G
49 J5G
50 J6G
J1U
52 J2U
53 J3U
54 J4U
55 J5U
56 J6U
57 BKC(J1-J6)
58 J1V
59 J2V
60 J3V
61 J4V
62 J5V
63 J6V
65 J2W
66 J3W
67 J4W
68 J5W
69 J6W
70 BK(J1)
J1W
71 BK(J2) 72 BK(J3) 73 BK(J4)
74 BK(J5)
75 BK(J6)
J3U
J3V
J3W
J3G
BKC(J3)
BK(J3)
K121
A660-2008-T754
M456M1
K001(H202)
A05B-1702-D009
K002(H302)
A05B-1702-D010
A63L-0002-0066#R20DX
A63L-0002-0066#CRM
(
X-KEY
BLACK
)
A1
A2
A3
A4
A5
A6
A7
A8
A9
J4U
J4W
J5U
J5W
J6U
J6W
BK(J4)
BK(J6)
A10
A63L-0002-0205#24SB
A63L-0002-0205#2428SCFA
A63L-0002-0205#4SB
A63L-0002-0205#2428SCFA
A63L-0002-0205#7SB
A63L-0002-0205#2428SCFA
7PB
2428PCFA
2 RS485_T2 1 RS485_T1
4 XRS485_T2 3 XRS485_T1
SHIELD
7 24V_T
6 0V_T
TS1
5
B1
B2
B3
B4
B5
B6
B7
B8
B9
F20DX
CTM
J4V
J4G
J5V
J5G
J6V
J6G
BK(J5)
K122
A660-2008-T755
BKC(J4-J6)
B10
24PB
2428PCFA
5 PRQJ5
4 XPRQJ4
3 PRQJ4
2 XPRQJ3
1 PRQJ3
10 0V(J3,J4) 9 5V(J3,J4) 8 XPRQJ6
6 XPRQJ5
7 PRQJ6
15 0V_C+
14 30V_C+
13 30V_C+
12 0V(J5,J6) 11 5V(J5,J6)
19
18
17
16 0V_C+
20
24 6V(BT1,BT2) 23 0V(BT1,BT2) 22 XRS485_C+ 21 RS485_C+
M3456P1
K123
A660-4005-T925
LED UNIT
A97L-0318-0704
IND1
2
4
A63L-0002-0205#7SB
A63L-0002-0205#2428SCFA
K115
A660-4005-T924
)
1
3
RDO1
RDO3
0V_DI/DO
RDO2
7PB
2428PCFA
2 RS485_T2 1 RS485_T1
4 XRS485_T2 3 XRS485_T1
SHIELD
7 24V_T
6 0V_T
TS2
5
K221
A660-4005-T937
K201
A660-4005-T936
A63L-0002-0205#13SB
A63L-0002-0205#2428SCFA
(
J1 CONNECTOR PANEL
FS1
A63L-0002-0098#10R-4P
1
2
0V_FS
TX2
4
3
24V_FS
TX1
BLACK
)
TS-J1
A97L-0318-0700
3 24V_T
2 0V_T
1
7
6 SHIELD
5 RS485_T2 4 RS485_T1
11 0V_T
10 0V_T
9 XRS485_T2 8 XRS485_T1
13
12 SHIELD
FS-A
A63L-0002-0205#5SW
3
TX1
5
K309
A05B-1702-D007
(
WHITE
5PW
2428PCFA
2 TX2
DRAIN
4
1 0V_FS
24V_FS
K310
A660-2008-T767
)
:可動部用
MOVABLE
Fig. B (c) Circuit diagram (force sensor cable) (CRX-10iA, CRX-10iA/L, CRX-20iA/L) (1/2)
- 168 -
B. MECHANICAL UNIT
CIRCUIT DIAGRAM
APPENDIX
B-84195EN/02
J1 MOTOR (βiS1/6000-B)
A63L-0002-0376#6SB
M1M
A63L-0002-0376#2022SCFA
A63L-0002-0284#A
V
W
A63L-0002-0285#A
J1V
J1W
U
G
A63L-0001-0848#E10SL1
A63L-0001-0850
+ BKC(J1)
- BK(J1)
M1P
4
5
6
7
8
9 5V(J1)
10 0V(J1)
6V(BT1)
XPRQJ1
PRQJ1
0V(BT1)
J3 MOTOR (βiS1/6000-B)
M3M
A63L-0002-0284#A
M3M3
1
2
3
4
5
6
M1BK
G
A63L-0002-0284#A
J1U
J1G
6PB
2022PCFA
J3U
J3V
J3W
J3G
BKC(J3)
BK(J3)
V
W
A63L-0002-0285#A
K133
A660-4005-T926
J3V
J3W
U
G
J3U
J3G
M3BK
G
A63L-0001-0848#E10SL1
A63L-0001-0850
+ BKC(J3)
- BK(J3)
M3P
8
9
10
1
2
3
5V(J3)
0V(J3)
4
5
6
7
6V(BT3)
XPRQJ3
PRQJ3
0V(BT3)
1
2
3
J2 MOTOR (βiS1/6000-B)
M2M
V
W
A63L-0002-0285#A
J2V
J2W
U
G
J2U
J2G
A63L-0002-0066#R06DX
A63L-0002-0066#CRM
M2BK
G
A63L-0001-0848#E10SL1
A63L-0001-0850
M2P
8
9
10
F06DX
CTM
A1 J4U
B1 J4V
A2 J4W
B2 J4G
A3 BKC(J4-J6) B3 BK(J4)
M4M3
+ BKC(J2)
- BK(J2)
4
5
6
7
5V(J2)
0V(J2)
6V(BT2)
XPRQJ2
PRQJ2
0V(BT2)
X-KEY
BLACK
A63L-0002-0066#R04DX
A63L-0002-0066#CRM
(
1
2
3
)
K141
A660-4005-T930
M5M3
F04DX
CTM
A1 J5U
A2 J5W
X-KEY
BLACK
A63L-0002-0066#R06DY
A63L-0002-0066#CRM
(
M3M2 6PB
2022PCFA
A63L-0002-0376#6SB
A63L-0002-0376#2022SCFA
1
2
3
4
5
6
J3U
J3V
J3W
J3G
BKC(J3)
BK(J3)
A1
A2
A3
A4
A5
A6
A7
A8
A9
(
X-KEY
BLACK
)
J4U
J4W
J5U
J5W
J6U
J6W
BK(J4)
BK(J6)
(
Y-KEY
BLACK
)
F20DX
CTM
B1
B2
B3
B4
B5
B6
B7
B8
B9
A10
F06DY
CTM
B1 J6V
B2 J6G
B3 BK(J6)
M6M3
A1 J6U
A2 J6W
A3 BK(J5)
K131
A660-2008-T756
M456M2
A63L-0002-0066#R20DX
A63L-0002-0066#CRM
B1 J5V
B2 J5G
)
J4V
J4G
J5V
J5G
J6V
J6G
BK(J5)
K132
A660-4005-T928
BKC(J4-J6)
B10
A63L-0002-0205#24SB
A63L-0002-0205#2428SCFA
A63L-0002-0205#24SB
A63L-0002-0205#2428SCFA
24PB
2428PCFA
5 PRQJ5
4 XPRQJ4
3 PRQJ4
2 XPRQJ3
1 PRQJ3
10 0V(J3,J4) 9 5V(J3,J4) 8 XPRQJ6
6 XPRQJ5
7 PRQJ6
15 0V_C+
14 30V_C+
13 30V_C+
12 0V(J5,J6) 11 5V(J5,J6)
17
16 0V_C+
20 6V(BT4-BT6) 19 0V(BT4-BT6) 18
22 XRS485_C+ 21 RS485_C+
24 6V(BT3)
23 0V(BT3)
M3456P2
BATTERY
BT123 A98L-0031-0011#D
A63L-0001-0812#F03SX
A63L-0001-0812#CTS
24PB
2428PCFA
5 PRQJ5
4 XPRQJ4
3 PRQJ4
2
1
9 5V(J4)
8 XPRQJ6
10 0V(J4)
6 XPRQJ5
7 PRQJ6
15 0V_H
14 POW_H
13 POW_H
12 0V(J5,J6) 11 5V(J5,J6)
K142
A660-4005-T931
19 DO1
18 DI2
17 DI1
16 0V_H
20 DO2
24 6V(BT4-BT6) 23 0V(BT4-BT6) 22 XRS485_H 21 RS485_H
M456P3
A63L-0002-0066#R04DX
A63L-0002-0066#CRM
A63L-0002-0066#CR2L
TOOL I/F BOARD
CRS54
K134
A660-4005-T927
1 6V(BT1-BT3)
2 0V(BT1-BT3)
3
(
X-KEY
BLACK
A63L-0001-0812#F03SX
A63L-0001-0812#CTS
A1 30V_C+
A2 0V_C+
A1
A2
A3
A4
1 6V(BT4-BT6)
2 0V(BT4-BT6)
3
(
X-KEY
BLACK
A63L-0002-0205#13SB
A63L-0002-0205#2428SCFA
7PB
2428PCFA
2 RS485_T2 1 RS485_T1
4 XRS485_T2 3 XRS485_T1
SHIELD
7 24V_T
6 0V_T
A63L-0002-0205#7SB
A63L-0002-0205#2428SCFA
TS-J2
)
3 24V_T
7
6
11 0V_T
10
13
2
SHIELD
0V_T
5
A97L-0318-0700
1 0V_T
5 RS485_T2 4 RS485_T1
9 XRS485_T2 8 XRS485_T1
12 SHIELD
A63L-0002-0205#13SB
A63L-0002-0205#2428SCFA
(
BLACK
7PB
2428PCFA
2 RS485_T2 1 RS485_T1
4 XRS485_T2 3 XRS485_T1
SHIELD
7 24V_T
6 0V_T
TS-J3
)
3 24V_T
2
7
6 SHIELD
11 0V_T
10 0V_T
13
TS-J4
3
7
11
(
5PW
2428PCFA
FS-B
A63L-0002-0205#5SW
3
TX1
5
WHITE
DO1
DO2
RS485_H
XRS485_H
TS4
K231
A660-4005-T938
A63L-0002-0205#13SB
A63L-0002-0205#2428SCFA
(
B1
B2
B3
B4
A63L-0002-0066#R08DX
A63L-0002-0066#CRM
A63L-0002-0066#CR2L
TS3
5
BLACK
POW_H
0V_H
DI1
DI2
)
A63L-0002-0205#7SB
A63L-0002-0205#2428SCFA
(
B1 RS485_C+
B2 XRS485_C+
CRS55
)
BATTERY
BT456 A98L-0031-0011#D
2 TX2
DRAIN
4
1 0V_FS
24V_FS
BLACK
)
3
TX1
5
(
)
:可動部用
MOVABLE
- 169 -
WHITE
)
A97L-0318-0700
1
5 RS485_T2 4 RS485_T1
9 XRS485_T2 8 XRS485_T1
12 SHIELD
A97L-0318-0701
24V_T
2 0V_T
1 0V_T
6 SHIELD
5 RS485_T2 4 RS485_T1
10 0V_T
9 XRS485_T2 8 XRS485_T1
13
12 SHIELD
FS-C
A63L-0002-0205#5SW
K311
A660-2008-T768
K241
A660-2008-T760
5PW
2428PCFA
2 TX2
DRAIN
4
1 0V_FS
24V_FS
K312
A660-2008-T769
B. MECHANICAL UNIT
CIRCUIT DIAGRAM
APPENDIX
B-84195EN/02
A63L-0002-0302#P
A63L-0002-0302#CA
J4 MOTOR (βiS0.3/6000-B)
M4M
PE J4G
A63L-0002-0366#P
A63L-0002-0366#CA
2
A63L-0002-0066#R06DX
A63L-0002-0066#CRM
F06DX
CTM
A1 J4U
B1 J4V
A2 J4W
B2 J4G
A3 BKC(J4-J6) B3 BK(J4)
)
M5M3
(
Y-KEY
BLACK
1
J4U
6V(BT4)
XPRQJ4
PRQJ4
0V(BT4)
1
2
3
F06DX
CTM
B1 J5V
B2 J5G
B3 BK(J5)
K151
A660-4005-T932
)
M6M4
A1 J6U
A2 J6W
A3 BKC(J6)
(
J4V
F06DY
CTM
B1 J6V
B2 J6G
B3 BK(J6)
K152
A05B-1702-D006
)
F06DY
CTM
B1 J6V
B2 J6G
B3 BK(J6)
M6M3
A1 J6U
A2 J6W
A3 BK(J5)
(
X-KEY
BLACK
B1 J5V
B2 J5G
)
Y-KEY
BLACK
4
5
6
7
5V(J4)
0V(J4)
M5M4
A63L-0002-0066#R06DY
A63L-0002-0066#CRM
F04DX
CTM
A1 J5U
A2 J5W
X-KEY
BLACK
A63L-0002-0066#R06DY
A63L-0002-0066#CRM
(
K141
A660-4005-T930
2
1 BKC(J4)
A1 J5U
A2 J5W
A3 BKC(J5)
X-KEY
BLACK
A63L-0002-0066#R04DX
A63L-0002-0066#CRM
(
BK(J4)
M4P
8
9
10
M4M3
J4W
M4BK
A63L-0001-0848#E10SL1
A63L-0001-0850
A63L-0002-0066#R06DX
A63L-0002-0066#CRM
3
)
A63L-0002-0205#6SB
A63L-0002-0205#2428SCFA
M5P4
3
6
PRQJ5
0V(J5)
2
5
0V(BT5)
5V(J5)
1
4
6PB
2428PCFA
6V(BT5)
XPRQJ5
K153
A660-2008-T758
A63L-0002-0205#24SB
A63L-0002-0205#2428SCFA
A63L-0002-0205#24SB
A63L-0002-0205#2428SCFA
5
10
15
20
A63L-0002-0205#7SB
A63L-0002-0205#2428SCFA
24PB
2428PCFA
4 XPRQJ4
3 PRQJ4
2
1
PRQJ5
9 5V(J4)
8 XPRQJ6
6 XPRQJ5
7 PRQJ6
0V(J4)
14 POW_H
13 POW_H
12 0V(J5,J6) 11 5V(J5,J6)
0V_H
K142
19 DO1
18 DI2
17 DI1
16 0V_H
DO2
A660-4005-T931
24 6V(BT4-BT6) 23 0V(BT4-BT6) 22 XRS485_H 21 RS485_H
7PB
2428PCFA
2 RS485_T2 1 RS485_T1
4 XRS485_T2 3 XRS485_T1
SHIELD
7 24V_T
6 0V_T
5
3
TX1
5
(
WHITE
2 TX2
DRAIN
4
1 0V_FS
24V_FS
7PB
2428PCFA
2 RS485_T2 1 RS485_T1
4 XRS485_T2 3 XRS485_T1
SHIELD
7 24V_T
6 0V_T
FS-D
A63L-0002-0205#5SW
3
TX1
5
K312
A660-2008-T769
)
(
WHITE
K154
A660-4005-T934
TS5
5
K241
A660-2008-T760
5PW
2428PCFA
FS-C
M6P4
A63L-0002-0205#7SB
A63L-0002-0205#2428SCFA
TS4
A63L-0002-0205#5SW
24PB
2428PCFA
5
4
3
2
1
9
8 XPRQJ6
10
7 PRQJ6
6
15 0V_H
14 POW_H
13 POW_H
11 5V(J6)
12 0V(J6)
19 D01
18 DI2
17 DI1
16 0V_H
20 DO2
24 6V(BT6) 23 0V(BT6) 22 XRS485_H 21 RS485_H
M456P3
K251
A660-4005-T939
5PW
2428PCFA
2 TX2
DRAIN
4
1 0V_FS
24V_FS
K313
A660-2008-T770
)
:可動部用
MOVABLE
Fig. B (d) Circuit diagram (force sensor cable) (CRX-10iA, CRX-10iA/L, CRX-20iA/L) (2/2)
- 170 -
B. MECHANICAL UNIT
CIRCUIT DIAGRAM
APPENDIX
B-84195EN/02
A63L-0002-0302#P
A63L-0002-0302#CA
J5 MOTOR (βiS0.3/6000-B)
M5M
PE
A63L-0002-0366#P
A63L-0002-0366#CA
3
J5W
2
J5V
1
J5U
M5BK
2
A63L-0001-0848#E10SL1
A63L-0001-0850
J5G
BK(J5)
M5P
8
9
10
5V(J5)
0V(J5)
1 BKC(J5)
4
5
6
7
6V(BT5)
XPRQJ5
PRQJ5
0V(BT5)
1
2
3
J6 BREAK
A97L-0318-0660
M6BK
A63L-0002-0066#R04DX
A63L-0002-0066#CRM
A1 BKC(J6)
A2
A63L-0002-0302#P
A63L-0002-0302#CA
B1 BK(J6)
B2
J6 MOTOR (βiS0.3/6000)
M6M
PE J6G
A63L-0001-0848#E10SL1
A63L-0001-0850
M6P
8
9 5V(J6)
10 0V(J6)
3
J6W
2
4
5
6
7
6V(BT6)
XPRQJ6
PRQJ6
0V(BT6)
1
2
3
J6V
1
J6U
A63L-0002-0205#4SB
A63L-0002-0205#2428SCFA
2
4
1
3
POW_H
0V_H
J6 FLANGE
EE
4PB
2428PCFA
POW_H
0V_H
EE1
A63L-0002-0374#MB
5 POW_H
4 DI1
8 0V_H
3 DI2
RS485_H 2 XRS485_H
6
K161
A660-4005-T935
A63L-0002-0205#6SB
A63L-0002-0205#2428SCFA
EE2
3 DO1
6 XRS485_H
A63L-0002-0205#7SB
A63L-0002-0205#2428SCFA
2
5
DI2
RS485_H
1
4
1
7PB
2428PCFA
2 RS485_T2 1 RS485_T1
4 XRS485_T2 3 XRS485_T1
SHIELD
7 24V_T
6 0V_T
A63L-0002-0205#13SB
A63L-0002-0205#2428SCFA
TS-J5
3
7
11
(
BLACK
)
3
3
TX1
5
(
WHITE
BLACK
2
24V_T
6 SHIELD
10 0V_T
13
)
A97L-0318-0701
24V_T
2 0V_T
1
6 SHIELD
5 RS485_T2 4 RS485_T1
10 0V_T
9 XRS485_T2 8 XRS485_T1
13
12 SHIELD
FS-E
A63L-0002-0205#5SW
TS-J6
7
11
K261
A05B-1702-D005
(
A63L-0002-0205#13SB
A63L-0002-0205#2428SCFA
DO2
DO1
6PB
2428PCFA
DI1
DO2
TS6
5
7
J6 FLANGE
A63L-0002-0098#07R-6S
FS2
5PW
2428PCFA
2 TX2
DRAIN
4
1 0V_FS
24V_FS
)
:可動部用
MOVABLE
- 171 -
K314
A05B-1702-D008
6
5
4
24V_FS
1
2
3
0V_FS
TX2
TX1
A97L-0318-0701
1 0V_T
5 RS485_T2 4 RS485_T1
9 XRS485_T2 8 XRS485_T1
12 SHIELD
C. PERIODIC MAINTENANCE TABLE
C
APPENDIX
B-84195EN/02
PERIODIC MAINTENANCE TABLE
FANUC Robot CRX-10iA, CRX-10iA/L, CRX-20iA/L
Accumulated operating
time (H)
Items
Mechanical unit
Check for external
0.1H
-
○
○
○
○
○
○
○
○
○
○
○
2 Check for water
0.1H
-
○
○
○
○
○
○
○
○
○
○
○
0.1H
-
○
○
○
0.1H
-
○
○
○
5 Tighten the end effector bolt 0.1H
-
○
○
○
-
○
○
○
○
○
○
○
○
○
○
○
○
Check the end effector
3 (hand) cable
Check the exposed
4 connector.(Loosening)
7
Controller
Oil
6
9
1
2
First
3
Grease check months months months year
years
amount 320
960 1920 2880 3840 4800 5760 6720 7680 8640 9600 10560
1 damage or peeling paint
6
*1
Check
time
Periodic Maintenance Table
8
9
Tighten the cover and main
bolt
Remove spatter and dust
etc.
Check the robot cable, teach
pendant cable and robot
connecting cable
Cleaning the controller
ventilation system
1.0H
1.0H
0.2H
-
0.2H
-
○
○
●: requires order of parts
○: does not require order of parts
- 172 -
○
○
○
○
○
○
○
APPENDIX
B-84195EN/02
C. PERIODIC MAINTENANCE TABLE
3
4
5
6
7
8
years
years
years
years
years
years
Item
11520 12480 13440 14400 15360 16320 17280 18240 19200 20160 21120 22080 23040 24000 24960 25920 26880 27840 28800 29760 30720
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
1
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
2
○
○
○
○
3
○
○
○
○
○
4
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
7
○
○
○
○
○
8
○
○
○
○
○
○
○
○
○
○
○
- 173 -
○
○
○
○
○
○
Overhaul
○
○
○
○
5
6
9
D. STRENGTH OF BOLT AND
BOLT TORQUE LIST
D
APPENDIX
B-84195EN/02
STRENGTH OF BOLT AND BOLT TORQUE
LIST
NOTE
When applying LOCTITE to a part, spread the LOCTITE on the entire length of
the engaging part of the female thread. If applied to the male threads, poor
adhesion can occur, potentially loosening the bolt. Clean the bolts and the
threaded holes and wipe off any oil on the engaging section. Make sure that
there is no solvent left in the threaded holes. When finished, remove all the
excess LOCTITE when you are finished screwing the bolts into the threaded
holes.
Use the following strength bolts. Comply with any bolt specification instructions.
Hexagon socket head bolt made of steel:
Size M22 or less:
Tensile strength 1200N/mm2 or more
Size M24 or more:
Tensile strength 1000N/mm2 or more
All size plating bolt:
Tensile strength 1000N/mm2 or more
Hexagon bolt, stainless bolt, special shape bolt (button bolt, low-head bolt, flush bolt .etc.)
Tensile strength 400N/mm2 or more
Refer to the following tables if the bolts tightening torque is not specified.
Recommended bolt tightening torques
Unit: Nm
Hexagon socket head
button bolt
Hexagon socket head
Hexagon socket head
Hexagon bolt
Hexagon socket head
bolt
bolt (stainless steel)
(steel)
flush bolt
Nominal
(steel)
Low-head bolt
diameter
(steel)
Tightening torque
Tightening torque
Tightening torque
Tightening torque
Upper limit Lower limit Upper limit Lower limit Upper limit Lower limit Upper limit Lower limit
――――
――――
――――
―――
M3
1.8
1.3
0.76
0.53
M4
4.0
2.8
1.8
1.3
1.8
1.3
1.7
1.2
M5
7.9
5.6
3.4
2.5
4.0
2.8
3.2
2.3
M6
14
9.6
5.8
4.1
7.9
5.6
5.5
3.8
M8
32
23
14
9.8
14
9.6
13
9.3
M10
66
46
27
19
32
23
26
19
――――
――――
M12
110
78
48
33
45
31
――――
――――
(M14)
180
130
76
53
73
51
――――
――――
M16
270
190
120
82
98
69
――――
――――
(M18)
380
260
160
110
140
96
――――
――――
M20
530
370
230
160
190
130
――――
――――
――――
――――
――――
――――
(M22)
730
510
――――
――――
――――
――――
――――
――――
M24
930
650
――――
――――
――――
――――
――――
――――
(M27)
1400
960
――――
――――
――――
――――
――――
――――
M30
1800
1300
――――
――――
――――
――――
――――
――――
M36
3200
2300
- 174 -
INDEX
B-84195EN/02
INDEX
MECHANICAL UNIT CIRCUIT DIAGRAM ............ 163
MODE SELECT SWITCH ......................................... s-26
<A>
ALL-AXES VISION MASTERING ............................ 144
AUTOMATIC OPERATION ..................................... s-37
<O>
Operating Modes ......................................................... s-26
OPERATION INSIDE OF THE SAFETY FENCE .... s-30
Other Cautions for Programming ................................ s-36
OTHER PRECAUTIONS ........................................... s-16
Other Protection Devices ............................................ s-29
OVERVIEW .......................................................... s-2,142
<B>
BACKLASH MEASUREMENT ................................... 18
Base plate installation .................................................. 148
Bracket Assembling ..................................................... 145
<C>
<P>
CABLE AND AIR TUBE REPLACEMENT .............. 114
Cable assembling ......................................................... 146
CABLE FORMING ..................................................... 112
CABLE WIRING ......................................................... 110
CHECK POINTS ............................................................. 4
Check the Mechanical Unit Connectors ........................... 5
CHECKS AND MAINTENANCE .................................. 1
COMMISSIONING AND FUNCTIONAL TESTINGs-34
CONFIGURATION OF ROBOT SYSTEM ................. s-3
Confirmation of Oil Seepage............................................ 4
CONTROL UNIT ....................................................... s-40
Payload value for wrist camera installation ................. 151
Periodic Check and Maintenance ..................................... 2
PERIODIC MAINTENANCE ......................................... 1
PERIODIC MAINTENANCE TABLE ....................... 172
PLACEMENT OF EQUIPMENT ............................... s-14
POWER SUPPLY AND PROTECTIVE EARTH
CONNECTION ....................................................... s-16
PREFACE .................................................................... p-1
Prior to Programming .................................................. s-35
PROCEDURE TO MOVE ARM WITHOUT DRIVE
POWER IN EMERGENCY OR ABNORMAL
SITUATIONS ......................................................... s-39
PROGRAM VERIFICATION .................................... s-36
PROGRAMMING ...................................................... s-35
PURPOSE OF ROBOT ................................................. s-3
<D>
Daily Checks .................................................................... 1
DAILY MAINTENANCE .......................................... s-40
DEFINITION OF WARNING AND CAUTION .......... s-2
DEFNITION OF THE USER........................................ s-4
Designation of the Restricted Space and Restriction of
User ......................................................................... s-34
DISMANTLING / SCRAPPING ................................ s-38
DRIVE MECHANISM .................................................. 26
During Programming................................................... s-35
<R>
RELEVANT STANDARDS ....................................... s-12
Removal of the fixture ................................................. 151
Replacing Cable K001,K002,K201,K301,K309
(connector panel to J2 base) ..................................... 114
Replacing Cable
K115,K121,K122,K123,K221,K303,K310 (J2 base
to J2 arm lower side) ................................................ 121
Replacing Cable
K131,K132,K13,K134,K231,K304,K311 (J2 arm
lower side to J3 casing) ............................................ 125
Replacing cable K133,K151,K153 (J3-axis, J5-axis
motor cable) ............................................................. 140
Replacing Cable K141,K142,K241,K306,K312 (J3
casing to J3 arm) ...................................................... 130
Replacing cable K152, K154, K251, K307, K313 (J3
arm part to J6 casing part) ........................................ 134
Replacing Cable K161,K261,K308,K314 (J6 casing to
wrist flange) ............................................................. 136
REPLACING CABLES ............................................... 109
REPLACING J1-AXIS MOTOR (M1) .......................... 29
REPLACING J1-AXIS REDUCER ............................... 31
REPLACING J1-AXIS SENSOR .................................. 39
REPLACING J2-AXIS MOTOR (M2) .......................... 44
REPLACING J2-AXIS REDUCER ............................... 46
REPLACING J2-AXIS SENSOR .................................. 50
REPLACING J3-AXIS MOTOR (M3) .......................... 54
<E>
EMERGENCY STOP ................................................. s-26
ENABLING DEVICE (DEADMAN SWITCH) ......... s-27
END EFFECTOR, WORKPIECE AND PERIPHERAL
EQUIPMENT .......................................................... s-19
Execute All-Axis Vision Mastering ............................. 148
<F>
FANUC COLLABORATIVE ROBOT SYSTEM ........ s-2
<G>
GENERAL .................................................................. s-13
GENERAL CAUTIONS ............................................. s-33
<I>
INSTALLATION ........................................................ s-33
<M>
MAINTENANCE..................................................... s-37,9
MAINTENANCE PARTS ........................................... 159
MASTERING .............................................................. 142
MECHANICAL UNIT ................................................ s-40
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INDEX
B-84195EN/02
REPLACING J3-AXIS REDUCER ............................... 56
REPLACING J3-AXIS SENSOR .................................. 61
REPLACING J4-AXIS MOTOR (M4) .......................... 66
REPLACING J4-AXIS REDUCER ............................... 69
REPLACING J4-AXIS SENSOR .................................. 78
REPLACING J5-AXIS MOTOR (M5) .......................... 84
REPLACING J5-AXIS REDUCER ............................... 89
REPLACING J5-AXIS SENSOR .................................. 92
REPLACING J6-AXIS MOTOR (M6) .......................... 97
REPLACING J6-AXIS REDUCER ............................... 99
REPLACING J6-AXIS SENSOR ................................ 103
REPLACING LED UNIT ............................................ 107
REPLACING PARTS .................................................... 25
REPLACING THE BATTERIES .................................... 9
REPLACING TOOL I/F BOARD ............................... 107
RESETTING ALARMS AND PREPARING FOR
MASTERING ........................................................... 143
Returning to Automatic Operation .............................. s-35
ROBOT SYSTEM DESIGN ....................................... s-13
Robot System Restart Procedures ............................... s-34
Robot Training .............................................................. s-5
<S>
SAFEGUARDS........................................................... s-28
Safety and Operational Verification ............................ s-34
SAFETY DEVICES .................................................... s-24
Safety Fence ................................................................ s-28
Safety Gate and Plugs ................................................. s-29
Safety of the Collaborative Worker............................... s-8
Safety of the Maintenance Engineer ........................... s-10
Safety of the Operator ................................................... s-8
Safety of the Programmer ............................................. s-9
Safety of the working person ........................................ s-6
SAFETY PRECAUTIONS ........................................... s-1
SAVING PROGRAMMED DATA ............................ s-36
SEALANT APPLICATION......................................... 108
Setting and Adjustment of Camera............................... 146
SINGLE AXIS MASTERING (FOR PARTS
REPLACING) .......................................................... 151
STOP TYPE OF ROBOT............................................ s-24
STORAGE ....................................................................... 6
STRENGTH OF BOLT AND BOLT TORQUE LIST 174
<T>
THE CHARACTERISTIC OF COLLABORATIVE
ROBOT AND LIMITATIONS AND USAGE
NOTES .................................................................... s-20
THE SAFETY SEQUENCE FOR FENCE ENTRY ... s-31
TROUBLESHOOTING ......................................... s-36,10
TROUBLESHOOTING DUE TO FUSE ....................... 17
TROUBLESHOOTING DUE TO MECHANICAL
UNIT .......................................................................... 10
<V>
VERFYING MASTERING.......................................... 155
<W>
WARNING & CAUTION LABEL ............................. s-39
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REVISION RECORD
B-84195EN/02
REVISION RECORD
Edition
02
01
Date
Aug., 2022 Addition of CRX-20iA/L
Apr., 2021
Contents
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B-84195EN/02
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