fanuc arc mate 100iB Maintenance Manual

FANUC Robot ARC Mate 100i MODEL B

FANUC Robot M-6i MODEL B

MAINTENANCE MANUAL

B--81545EN/01

B--81545EN/01

A

ARCMate100i

M

MODEL

B

PREFACE

PREFACE

This manual explains the maintenance and connection procedures for the
mechanical units (R--J3i controller) of the following robots. Before
replacing the purts, determine thespecification number ofthe mechanical
unit.:

Model name Abbreviation

FANUC Robot ARC Mate 100i
MODEL B
(WithJ2 and J3--axis brake)

FANUC Robot ARC Mate 100i
MODEL B
(Withall axes brake)

FANUC Robot M--6i MODEL B
(WithJ2 and J3--axis brake)

FANUC Robot M--6i MODEL B
(Withall axes brake)

RC Mate 100i

MODEL B

--6i

Mechanical unit

specification No.

A05B--1215--B201

A05B--1215--B601

A05B--1215--B202

A05B--1215--B602

PREFACE

LETTERS

SERIA

L

PRODUCTIO

N

B--81545EN/01

No. (1) (2) (3) (4) (5)

CONTENTS MODEL TYPE No. DATE

FANUC Robot ARC Mate 100i
MODEL B (2-- axis brake)

FANUC Robot ARC Mate 100i
MODEL B (6-- axis brake)

FANUC Robot M--6i MODEL B
(2--axis brake)

FANUC Robot M--6i MODEL B
(6--axis brake)

A05B--1215--B201 184 kg

A05B--1215--B601

A05B--1215--B201

PRINT

NO.

PRINT

PRODUCTION

YEAR AND

MONTH

A05B--1215--B601 138 kg

WEIGHT

(Withoutcontroller)

138 kg

184 kg

B--81545EN/01

g

p

PREFACE

Specification

Item R--2000i/165F

Type Articulated type
Controlledaxes 6 axes (J1, J2, J3, J4, J5, J6)
Installation Floor, Upside--dowm (Wall& Angle mount) (Note 1)
Motion range

(Maximumspeed)

Maximum speed

Max. load capacity at wrist 6kg
Max. load capacity on J3 catting 12kg
Allowableloadmomentatwrist

Allowable load inertiaat wrist

Drive method Electricservo driveby AC servo motor
Repeatability 0.06mm
Weightof mechanicalunit 134kg (2--axis brake type)

Installation environment Ambient temperature : 0 -- 45°C

J1 axis rotation 340° (5.93rad)
J2 axis rotation 250° (4.36rad)
J3 axis rotation 315° (5.60rad)
J4 axis wrist rotation 380° (6.63rad)
J5 axis wrist swing 280° (4.89rad)
J6 axis wrist rotation 720° (12.57rad)
J1 axis 150°/s (2.62rad/s)
J2 axis 160°/s (2.79rad/s)
J3 axis 170°/s (2.97rad/s)
J4 axis 400°/s (6.98rad/s)
J5 axis 400°/s (6.98rad/s)
J6 axis 500°/s (8.73rad/s)

J4 axis 15.7N·m (1.8kgf·m)
J5 axis 9.8N·m (1.0kgf·m)
J6 axis 5.9N·m (0.5kgf·m)
J4 axis 0.63kg·m2(6.4kgf·cm·s2)
J5 axis 0.22kg·m2(2.2kgf·cm·s2)
J6 axis 0.061kg·m2(0.62kgf·cm·s2)

138kg (6--axis brake type)

Ambient humidity : Normally :75%RH or less

: Short time 95%RH or less

(within 1 month)
(No dew or frostallowed)

Vibration : 0.5G (4.9m/s

2

)orless

NOTE

1 Under the installation condition within ( ), the J1 and J2 axis motion range will be limited.

PREFACE

B--81545EN/01

Dust--proof/waterproof performance of M--6i B

Normal specification

Wrist+J3 arm IP67
Other part IP54

NOTE

Definition of IP code

Definition of IP 67

6=Dust--tight
7=Protection from water immersion

Definition of IP 54

5=Dust--protected
4=Protection from splashing water

Performance of resistant chemicals and resistant solvents
(1)(1)The robot (including severe dust/liquid protection model) cannot

be used with the following liquids because there is feat that rubber
parts (packing, oil seal, O ring etc.) will corrode.

(a) Organic solvcnts
(b) Coolant including chlorine / gasoline
(c) Acid, alkali and liquid causing rust
(d) Other liquids or solutions, that will harm NBR

(2) When the robots work in the environment, using water or liquid,

complete draining of J1 base must be done. Incomplete draining of
J1 base will make the robot break down.

B--81545EN/01

PREFACE

RELATED MANUALS

Safety handbook B--80687EN
All persons who use the FANUC Robot and system de-

signer must read and understand thoroughly this handbook
R--J3i MODEL B controller Setup and Operations

manual
SPOT TOOL

B--81464EN--1

HANDLING TOOL

B--81464EN--2

ARC TOOL

B--81464EN--3

SEALING TOOL

B--81464EN--4

Maintenance manual

B--81465EN
B--81465EN--1

(European

specification)

Mechanical unit Maintenance manual

FANUC Robot ARC Mate
100i B
M--6i B
B--81545EN

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

Intended readers :
All persons who use FANUC Robot, systemdesigner
Topics :
Safety items for robot system design, operation, maintenance

Intended readers :
Operator, programmer, maintenance person, system designer
Topics :
Robot functions, operations, programming, setup, interfaces, alarms
Use :
Robot operation, teaching, system design

Intended readers :
Maintenance person, systemdesigner
Topics :
Installation, connection to peripheral equipment, maintenance
Use :
Installation, start--up, connection, maintenance

Intended readers :
Maintenance person, systemdesigner
Topics :
Installation, connection to the controller, maintenance
Use :
installation, start--up, connection, maintenance

B--81545EN/01

Table of Contents

I. MAINTENANCE

1. CONFIGURATION 3............................................................

1.1 J1--AXIS DRIVE MECHANISM 4......................................................

1.2 J2--AXIS DRIVE MECHANISM 5......................................................

1.3 J3--AXIS DRIVE MECHANISM 6......................................................

1.4 J4--AXIS DRIVE MECHANISM 7......................................................

1.5 J5-- AND J6--AXIS DRIVE MECHANISMS 8............................................

1.6 SPECIFICA TIONS OF THE MAJOR MECHANICAL UNIT COMPONENTS 9.................

2. PREVENTIVE MAINTENANCE 11................................................

2.1 DAILY INSPECTION 12.............................................................

2.2 QUARTERLY INSPECTION 14.......................................................

2.3 YEARLY INSPECTION 15...........................................................

2.4 ONE-- AND HALF--YEAR PERIODIC INSPECTION 16...................................

2.5 THREE--YEAR PERIODIC INSPECTION 17............................................

2.6 MAINTENANCE TOOLS 18..........................................................

3. PERIODIC MAINTENANCE 19..................................................

3.1 GREASING 20.....................................................................

3.2 GREASE REPLACEMENT 22........................................................

3.3 BATTERY REPLACEMENT 25.......................................................

4. TROUBLESHOOTING 26......................................................

4.1 OVERVIEW 27.....................................................................

4.2 TROUBLES AND CAUSES 28........................................................

4.3 COMPONENT REPLACEMENT AND ADJUSTMENT ITEMS 31...........................

5. ADJUSTMENTS 32............................................................

5.1 REFERENCE POSITION AND MOVING RANGE 33.....................................

5.2 SIMPLIFIED MASTERING 37........................................................

5.3 MASTERING BY ZERO POSITION MARK ALIGNMENT 39..............................

5.4 JIG--BASED MASTERING 41.........................................................

5.5 CONFIRMING MASTERING 47.......................................................

5.6 J5--AXIS GEAR BACKLASH ADJUSTMENTS 48........................................

5.7 BRAKE RELEASE 50...............................................................

6. COMPONENT REPLACEMENT AND ADJUSTMENTS 52..........................

6.1 REPLACING THE J1--AXIS MOTOR

6.2 REPLACING THE J1--AXIS REDUCER 55..............................................

6.3 REPLACING THE J2--AXIS MOTOR

6.4 REPLACING THE J2--AXIS REDUCER 59..............................................

6.5 REPLACING THE J3--AXIS MOTOR

6.6 REPLACING THE J3--AXIS REDUCER 64..............................................

M1

M2

M3

53...........................................

57...........................................

62...........................................

TABLE OF CONTENTS

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6.7 REPLACING THE J4--AXIS MOTOR

6.8 REPLACING THE J4--AXIS GEARBOX 67..............................................

6.9 REPLACING THE J5--AXIS MOTOR

6.10 REPLACING THE J5--AXIS GEAR 71..................................................

6.11 REPLACING THE J6--AXIS MOTOR

M4

M5

M6

AND REDUCER 73............................

7. PIPING AND WIRING 77.......................................................

7.1 PIPING DRAWING 78...............................................................

7.2 WIRING DIAGRAMS 79.............................................................

7.3 CABLE MOUNTING DIAGRAM 81...................................................

8. CABLE REPLACEMENT 82....................................................

8.1 CABLE DRESSING 83..............................................................

8.2 REPLACING CABLES 85............................................................

9. COVER OPTION REPLACEMENT 90............................................

9.1 REPLACING THE J2 COVER OPTION (A05B--1210--J401) 91..............................

9.2 REPLACING THE J4 COVER OPTION (A05B--1210--J402) 92..............................

66...........................................

69...........................................

10. M--6i PACKAGES WITH REINFORCED DUST--PROOF AND

DRIP--PROOF CHARACTERISTICS 93.........................................

10.1 DUST--PROOF AND DRIP--PROOF PERFORMANCE OF THE PACKAGES WITH

REINFORCED DUST--PROOF AND DRIP--PROOF CHARACTERISTICS 94..................

10.2 CONFIGURATION OF THE PACKAGES WITH REINFORCED DUST--PROOF AND

DRIP--PROOF CHARACTERISTICS 95.................................................

10.3 CAUTIONS IN SELECTING THE PACKAGES WITH REINFORCED DUST--PROOF

AND DRIP--PROOF CHARACTERISTICS 97............................................

10.4 REPLACING THE COMPONENTS OF THE PACKAGES WITH REINFORCED DUST--PROOF

AND DRIP--PROOF CHARACTERISTICS 98............................................

II. CONNECTION

1. ROBOT OUTLINE DRAWING AND OPERATION AREA DIAGRAM 103.............

1.1 OUTLINE DRAWING AND OPERATION AREA DIAGRAM 104...........................

2. MOUNTING DEVICES ON THE ROBOT 107......................................

2.1 WRIST SECTION END EFFECTOR MOUNTING SURFACE 108...........................

2.2 DEVICE MOUNTING SURFACES 109.................................................

2.3 SETTING THE SYSTEMVARIABLES FOR SHORTEST--TIME CONTROL 111...............

2.4 WRIST LOAD CONDITIONS 114.....................................................

2.5 END EFFECTOR AIR PIPING 115.....................................................

2.6 END EFFECTOR INPUT SIGNALS (RDI/RDO) 116......................................

2.7 CONNECTOR SPECIFICATIONS 117..................................................

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TABLE OF CONTENTS

3. TRANSPORTATION AND INSTALLATION 118....................................

3.1 TRANSPORTATION 119.............................................................

3.2 STORING THE ROBOT 121..........................................................

3.3 INSTALLATION 122................................................................

3.4 MAINTENANCE CLEARANCE 125...................................................

3.5 ASSEMBLING THE ROBOT FOR INSTALLATION 127...................................

3.6 AIR PIPING 128....................................................................

3.7 INSTALLATION CONDITIONS 130...................................................

APPENDIX

A. SPARE PARTS LISTS 133.....................................................

B. INTRA--MECHANICAL UNIT CONNECTION DIAGRAMS 139......................

C. PERIODIC INSPECTION TABLE 144............................................

D. BOLT MOUNTING TORQUE LIST 145...........................................

I. MAINTENANCE

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1

1. CONFIGURATIONMAINTENANCE

CONFIGURATION

Fig. 1 shows the configuration of the mechanical unit.

AC servo motor forJ4--axis (M4)

AC servo motor forJ3--axis (M3)

AC servo motor forJ1--axis (M1)

J3--axis arm

AC servo motor forJ5--axis (M5)

AC servo motor forJ6--axis (M6)

Wristunit

J3--axis casing

J2--axis arm

AC servo motor forJ2--axis (M2)

J2--axis base

J1--axis base

Fig 1 Mechanical unit configuration

1. CONFIGURATION

MAINTENANCE

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1.1

J1--AXIS DRIVE
MECHANISM

Fig. 1.1 shows the J1--axis drive mechanism.
TheJ1--axis drivemechanismisconfiguredinsuch a waythattheJ2--axis
base is rotated by reducing the rotation speed of an AC servo motor with
a reducer.
The J2--axis base is supported on the J1--axis base through the reducer.

J1--axis AC servo motor

J2--axis base

J1--axis reducer

J1--axis base

Fig 1.1 J1--axis drive mechanism

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1. CONFIGURATIONMAINTENANCE

1.2

J2--AXIS DRIVE
MECHANISM

Fig. 1.2 shows the J2--axis drive mechanism. The J2--axis drive
mechanismis configuredin such a waythat the J2--axis armis rotatedby
reducing the rotation speed of an AC servo motor with a reducer.
The J2--axis arm is supported on the J2--axis base through the reducer.

J2--axis AC servo motor

J2--axis base

J2--axis arm

J2--axis reducer

Fig 1.2 J2--axis drive mechanism

1. CONFIGURATION

MAINTENANCE

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1.3

J3--AXIS DRIVE
MECHANISM

Fig. 1.3 shows the J3--axis drive mechanism. The J3--axis drive
mechanism is configured in such a way that the J3--axis casing is rotated
by reducing the rotation speed of an AC servo motor with a reducer.
The J3--axis casing is supported on the J2--axis arm through the reducer.

J3--axis reducer

J3--axis AC servo motor

J3--axis casing

J2--axis arm

Fig 1.3 J3--axis drive mechanism

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1. CONFIGURATIONMAINTENANCE

1.4

J4--AXIS DRIVE
MECHANISM

Fig. 1.4 shows the J4--axis drive mechanism. The J4--axis drive
mechanismis configuredin such a waythat the J3--axis armis rotatedby
reducing the rotation speedof an AC servo motor with a two--stage gear.

J3--axis arm

Final gear

Second gear

J3--axis casing

Input gear

J4--axis AC servo motor

Fig 1.4 J4--axis drive mechanism

1. CONFIGURATION

MAINTENANCE

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1.5

J5-- AND J6--AXIS
DRIVE MECHANISMS

Fig. 1.5 shows the J5-- and J6--axis drivemechanisms. TheJ5--axis drive
mechanism is configured in such a waythat the J6--axis unit is rotated by
reducingthe rotation speedofan AC servomotor witha three--stage gear.
The J6--axis drivemechanism is configured in such a way that theoutput
flangeisrotatedby reducingtherotationspeedofanACservo motorwith
a reducer.

J5--axis AC servo motor J6--axis unit J6--axis AC servo motor

Output flange

Input gear

Second gear

Final gear

Third gear

Fig 1.5 J5-- and J6--axis drive mechanisms

J6--axis reducer

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1. CONFIGURATIONMAINTENANCE

1.6

SPECIFICATIONS OF
THE MAJOR
MECHANICAL UNIT
COMPONENTS

1) Motors

ARC Mate 100i MODEL B

(two--axis, equipped with a brake): A05B--1215--B201

M--6i MODEL B

(two--axis, equipped with a brake): A05B--1215--B202

Specification Axis Remark

A06B-0223-B005 J1 α 4/4000i
A06B-0223-B605 J2 α 4/4000i Equipped witha brake
A06B-0202-B605 J3 α 1/5000i Equipped witha brake
A06B-0202-B005 J4 α 1/5000i
A06B-0115-B075#0008 J5 β M0.5/4000
A06B-0114-B075#0008 J6 β M0.4/4000

ARC Mate 100i MODEL B

(six--axis, equipped with a brake): A05B--1215--B601

M--6i MODEL B

(six--axis, equipped with a brake): A05B--1215--B602

Specification Axis Remark

A06B-0223-B605 J1 α 4/4000i Equipped witha brake
A06B-0223-B605 J2 α 4/4000i Equipped witha brake
A06B-0202-B605 J3 α 1/5000i Equipped witha brake
A06B-0202-B605 J4 α 1/5000i Equipped witha brake
A06B-0115-B275#0008 J5 β M0.5/4000

Equipped with a brake

A06B-0114-B275#0008 J6 β M0.4/4000

Equipped with a brake

2) Reducers

Specification Axis

A97L-0218-0288#33 J1
A97L-0218-0289#153 J2
A97L-0218-0295#161 J3
A97L-0218-0224 J6

3) J4--axis gearbox

Specification Axis

A05B-1215-K401 J4

1. CONFIGURATION

MAINTENANCE

4) Gears

Specification Axis

A290-7215-X511 J5
A290-7215-V501 J5
A290-7215-V502 J5
A290-7215-X514 J5

5) Stoppers

Specification Axis

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A290-7215-X241 J1
A290-7215-X323 J2
A290-7215-X324 J3

Note) 330° stopper

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2

2. PREVENTIVE MAINTENANCEMAINTENANCE

PREVENTIVE MAINTENANCE

Performing daily inspection, periodic inspection, and maintenance can
keep the performance of robots in a stable state for a long period.

2. PREVENTIVE MAINTENANCE

MAINTENANCE

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2.1

DAILY INSPECTION

Clean and maintain each component of robots during everyday system
operations. At the same time, check the components to see if there is a
crack or break in them. Also check and maintain the following items as
required.

a) Before automatic operation

No. Inspection item Inspection procedure

1 Pneumatic pressure

check

2

For
machines
with a
three--piece
pneumatic
option

Check on the amount of
oil mist

Make a pneumatic pressure
check, using the three--piece
pneumatic option shown in Fig.

2.1.
Ifthemeasuredpneumaticpres­sure does not fall in the range
between0.5and 0.7MPa(5and
7kg/cm
usingtheregulatorpressureset­ting handle.

Putthepneumaticpressuresys­tem in operation and check the
amount of oil dripping. If the
measuredamountof oildripping
does not meet the rating (one
drop/10 to 20 seconds), make
adjustments, using the oil ad­justment knob. The oiler be­comes empty after10to 20 days
of normal operation.

2

), make adjustments,

3 Check on the amount of

oil

4 Check for leakage from

the piping

5 Whethercables are abnormal

Mechanical unit

6 Battery voltagecheck Make sure that when thepower

7 Whether there is any abnormal vibra-

tion,noise,or heatgenerationin motors

8 Whetherthereisa change topositioning

precision

Check to see iftheamount of oil
inthethree-- piece option is with­in the rated level shown in Fig.

2.1.
Check to see if a joint or hose

leaks.
Ifyou finda problem, tighten the
joint or replace any defective
component.

See Chapter8.

isturnedon,theBLAL alarmhas
not been raised. If the BLAL
alarm has been raised, replace
the battery as directed in Sec­tion 3.3.

Check thateach axis is running
smoothly.

Check to see if thereis any dis­placement from the previous
positionand there are variations
in the stop position.

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2. PREVENTIVE MAINTENANCEMAINTENANCE

No. Inspection procedureInspection item

9 Reliable operation of peripheral equip-

ment

10 Check on the operation of the J2-- and

J3--axis brakes.

Oiler’s oil inlet

Filter

Regulator pressure setting handle

Fig 2.1 Three--piece pneumatic option

Pressure gauge

Check to see if the machine op­erates exactly according to
directionsfromtherobotandpe­ripheralequipment.

See Section4.2.

Oileradjustmentknob

Check oiler’s oil level

Oiler

b) After automatic operation

Once you are finishedwith automatic operation, bring therobot to its
reference position, and turn it off.

No. Inspection item Inspection procedure

1 Componentcleaning

and inspection

Clean and maintain each component. At the
same time, check the components to see if
there is a crack or break in them.

2. PREVENTIVE MAINTENANCE

MAINTENANCE

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2.2

QUARTERLY
INSPECTION

Inspectthe following items at regularintervalsof threemonths. Increase
the locations and the frequency of i nspection if the conditions under
which the robot is used and the environment in which it runs require so.

No. Inspection item Inspection procedure

1 Loose connector Check that themotor connectors or other con-

nectors are not loose.

2 Loose bolt Check thatthecoverretainingboltsorexternal

bolts are not loose.

3 Debris removal Remove any spatter, debris,anddust from the

mechanical unit.

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2. PREVENTIVE MAINTENANCEMAINTENANCE

2.3

YEARLY INSPECTION

Inspect the following item at regular intervals of one year.

No. Inspection item Inspection procedure

1 Greasing See Section 3.1.

2. PREVENTIVE MAINTENANCE

MAINTENANCE

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2.4

ONE-- AND
HALF--YEAR
PERIODIC
INSPECTION

Performthe followinginspection/maintenanceitem at regularintervalsof
one year and half.

No. Inspection item Inspection procedure

1 Battery replacement Replace the battery in the mechanical unit.

(See Section 3.3.)

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2.5

2. PREVENTIVE MAINTENANCEMAINTENANCE

THREE--YEAR
PERIODIC
INSPECTION

No.

1 Greasereplacement See Section3.2.

Inspection item Inspection procedure

2. PREVENTIVE MAINTENANCE

MAINTENANCE

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2.6

MAINTENANCE
TOOLS

You should have the following instruments and tools ready for
maintenance.

a) Measuring instruments

Instrument Condition Use

Dial gauge 1/100mm Forpositioningprecision and backlash

measurement

Calipers 150mm

b) Tools

Phillips screwdrivers (large, medium, and small sizes)
Flat--blade screwdrivers (large, medium, and small sizes)
Box wrenches (M3 to M6)
Allen wrenches (M3 to M16)
Torque wrench
Long T wrenches (M5 and M6)
Adjustable wrenches (medium and small sizes)
Pliers
Long--nose pliers
Cutting pliers
Both--ended wrench
Grease gun
C--ring pliers
Flashlight

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3

3. PERIODIC MAINTENANCEMAINTENANCE

PERIODIC MAINTENANCE

3. PERIODIC MAINTENANCE

MAINTENANCE

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3.1

GREASING

When greasing the robot, keep its power turned off.
i) Roughly speaking, replenish the robot with grease once a year.
ii) See Fig. 3.1 and Table 3.1 for greasing points and the method.

Table. 3.1 Greasing points

Greasing

No.

1 J6--axis

point

reducer

Specified

grease

Mori White
RE No.00
(Specification:
A97L-0040-0119)

Amount

of

grease

40cc J6--axis grease inlet and out-

Greasing method

let, and attach the supplied
greasenipple to the greasein­let. Aftergreasing, remove the
grease nipple, and attach the
flat--head bolts and sealing
washers to the grease inlet
and outlet.

CAUTION

If you grease incorrectly, the pressure in the grease bath
may increase steeply, leading to a broken seal, which will
eventually cause grease leakage or malfunction.
When greasing, be sure to follow the cautions stated in
Section 3.2.

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Grease nipple at the
grease inlet for the
J3-axis reducer

Seal bolt at the
grease outlet for the
J1-axis reducer

Low head bolt and seal
washer at the grease outlet
for the J5-axis reducer

Grease nipple at the
grease inlet for the
J4-axis reducer

Low head bolt and
seal washer at the grease
outlet for the J6-axis reducer

Low head bolt and seal washer at the
grease inlet for the J5-axis reducer

Grease nipple at the grease inlet
for the J2-axis reducer

3. PERIODIC MAINTENANCEMAINTENANCE

Low head bolt and seal
washer at the grease outlet
for the J6-axis reducer

Low head bolt and seal
washer at the grease out­let for the J4-axis reducer

Grease nipple at the
grease outlet for the
J1-axis reducer

Seal bolt at the
grease outlet for the
J3-axis reducer

Seal bolt at the
grease outlet for the
J2-axis reducer (2 locations)

Fig 3.1 Greasing points

3. PERIODIC MAINTENANCE

greasetob

e

turewhe

n

(

S

ificat

i

MAINTENANCE

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3.2

GREASE
REPLACEMENT

Follow the procedure stated below to replace the grease in the J1--, J2--,
and J 3--axis reducersand theJ4-- and J5--axis gearboxesonce every three
yearsor after11,520hours of operation. See Fig. 3.1for greasingpoints.

1) Remove the seal bolts from the J1--, J2--, and J3--axis grease outlets
shown in Fig. 3.1. Also remove the flat--bolts and sealing washers
from the J4-- and J5--axis grease outlets.

2) Uncap thegreasenipplesat theJ1--, J2--, J3--, andJ4--axis greaseinlets.
Remove the flat--head bolt fromthe J5--axis grease inlet and attach the
supplied grease nipple to the J5--axis grease inlet.

3) Supply the grease specified in Table 3.2 to the J1--, J2--, and J3--axis
reducers, and J4-- and J5--axis gearboxes through their respective
greasenipples. Keepgreasing untilthe newgrease pushesout theold
grease and comes out from each grease outlet. Ensurethat the amount
of the newly supplied grease equals the amount of the drained grease
so that the grease bath will not become full.

4) Wind sealing t ape around the J1--, J2--, and J3--axis seal bolts you
removed, and attach them to the respective grease outlets.

5) Attach the J4-- and J5--axis flat--head bolts and t he J4-- and J5--axis
sealing washers to the respective grease i nlets and outlets.

Table. 3.2 Grease to be replaced at regular intervals of three years

Specified grease Amount of

Robot pos-

Kyodo Yushi

J1--axis reducer
J2--axis reducer
J3--axis reducer About300 -­J4--axis gearbox About 700 -­J5--axis gearbox About 400 J4=+90°

Mori White RE No.00

pec

A98L-0040-0119#2.4KG)

on:

applied (cc)

About 1100 --

About 570 --

greased

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3. PERIODIC MAINTENANCEMAINTENANCE

CAUTION

If you grease incorrectly, the pressurein the grease bath may
increasesteeply,leadingtoabrokenseal,whichwilleventually
cause grease leakage or malfunction.
When greasing, be sure to follow the cautions stated below.
1 Before starting greasing, open the grease outlets (remove

bolts and the like from the grease outlets).
2 Using a manual greasing pump, grease gently and slowly.
3 Avoid using a pneumatic pump driven from a factory

pneumatic line as much as possible.

Ifyou cannotavoid usingit, observea greasingspeedof 15

2

cc/s or lower and a pressure of 75 kgf/cm

or lower.

4 Be sureto use thespecifiedgrease. Otherwise,damage to

reducers or a similar abnormality may occur.
5 Beforecapping thegreaseoutlets, makesure thata grease

flow from the grease outlet has stopped (the remaining

pressure has been released).
6 Wipe offany greasefromthe floor androbot completely, so

no one will slip on it.

3. PERIODIC MAINTENANCE

MAINTENANCE

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Whenreplacing or supplying grease, keepthe robot in the postureshown
in Fig. 3.2.

Fig 3.2 Robot posture forgreasing

Axis Posture

Free

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3. PERIODIC MAINTENANCEMAINTENANCE

3.3

BA TTER Y
REPLACEMENT

A backup batteryis used to keep thereference--position data for eachaxis
of the robot.
The battery needs to be replaced at regular intervals of one year and half.
Follow this procedure for battery replacement.

1) Keep the power turned on.
Press the EMERGENCY STOP button of the robot to keep it from
moving.

2) Uncap the battery case.

3) Take out the battery from the battery case.

4) Insert a new batteryinto the batterycasewhile payingattention to the
polarity of the battery.

5) Cap the battery case.

Batterycase

Cap

Battery specifications : A98L--0031-- 0005

(1.5V size--D 4pcs)

Fig 3.3 Battery replacement

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4

4. TROUBLESHOOTINGMAINTENANCE

TROUBLESHOOTING

4. TROUBLESHOOTING

MAINTENANCE

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4.1

OVERVIEW

A trouble with a mechanical unit may occur due to a combination of
multiple causes. It is difficult to find out the true cause,and an incorrect
measure may make the trouble worse. When troubleshooting, it is
important to get hold of the situation of any error accurately and take a
correct measure.

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4. TROUBLESHOOTINGMAINTENANCE

4.2

TROUBLES AND
CAUSES

Symptom

BZAL alarmissued
(battery zero)

Incorrectpositioning

Table 4.2 (a) lists the major troubles in the mechanical unit and their
causes. Ifyoucannot find a causeaccuratelyordonotknowwhatmeasure
to take, please contact FANUC.
Note, however, that the backlash and drop levels listed, respectively, in
Table 4.2 (b) and Table 4.2 (c) and lower are not abnormal.

Table 4.2 (a) Major troubles and causes (1/3)

Cause Measure Remark

The voltage of the memory
backup battery has dropped.

Broken pulse coder signal
cable

Something hit the robot. Correctthe taught point.
The robotis not firmly fixed. Fix it. See Section 3.2 of Part II,

Peripheral equipment has
shifted.

Load too heavy Reducethe load.

Replace the battery,and per­form simplified mastering.

Replace the cable, and per­form simplified mastering.

Fix it.

Limitthe operatingcondition.

See Section3.3.
See Section5.3.

See Section8.2.
See Section5.3.

“Connection”.

Load on the wrist:

Refer to “Descriptions”.

Peripheralequipment:

See Section 2.2of Part II,

“Connection”.
Incorrectparametersetting Correct it. Referto“Operator’sManual”.
Broken cable Replace the cable. See Section8.2.
Pulse c oder error Replace the motor. See Sections6.1 to 6.11.
Backlash in the mechanical

unit ---- see the next section.

4. TROUBLESHOOTING

MAINTENANCE

Table 4.2 (a) Major troubles and causes (2/3)

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Vibration

Symptom

Cause Measure Remark

The robotis not firmly fixed. Fix it. See Section 3.2 of Part II,

“Connection”.

The floor is vibrating (espe­cially when the robot is
installed on the second floor
or above).

Load too heavy Reducethe load.

Servo maladjustment Adjust the servo section. Contact FANUC.
Broken cable Replace the cable. See Section8.2.
Robot not grounded Ground the robot. Referto“MaintenanceManu-

Defective motor Replace the motor. See Sections 6.1 to 6.11.
Defective axis printed--circuit

board
Defective reducer Replacethe reducer. See Sections6.2 to 6.11.

Re--examine the location of
installation.

Limitthe operatingcondition

Replace the axis printed--cir­cuit board.

Load on the wrist:

Refer to “Descriptions”.

Peripheralequipment:

See Section 2.2of Part II,

“Connection”.

al for the Controller”.

Referto “MaintenanceManu­al for the Controller”.

Backlash or wobbling

Abnormal sound

Invalid time constant setting Change the time constant. Referto“Operator’sManual”.
Backlash in the mechanical

unit ---- see the next section.
Loose screw or pin Tighten it (and apply Loctite

to it if specified so)
Defective reducer Replacethe reducer. See Sections6.2 to 6.11.
Gear maladjustment Adjustthe gear. See Section5.7.
Worn gear Adjustor replace the gear. Contact FANUC.
Worn bearing Replacethe bearing. Contact FANUC.
Broken casting or otherpart Replace the broken compo-

nent.
Insufficientgreaseforgear or

reducer
Foreign matter in gear or re-

ducer
Gear maladjustment Adjustthe gear. Contact FANUC.
Worn gear Adjustor replace the gear. Contact FANUC.

Apply grease. See Sections3.1 and 3.2.

Washthegearor reducerand

apply grease.

Contact FANUC.

See Sections 6.2 to 6.11,3.1,
and 3.2.

Worn bearing Replacethe bearing. Contact FANUC.
Servosectionmaladjustment Adjust the servo section. Contact FANUC.

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4. TROUBLESHOOTINGMAINTENANCE

Table 4.2 (a) Major troubles and causes (3/3)

Symptom

Abnormal heat generation

Arm drop at power turn--off

Grease leakage

Cause Measure Remark

Insufficientgreaseforgear or
reducer

Non--specified grease used Replace the grease. See Sections3.1 and 3.2.
Load too heavy Reduce the load.

Gear maladjustment Adjustthe gear. Contact FANUC.
Invalid time constant setting Change the time constant

Too large a brake gap Replace the motor. See Sections 6.1 to 6.11.
Brake drive relay contactde-

position
Deteriorated or broken

O--ring, oil seal, or gasket
Broken casting or otherpart Replace the broken compo-

Apply grease. See Sections3.1 and 3.2.

Load on the wrist:

Limitthe operatingcondition.

setting.

Replace the relay Referto“MaintenanceManu-

Replace the O--ring, oil seal,

or gasket.

nent.

Refer to “Descriptions”.

Peripheralequipment:

See Section 2.2of Part II,
“Connection.”

Referto“Operator’sManual”.

al for the Controller”.
Contact FANUC.

Contact FANUC.

Loose screw Tightenit.

Table 4.2 (b) Allowable backlash level for each axis

J1 J2 J3 J4 J5 J6

Backlashintermof
angle (min)

Backlashintermof
displacement(mm)

2.5 2.5 2.5 3.0 4.5 3.0

0.95

(1300)

NOTE

The backlash in term of displacement (mm) is measured in
the direction of rotation at a distance represented with a
value enclosed in parentheses.

Table 4.2 (C) Allowable arm drop

At power turn--off time
At emergency stop time 5mm

0.44

(600)

5mm

0.44

(600)

0.17

(200)

0.2

(200)

0.17

(200)

4. TROUBLESHOOTING

MAINTENANCE

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4.3

COMPONENT
REPLACEMENT AND
ADJUSTMENT ITEMS

Adjustments are needed after a component is replaced.
The following table lists componentsand the adjustment items that must
be made after their replacement. After replacing a component, make
necessary adjustments according to this table.

Component replacement or

function change

Cable replacement (a) Cable dressing

(b) Simplified mastering

Change to J1--axis stroke (a) Change to stopper position

(b) Change to parameter

Battery replacement
(The battery should be replaced once
a year.)

Replace the battery with the power
kept on.
No adjustmentis needed.

Adjustment item

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5

5. ADJUSTMENTSMAINTENANCE

ADJUSTMENTS

Each part of the mechanical units of a robot is set to the best condition
beforethe robot is shipped to the customer. The customerdoes not need
to make adjustments on the robot when it is delivered.
If a mechanical unit of the robot has a large backlash because of a
long--term use or component replacement, make adjustments according
to this section.

5. ADJUSTMENTS

MAINTENANCE

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5.1

REFERENCE
POSITION AND
MOVING RANGE

1) Reference position and operation limit
Each controlled axis is provided with a reference position and

operation limit.
A state in which a controlled axis has reached its operation limit is
known as overtravel (OT). For each axis, an overtravel condition can
be detected at the both ends of it. As long as the robot does not
encountera servo section error or system errorthat causes a reference
position to be lost, the robot is controlled insuch a way that it will not
go out of its operation area.
Fig. 5.1 (a) to Fig. 5.1 (g) show the reference position and operation
area (stroke) of each axis and their mechanical stopper positions.
Fig. 5.1 (h) shows the operation directions (+/-- directions) of each
axis.

Stroke

Mechanical stopper Mechanical stopper

Fig 5.1 (a) J1--axis swiveling (typically 340°)

Note)Motion limit is restricted by the

position of the J3--axis

Mechanical
stopper

Stroke end

Fig 5.1 (b) J2--axis rotation

Stroke endStroke end

Stroke

Stroke end

Mechanical stopper

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Note)Motion limit is restricted by the

position of the J2--axis

Stroke end

Mechanical
stopper

Mechanical
stopper

Stroke end

Fig 5.1 (c) J3--axis rotation

5. ADJUSTMENTSMAINTENANCE

Stroke

Stroke endStroke end

Note) The mechanical s topper are not provided forJ4--axis

Fig 5.1 (d) J4--axis rotation

Stroke end

Mechanical stopper

Mechanical stopper

Stroke end

Fig 5.1 (e) J5--axis wrist rotation

Stroke

5. ADJUSTMENTS

MAINTENANCE

Fig 5.1 (f) J6--axis wristrotation

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Stroke endStroke end

Stroke

Mechanical stopper

Stroke end

J3--axis arm

Interference
angle 170°

J2--axis arm

Fig 5.1 (g) J2/J3 limit interference angle

Interference angle 10°

Stroke end

Mechanical stopper

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5. ADJUSTMENTSMAINTENANCE

Fig 5.1 (h) Operation directions of each axis

5. ADJUSTMENTS

MAINTENANCE

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5.2

SIMPLIFIED
MASTERING

The term simplified mastering refers to a procedure for resuming the
previous position completely after a pulse coder battery backup is
disconnected because of cable replacement.
Simplifiedmasteringcannotbe usedifthe pulse coderphasehas changed
mechanically because of a motor or reducer having been replaced. To
calibrate the robot position accurately, perform the jig--based mastering
describedinSection5.4.

1) Procedure
Described below is the simplified mastering to be performed with a

posture of zero degrees for all axes after cable replacement.
1 Before replacing the cable, be sure to take note of the system

variable $DMR_GROUP.$MASTER_COUN[1] to [6] (previous
mastering data).

2 Replace the cable according to the cable replacement procedure

describedinSection8.2.

3 If you want to release brake control, set the system variable

$PARAM_GROUP.$SV_OFF_ENB to FALSE for all axes, turn
off the power, and then perform a cold start.

4 After the power is turned on, the alarm message BZAL alarm is

displayed. Select “TRUE” for the system variable
$MCR.SPC_RESET, turn off the power, and then perform a cold
start.

5 After the power is turned on again, the message Pulse not

established is displayed. Rotate each axis through 20° or so in
either (+ or --) direction, using an individual--axis feed command,
and then press the alarm reset key to reset this message.

6 By performing an individual--axis feed command foreach axis, set

the zero--degree mark within +/--1 mm from the scribed line. (See
Fig. 5.2.) If no reference position has been set up at zero degrees
for all axes, using simplified mastering, go to 7. Otherwise, go to

8.

7 Assign the mastering data in $DMR_GROUP.$MASTER_

COUN[1] to [6] that was taken note of at 1 to the system variable
$DMR_GROUP.$REF_CONUT[1] to [6] (simplified mastering
data). Loadthesystemvariable$DMR_GROUP. $REF_POS[1]to
[6] (simplified mastering reference positions) with “0”. Select
“TRUE” for the $DMR_GROUP.$REF_DONE (simplified
mastering completion flag). Now the simplified mastering
reference position has been set up at zero degrees for all axes.

8 Press the screen selection key to select “0” NEXT, and select

SYSTEM from the menu.

9 Press the F1 key TYPE, select the system variable, and set

$MASTER_ENB value inthelist to1. Press theF1 key TYPEand
select MASTER / CAL.

10 Select The system calibration menu from the system positioning

menu, andpress theFAkey YES to performsimplified mastering.
Now the mastering data obtained from the pulse coder counter
valueisset inthesystem variable$DMR_GRP .MASTER_COUN,
and the system variable $DMR_GRP.MASTER_DONE
(mastering completion flag) is set to “TRUE”.

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5. ADJUSTMENTSMAINTENANCE

11 Select CALIBRATE from the system positioning menu, and press

the F4 key YES Now positioning is carried out, and teaching and
replaying are enabled.

12 After you are finished with mastering, reset the system variable

$MASTER_ENB to 0.

13 If you released brake control before, re--set the system variable

$P ARAM_GROUP.$SV_OFF_ENB for each axis to the previous
value, turn off the power, and then perform a cold start.

Oncemasteringis completed,updatethedatasheetsupplied togetherwith
the robot with the new mastering data ($DMR_GROUP.$MASTER_
COUN[1] to [6]).

J3--axis

J4--axis

J2--axis

J5--axis

J6--axis

J1--axis

Fig 5.2 Marking of the zero--degree position for each axis

5. ADJUSTMENTS

MAINTENANCE

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5.3

MASTERING BY
ZERO POSITION
MARK ALIGNMENT

Each robot axis is provided with the scribed lines shown in Fig. 5.2 for
positioning. When these markings are aligned to each other, each axis is
at the zero--degree position. If the markings get misaligned because of
motor or reducer replacement, the following procedure can be used for
rough positional calibration. This is a simplified method. To perform
accurate positional calibration, use the jig--based mastering described in
Section 5.4.

1) Procedure (zero--position mastering)
1 If you want to release brake control, set the system variable

$PARAM_GROUP.$SV_OFF_ENBto “FALSE”forall axes, turn
off the power, and then perform a cold start.

2 After the power is turned on, if the alarm message BZAL alarm is

displayed, select “TRUE” for the system variable $MCR.SPC_
RESET, turn off the power, and then perform a cold start.

3 After the power is turned on again, if the message Pulse not

established isdisplayed, rotate each axisthrough 20° orso in either
(+ or --) direction, using an individual--axis feed command, and
then press the alarm reset key to reset this message.

4 By performing an individual--axis feed command foreach axis, set

each axis to the zero--degree mark. (See Fig. 5.2.)

5 Press the screen selection key to select “0” NEXT, and select

SYSTEM from the menu.

6 Press the F1 key TYPE, select the system variable, and set

$MASTER_ENB value inthelist to1. Press theF1 key TYPEand
select MASTER/CAL.

7 Select ZERO POSITION MASTER from the system positioning

menu, and press the F4 key YES to perform zero--position
mastering. Now the system variable $DMR_GRP.MASTER_
COUNis set withthemasteringdata obtained fromthepulse coder
counter value, and the system variable $DMR_GRP.MASTER_
DONE (mastering completion flag) is set to “TRUE”.

8 Select MASTER/CAL from the system positioning menu, and

press the F4keyYES. Now positioningis carriedout, andteaching
and replaying are enabled.

9 After you are finished with mastering, reset the system variable

$MASTER_ENB to 0.

10 If you released brake control before, re--set the system variable

$PARAM_GROUP.$SV_OFF_ENB to the previous value for all
axes, turn off the power, and then perform a cold start.

Oncemasteringis completed,updatethedatasheetsupplied togetherwith
the robot with the new mastering data ($DMR_GROUP.$MASTER_
COUN[1] to [6]).

If you want to perform mastering for a specific axis, use the following
single--axis masteringprocedure. Newposition informationfor thataxis
is stored, and position information for the other axes is preserved.
As for the J2-- and J3--axes, each of which is accompanied by the other,
perform mastering for them simultaneously.

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5. ADJUSTMENTSMAINTENANCE

2) Procedure (single--axis mastering)
1 If you want to release brake control, set the system variable

$PARAM_GROUP.$SV_OFF_ENBto “FALSE”forall axes, turn
off the power, and then perform a cold start.

2 After the power is turned on, if the alarm message BZAL alarm is

displayed, select “TRUE” for the system variable $MCR.SPC_
RESET, turn off the power, and then perform a cold start.

3 After the power is turned on again, if the message Pulse not

established isdisplayed, rotate each axisthrough 20° orso in either
(+ or --) direction, using an individual--axis feed command, and
then press the alarm reset key to reset this message.

4 Byperformingan individual-- axis feedcommandfora desiredaxis,

set the axis to the zero--degree mark. (See Fig. 5.2.)

5 Press the screen selection key, select “0” NEXT, and select

SYSTEM from the menu.

6 Press the F1 key TYPE, select the system variable, and set

$MASTER_ENBvalueinthelist to 1. PresstheF1key TYPE, and
select MASTER/CAL.

7 Select SINGLE AXIS MASTER from the system positioning

menu. Asettingmenu foreach axisappears. Enter“1” in the(SEL)
column for the axis for which you want to perform mastering.
Enter “0” for the other axes. Enter “0” (zero degrees) i n the
MASTERING POSITION column, and press the F5 key EXEC to
perform zero--degree position mastering for the selected axis.

8 Select MASTER/CAL from the system positioning menu, and

press the F4keyYES. Now positioningis carriedout, andteaching
and replaying are enabled.

9 After you are finished with mastering, reset the system variable

$MASTER_ENB to 0.

10 If you released brake control before, re--set the system variable

$PARAM_GROUP.$SV_OFF_ENB to the previous value for all
axes, turn off the power, and then perform a cold start.

Oncemasteringis completed,updatethedatasheetsupplied togetherwith
the robot with the new mastering data ($DMR_GROUP.$MASTER_
COUN[1] to [6]).

5. ADJUSTMENTS

MAINTENANCE

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5.4

JIG--BASED
MASTERING

If the current--position value stored through the pulse coder becomes
differentfrom the actualposition ofeach axis becausea majorcomponent
of the mechanical unit of the robot is replaced, masteringis performed by
specifying the geometric position of the robot. (Mastering is performed
at a position of J1 = 0(.) For all robots, mastering is performed at the
factory.

When calibrating the robot, have it satisfy the following conditions.

D Level out the installation base for the robot (1 mm/base).
D Remove the hand and all other components from the wrist.
D Keep the robot from any external force.

NOTE

When the robotisbeing subjected to mastering, itdoesnot
make a stroke check. Pay sufficient attention to the
operation of the robot axes.

1) Mastering procedure
a) Assembling mastering jigs

i) Assembling the jig base

As shown in Fig. 5. 4 (a),attachmasteringjig Bto mastering jig
C.

Mastering jig C

Bolt:M5×16 (3pcs)
Washer: M5 (3pcs)

Fig 5.4 (a) Assembling the jib base

Mastering jig B

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5. ADJUSTMENTSMAINTENANCE

ii) Attaching to the robot main body

As shown in Fig. 5.4 (b), mount dial gauges to the jig base.
Using a calibration block, set the pointer of each dial gauge to

3.0mm,andfixthedialgaugeswith M5 bolts. (Becarefulwhen
tightening the bolts. Tightening them too firmly can break the
dial gauges.)

Calibration block

Dial gauge

(Push all the dial gauges against the calibration
block, and make adjustments so that they read
3 mm.)

Fig 5.4 (b) Attaching the dial gauge

(6pcs)

5. ADJUSTMENTS

MAINTENANCE

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iii)Attaching to the robot main body

As shown in Fig. 5.4 (c), attach the jig baseto the J1 base with
bolts and pins.

Pin A
A290-7215-X955
Pin B
A290-7215-X956

Bolt:M12×25 (2pcs)
Washer: M12 (2pcs)

J1 base

Fig 5.4 (c) Attaching to the robot main body

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5. ADJUSTMENTSMAINTENANCE

iv)Attaching the jig to the wrist

Manuallymove thewrist axis to a position of J4 = J5 = J6 = 0°.
Attach mastering jig A to the J6--axis in the orientation shown
in Fig. 5.4 (d).

Mastering jig A

Bolt:M6×12 (2pcs)
Washer: M6 (2pcs)

Pin

Fig 5.4 (d) Attaching the jig to the wrist

b) Performing mastering

1 First perform the mastering by zero--degree positioning

describedinSection5.3.
This procedure will set an approximate, temporary coordinate
origin in the robot.

2 To disable brake control, set the system variable

$PARAM_GROUP_SV_OFF_ENB to FALSE for all axes,
turn the power off, and perform a cold start.

3 Press the screen selection key ,select “0” NEXT ,and thenselect

SYSTEM from the menu. Press the F1 key TYPE, and select
the system variable. For $DMR_GROUP.$MASTER_DONE
(simplifiedmasteringcompletionflag),select“FALSE”so that
each axis can move out of the stroke range. When operating the
robot, keep its taught override speed low.

4 Using a single--axis feed command, place the robot in the

mastering posture shown in Fig. 5.4 (e).

5. ADJUSTMENTS

MAINTENANCE

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Masteringposture

Fig 5.4 (e) Mastering posture

5 Press the screen selection key , select “0” NEXT, and select

SYSTEM from the menu. Press the F1 key TYPE, and select
thesystemvariable. In thelist, set$MASTER_ENB to 1. Then
press the F1 key TYPE, and select MASTER/CAL.

6 Select FIXTURE POSITION MASTER from the system

positioning menu, and press the F4 function key YES.
Mastering is performed. Now, the system variable $DMR_
GRP.MASTER_COUN is set with themastering dataobtained
from the pulse coder counter value, and the system variable
$DMR_GRP.MASTER_DONE (mastering completion flag)is
set to “TRUE”.

7 Select MASTER/VOL from the system positioning menu, and

press the F4 key YES. Positioning is performed, and teaching
and replaying become enabled.

8 Onceyou arefinishedwith mastering,resetthe system variable

$MASTER_ENB value to 0.

9 To enablebrake control, re--set the $PARARM_GROUP.$SV_

OFF_ENB to theprevious value forall axes, turnoffthe power,
and perform a cold start.

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5. ADJUSTMENTSMAINTENANCE

Oncemasteringis completed,updatethedatasheetsupplied togetherwith
the robot with the new mastering data ($DMR_GROUP.$MASTER_
COUN[1] to [6]).

Ifyou want to performmasteringforaspecific axis, takenoteof thevalue
of the mastering data (system variable $DMR_GROUP.$MASTER_
COUN), and then perform mastering for all axes. Once you are finished
with mastering, re--enter the mastering data of the axes other than that
specific axis. New position information for that axis is stored, and
position information for the other axes is preserved.

5. ADJUSTMENTS

MAINTENANCE

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5.5

CONFIRMING
MASTERING

1) Confirming that mastering was performed normally
Usually, positioning is performed automatically when the power is

turned on. To confirmthat mastering was performednormally, check
that the current--position display matches the actual position of the
robot, using this procedure.

a) Replay the taught operation of the robot to set each axis to zero

degrees, and visually check that the zero--degree position marks
shown in Fig. 5.2 are aligned.

b) Replay a specific portion of the program,and check that the robot

has moved to the taught position.

2) Possible alarms in positioning
The following paragraphs describe alarms that may occur in

positioning and explain how to handle them.
a) BZAL alarm

This alarm is raisedif thevoltageof the pulsecoderbackupbattery
becomes 0V when the controller power is off. Mastering must be
performed again because the counter has already lost data.

b) BLAL alarm

This alarm indicates that the voltage of the pulse coder backup
battery is too low to run the pulse coder. If this alarm is issued,
replace the backup battery soon while keeping the power on, and
checkwhether the current--position datais correct,using amethod
described in item (1).

c) CKAL,RCAL,PHAL,CSAL, DTERR,CRCERR, STBERR, and

SPHAL alarms
If any of these alarms is issued, contact your FANUC service
representative. A motor may have to be replaced.

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5. ADJUSTMENTSMAINTENANCE

5.6

J5--AXIS GEAR
BACKLASH
ADJUSTMENTS

Gear 2 assembly

Seal bolt with washer :
M5×12 (4pcs)

Plane washer (4pcs)

Low head bolt : M5×10 (9pcs)

If the backlash in the J5--axis is harder than the allowable value (output
axis angle of 4.5 minutes) listed in Table 4.2 (b), make backlash
adjustments, using this procedure. (See Fig. 5.6.)

1 Place the robot in a posture of J4 = +90° andJ5=J6=0°.
2 Remove the nine M5×10 flat--head bolts, and dismount the J5--axis

gearbox cover (A290--7215--X524) from the J3 arm (A290--7215-­X402).

J3 arm

Gear J5--4

Bolt with washer :
M5×25 (6pcs)

Loctite

Gear 3 assembly

Seal bolt with washer :M5×12 (6pcs)

Cover J 5--1

Reference bolt

(Do not remove the bolt. Just loosen it.
Be sure to replace it with a new one after
adjustmentsare completed.)

Fig 5.6 J5--axis gear backlash adjustments

1) Gear 3 assembly and gear J5--4 backlash adjustments
1 Remove the four M5×12 seal bolts with a washer, and retract the

gear2 assembly (A290--7215--V501) tosuch a pointthat it will not
be engaged with the gear 3 assembly (A290--7215--V502).

5. ADJUSTMENTS

MAINTENANCE

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2 Remove the five M5×12 seal bolts with a washer. These bolts

work not only for mounting but also sealing the gear unit grease
bath. Once you have removed them, replace them with new ones.
In reference to the bolt (Do not remove this bolt; just loosen it.
However, looseningitimpairsits ability toseal. Once adjustments
are completed, after the other seal bolts are tightened, replace this
bolt with a new one. Otherwise, grease may leak.) shown in Fig.

5.6, push the gear 3 assembly against the output gear
(A290--7215--X514), and fix the gear 3 assembly temporarily.
Afteryou havefixed the gear3 assemblytemporarily, rotate theJ6
housing (output gear)in bothpositive andnegative directions, and
check whether their rotation is abnormally heavy and any portion
has a serious backlash. Repeat the above procedure until any
backlash becomes lower than the maximum allowable value and
the engagement and rotation torque becomes moderate.

3 Onceyou have completed adjustments,fixthe J3 armwith new six

M5×12 seal bolts.

2) Gear 2 assembly and gear 3 assembly backlash adjustments
1 Shift the gear 2 assembly in a direction vertical to the gear 3

assembly and input gear (A290--7215--X511) so that the backlash
is reduced, and fix t he gear 2 assembly to the J3 arm with four
M5×12 seal bolts with a washer.

2 Rotate t he gear 2 assembly, and check the operation of the J5--axis

by operating i t within its stroke (--140° to +140°). Repeat step 1
forreducing thebacklashuntilthe gearswill notinterfere with each
other.
Fix the gear 2 assembly temporarily in the same manner as stated
in(1). Once you havecompletedadjustments,mount theassembly
with new M5×12 seal bolts with a washer.

3 Make sure that the total backlash in the J5--axis unit is lower than

the maximum allowable value (output axis angle of 4.5 minutes)
listed in Table 4.2 (b). If the requirement is not satisfied, go back
to 1 of procedure (1).

4 Fix the J5--axis gearbox cover to the J3 arm with nine M5×10

flat--head bolts.

5 Apply the specifiedgreaseto theJ5--axis gearbox by followingthe

grease replacement procedure stated in Section 3.2.

6 Perform mastering as stated in Sections 5.3 and 5.4.

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5. ADJUSTMENTSMAINTENANCE

5.7

BRAKE RELEASE

Whenthe robotpower is off, the brakesof the robot can bereleasedusing
the brake release unit (option). In this case, the robot can be put in a
different posture. Observe Notes 1 to 4 given below.

NOTE

1 When releasing the brakes of the J2-- axis or J3--axis motor

(M2orM3), suspendtherobot witha craneas showninFig.

5.7.

2 When releasing the brakes of the J4--axis to J6--axis motor

(M4 to M6), suspend the end effector with a crane so that
it will not fall.

3 When releasing the brakes of motors, use slings having a

sufficient tensile strength.

4 Do not release the brakes of more than one motor

simultaneously.

5. ADJUSTMENTS

MAINTENANCE

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Fig 5.7 Releasing the brakes of the J2--axismotor

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6

MAINTENANCE

6. COMPONENT REPLACEMENT AND
ADJUSTMENTS

COMPONENT REPLACEMENT AND ADJUSTMENTS

Adjustments are needed after a component is replaced.
The following table lists componentsand the adjustment items that must
bemade after thecomponents arereplaced. Afterreplacing acomponent,
make necessary adjustments according to this table.

Replacement component Adjustment item

Motor (a) Mastering
J1--, J2--, and J3--axis reducers (a) Mastering
J4--axis gearbox (a) Mastering
J5--axis gearbox (a) Mastering
J6--axis reducer (a) Mastering

NOTE

Be verycarefulwhen dismounting andmounting the heavy
components that are listed below.

Component Weight

J3--axis arm (See Fig. 6.8.) 10.4kg
All components from J3--axis reducer to wrist unit (See

Fig. 6.6.)

All components from J2--axisarm to wrist unit(See Fig.

6.4. (a).)
All components from J2--axis base to wrist unit (See

Fig. 6.2 (a) and (b).)

31kg

38.7kg

69.4kg

6 COMPONENT REPLACEMENT

AND ADJUSTMENTS

6.1

REPLACING THE
J1--AXIS MOTOR M1

MAINTENANCE

1 Turn off the controller power.
2 Remove the J1--axis motor connector.
3 Removethe four M8×20 motormountingbolts. Dismountthemotor

fromthe J1--axis unit. When dismounting the motor,be careful ofthe
grease that may drop from the motor if the robot is suspended from a
ceiling or mounted on a wall.

4 Remove the M10 hexagonal nutfrom themotor shaft, andpull outthe

gear (A290--7215--X211).

5 Attach the gear to a new motor (with two axes equipped with a brake

(A06B--0223-- B005) or six axes equippedwith a brake(A06B--0223-­B605)).

6 Attach an M10 spring washer, apply Loctite 242 to the M10 threaded

portion of the motor, and tighten the M10 nut with a specifiedtorque
of [16.7 Nm].

7 Make sure that the O--ring (G105) is correctly attached to the J2 base

(A290--7215--X301) portion where the J1--axis motor is to be

mounted, and fasten them with four M8×20 bolts.
8 Attach the cable connector to the J1--axis motor.
9 According to Section 3.2, supply the J1--axis grease bath with the

specified grease.
10 While referencing Chapter 5, perform mastering.

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NOTE

If there is a danger that the J1-- axis section may swivel, for
example, because the robot is installed on a tilted surface,
fix the J1-- axis section during replacement work, for
example, by pushing the J1--axis mechanical stopper
against to the J1--axis section.

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M10 Screw washer

M10 hex agonal nut

Loctite

MAINTENANCE

6. COMPONENT REPLACEMENT AND
ADJUSTMENTS

Bolt:M8×20 (4pcs)

Washer: M8 (4pcs)

J1--axis motor

Gear

O--ring

J2 base

Fig 6.1 Replacing the J1--axis motor

6 COMPONENT REPLACEMENT

AND ADJUSTMENTS

6.2

REPLACING THE
J1--AXIS REDUCER

MAINTENANCE

1 Put the robot in such a posture that the J2 base andthe portions above

it can be suspended with a crane or the like (hereafter abbreviated as
a crane), and then turn off the controller power.

2 While referencing Section 8.2, pull out the cables below the J2 base

(A290--7215--X301) from the J1--axis hollow pipe section toward the
upper portion of the J2 base.

3 While referencing Section 6.1, remove the J1--axis motor from the J2

base.

4 As shown in Fig. 6.2 (a), remove the eight M10×50 bolts that fasten

the J2 base to the J1--axis reducer .

5 While referencing Section 3.1 of Part II, “Connection,” hoist the J2

base and portions above it slowly.

6 As shown in Fig. 6.2 (a), remove the O--ring (A290--7207--X342),

bearing, and center gear (A290--7215--X212).

7 Remove the six M12×80 bolts that fasten the J1--axis reducer to the

J1 base (A290--7215--X201), and dismount the reducer.

8 Asshown in Fig. 6.2 (b),removethefour M4×10 boltsthatfastenthe

pipe (A290--7215--X213) to the reducer, and dismount the pipe.

9 Make sure that the pipe is fitted with the O--ring (G60) correctly, and

attach the pipe to a new reducer (A97L--0218--0288#33) with four
M4×10 bolts.

10 Attach the O--rings (SO100 and SO150) to the reducer, and fasten the

reducerto a newJ1 basewith six M12×80 bolts(by applying Loctite
262 and tightening with a torque of [129 Nm]).

11 Mount the center gear, bearing (with Loctite 675 applied to its outer

ring), and O--ring (A290--7207--X342) to the reducer.

12 Fasten the J2 base to the reducer with eight M10×50 bolts (by

applying Loctite 262 and tightening with a torque of [73.5 Nm]). Be

careful not to let the pipe damage the oil seal.
13 According to Section 6.1, mount the J1--axis m otor on the J2 base.
14 According to Section 3.2, supply the J1--axis grease bath with the

specified grease.
15 While referencing Chapter 5, perform mastering.

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(4pcs)

MAINTENANCE

6. COMPONENT REPLACEMENT AND
ADJUSTMENTS

O--ring

Bearing

Bolt:M12×80 (6pcs)

Loctite

Washer : M12 (6pcs)

J1--axisreducer

J1--axis motor

Bolt: M10X50 (8pcs)

Loctite

Washer : M10 (8pcs)

O--ring

Center gear

O--ring

O--ring

Fig 6.2 (a) Replacing the J1--axis reducer

J1 reducer

O--ring

Pipe

Bolt

(4pcs)

Washer

Fig 6.2 (b) Replacing the J1--axis reducer

6 COMPONENT REPLACEMENT

AND ADJUSTMENTS

6.3

REPLACING THE
J2--AXIS MOTOR M2

MAINTENANCE

1 Push the J2--axis section against the mechanical stopper, or fix it in

such a way that it will not swivel when the motor is dismounted, for
example, by placing it in the direction of gravity.

NOTE

If the J2--axis section is not pushed against the stopper
correctly, or it is not placed in the direction of gravity, there
is a danger that the J2--axis section will swivel when the
J2--axis motor is removed.

2 Turn off the controller power.
3 Remove the J2--axis motor connector.
4 Remove the four M8×20 motor mounting bolts, and dismount the

motor from the J2 base.

5 Remove the M6 hexagonal nut that fastens the input spline, and

dismount theinput spline. Also remove the draw bolt from the motor
shaft.

6 Apply Loctite 242 to the threaded portion of a new motor

(A06B--0223--B605), and tighten the drawbolt with a torque of [16.7
Nm].

7 Put the input gear over the draw bolt, attach an M6 spring washer,

apply Loctite 242 to the M6 threaded portion of the draw bolt, and
tighten the M6 nut with a torque of [5.5 Nm].

8 Make sure that the O--ring (G115) is correctly attached to the J2 base

(A290--7215--X301) portion where the motor is to be mounted, and
fasten the motor to the J2 base with four M8×20 bolts. Do not force
in the motor. Otherwise,the input spline may not settle in the correct
place, possibly causing vibration (ifthe splineis engagedcorrectly,the

motor will be mounted smoothly).
9 Attach the cable connector to the J2--axis motor.
10 According to Section 3.2, supply the J2--axis grease bath with the

specified grease.
11 While referencing Chapter 5, perform mastering.

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MAINTENANCE

Draw bolt

Loctite

6. COMPONENT REPLACEMENT AND
ADJUSTMENTS

Input spline

M6 Springwasher

J2--axis motor

O--ring

Bolt:M8×20 (4pcs)

Washer: M8 (4pcs)

J2 base

M6 nut

Loctite

Fig 6.3 Replacing the J2--axis motor

6 COMPONENT REPLACEMENT

AND ADJUSTMENTS

6.4

REPLACING THE
J2--AXIS REDUCER

MAINTENANCE

1 Put the robot insuch aposture that the J2arm (A290--7215--X302)and

the componentson it can be suspended with a crane,and then turn off
the controller power.

2 Suspend the J2 arm andthe componentson it with a crane so that they

will not drop when the J2 arm is dismounted.

3 Asshown in Fig. 6.4 (a),removetheten M10×50 boltsthatfastenthe

J2 arm, dismount the J2 arm and plate (A290--7215--X321) from the
J2--axisreducer,andthendismountadapter1(A290--7210--X321). B e
careful not to allow an excessive load to be put on the cables (because
the cables are left attached when the reducer is dismounted).

4 Remove the eight M8×35 bolts that fasten the J2--axis reducer to the

J2 base, and dismount the J2--axis reducer from the J2 base.

5 Attach the O--ring (AS258) to a new reducer (A97L--0218--0289#153),

insert it into the J2 base, and fasten them with eight M8×35 bolts (by
applying Loctite 262 and tightening with a torque of [37.2 Nm]).

6 Degrease both the J2 arm and the J2--axis reducer surfaces that are to

meet each other, and as shown in Fig. 6.4 (b), apply sealant (Loctite
No. 518) to the J2 arm surface on which the J2 reducer is to be
mounted.

7 After attachingadapter 1 (A290--7210--X321) to the J2--axis reducer,

mount the J2 arm on the J2 reducer, insert the plate
(A290--7215--X321), and fasten the J2 arm with ten M10×50 bolts
(by applying Loctite 262 and tightening with a torque of [73.5 Nm]).

8 According to the grease replacement procedure described in Section

3.2, supply the J2--axis grease bath with the specified grease.

9 While referencing Chapter 5, perform mastering.

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MAINTENANCE

Adapter

6. COMPONENT REPLACEMENT AND
ADJUSTMENTS

Bolt:M8×35 (8pcs)

Loctite

Washer : M8 (8pcs)

Plate

J2- -axis reducer

O--ring

Bolt:M10×50 (10pcs)

Loctite

Washer : M10 (10pcs)

Fig 6.4 (a) Replacing the J2--axis reducer

Fig 6.4 (b) Applying sealant to the J2--axis reducer

6 COMPONENT REPLACEMENT

AND ADJUSTMENTS

MAINTENANCE

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NOTE

Observe the following cautions when applying sealant
(Loctite No. 518).

1 Greasing the surface where sealant is to be applied

1) Remove dust from the surface and the inside of the tap,
for example, by blowing it off.

2) Degrease thesurfacecompletelywith acloth dampened
with solvent. Do not spray solvent directly onto the
surface.

3) Wipe off any solvent from the surface with a dry cloth.
Makesurethat nosolventisleftin thetap oron anyother
portion.

4) Always use a new surface of a cloth so that the grease
oncewipedupwiththe clothwillnotgeton thedegreased
surface.

2 Allowing time during which the sealant can cure

To let the applied sealantcure, avoid runningthe robot and
applying grease for at least four hours after the sealant is
applied.

3 Wiping off excessive sealant

After attaching the cover, wipe off any excessive sealant
that comes out from the sealed section with a cloth or
spatula. Do not use solvent.

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6.5

REPLACING THE
J3--AXIS MOTOR M3

MAINTENANCE

1 Push the J3--axis section to the mechanical stopper, or fix it in such a

waythat it willnot swivel when themotor isdismounted,forexample,
by placing it in the direction of gravity.

NOTE

If the J3--axis section is not pushed against the stopper
correctly, or it is not placed in the direction of gravity, there
isadangerthat J3--axissectionwillswivelwhen theJ3--axis
motor is removed.

2 Turn off the controller power.
3 Remove the connector of a cable leading to the J3--axis motor.
4 Remove the fourM6×14 boltsthat fastenthe J3--axis motor to theJ3

casing (A290--7215--X401), and dismount the motor and gasket.

5 Remove the M5 nut from the motor shaft, and dismount the input

spline and draw bolt.

6 Apply Loctite 242 to the threaded portion of a new motor

(A06B--0202--B605), and tighten the draw bolt with a torque of [3.2
Nm].

7 Put the input gear over the draw bolt, attach an M5 spring washer,

apply Loctite 242 to the M5 threaded portion of the draw bolt, and
tighten the M5 nut with a torque of [3.2 Nm].

8 Attachanewgasket(A98L--0040--0042#03),andinsertthe motor into

the reducer. Keep the J3--axis degrease outlet on the J2 arm side open
(seeFig.3.1),andlook into the outlettomakesurethatthe input spline
hassettledin thecorrectplace. Evenone teethof ashift inengagement
cancausevibration. (Iftheinput splineis engagedcorrectly, themotor
can get in the reducer smoothly.)

9 Fasten the motor to the J3--axis reducer with four M6×14 bolts. Be

sure to use a new gasket so as to prevent grease leakage.
10 Attach the cable connector to the J3--axis motor.
11 According t o Section 3.2, supply the J3--axis grease bath with the

specified grease.
12 While referencing Chapter 5, perform mastering.

6. COMPONENT REPLACEMENT AND
ADJUSTMENTS

6 COMPONENT REPLACEMENT

AND ADJUSTMENTS

Packing

MAINTENANCE

M5 Springwasher

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J3--axis motor

M5 nut

Loctite

Input gear

J3--axis casing

Fig 6.5 Replacing the J3--axis motor

Draw bolt

Loctite

Bolt:M6×14 (4pcs)
Washer: M6 (4pcs)

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6.6

REPLACING THE
J3--AXIS REDUCER

MAINTENANCE

1 Put the robot in such a posture that the J3--axis section and the

components on it can be suspended with a crane, and then turn off the
controller power.

2 While referencing Section 8.2, remove the cable from the J2 arm

section.
Suspend theJ3--axis section and the components on it with a crane so
thattheywillnotdropwhenthereducerisdismountedfromtheJ2 arm.
Be careful not to allow an excessive load to be put on the cable
(because the cables areleft attached when the reducer is dismounted).

3 As shown in Fig. 6.6, remove the six M10×45 bolts that fasten the

J3--axis reducer to the J2 arm, and dismount the J3 arm unit from the
J2 arm.

4 While referencing Section 6.5, dismount the J3--axis motor from the

J3 arm unit.

5 Remove ten M6×30 bolts that fasten the J3--axis reducer to the J3

casing(A290--7215--X401), dismount theJ3--axis reducerfrom theJ3
casing, and remove the O--ring from the J3--axis reducer.

6 AttachanO--ring (SO120)toa new reducer(A97L--0218--0295#161),

mount thereducer on the J3casing, andfasten themwith tenM6×30
bolts (by applying Loctite 262 and tightening with a torque of [15.7
Nm]).

7 WhilereferencingSection6.5, mountthe J3--axismotor onthe J3 arm

unit.

8 Remove the O--ring from the J2 arm, degrease both the J2 arm andthe

J3--axis reducer surfaces that are to meet each other, and as shown in
Fig. 6.6 (b), apply sealant (Loctite No. 518) to the J2 arm surface on
which the J3 reducer is to be mounted.

9 Attach adapter 2 (A290--7210--X322) and the O--ring (SO100) to the

J2 arm surface on which the J3--axis reducer is to be mounted.

10 Suspend the J3--axissectionandthe components on it with a crane,and

fasten the J2 arm and J3--axis reducer with six M10×45 bolts (by

applying Loctite 262 and tightening with a torque of [73.5 Nm]).
11 While referencing Section8.2, dress thecable into the previousform.
12 According to Section 3.2, supply the J3--axis grease bath with the

specified grease.
13 While referencing Chapter 5, perform mastering.

6. COMPONENT REPLACEMENT AND
ADJUSTMENTS

6 COMPONENT REPLACEMENT

AND ADJUSTMENTS

Bolt:M10×45 (6pcs)

Loctite

MAINTENANCE

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Washer : M10 (6pcs)

Plate

Adapter

O--ring

Bolt:M6×30 (10pcs)

Loctite
Washer : M6 (10pcs)

J3 casing

Packing

O--ring

J3- -axis reducer

J3--axis motor

Fig 6.6 (a) Replacing the J3--axis reducer

Fig 6.6 (b) Applying sealant to the J3--axis reducer

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6.7

REPLACING THE
J4--AXIS MOTOR M4

MAINTENANCE

6. COMPONENT REPLACEMENT AND
ADJUSTMENTS

1 Placetherobot in aposture ofJ4 =--90°. Keepthiscondition until step

<10> (mastering). Note that if the operation for setting the
zero--degree position is performed incorrectly, the cable may be
twisted more than allowed, leading to a broken cable. If the robot is
in a posture of J3 = --90°, grease will not drop when the motor is

dismounted.
2 Turn off the controller power.
3 Remove the connector of a cable leading to the J4--axis motor.
4 As shown in Fig. 6.7, remove the three M6×14 bolts that fasten the

J4--axis motorto theJ3 casing(A290--7215--X401), and dismount the

motor.
5 Remove the nut (A290--7215--X412) that fastens the J4--1 gear

(A290--7215--X411) to the motor shaft, and dismount the J4--1 gear

andM5springwasher.
6 Mount the J4--1 gear to a new motor (with two axes equipped with a

brake (A06B--0202--B005) or six axes equipped with a brake

(A06B--0202--B605)), applyLoctite242 to thethreadedportion of the

motor shaft, and fasten them with a nut (A290--7215--X412) by

tightening with a torque of [9 Nm]. (Be very careful whentightening

the nut because if you do not tighten with the specified torque, the

J4--axis may get out of place.)
7 Make sure that the O--ring (G75) is put accurately in the J3 casing

portion wherethe motor is to be mounted, and fasten the motor to the

J3 casing with three M6×14 bolts.
8 Attach the cable connector to the J4--axis motor.
9 According to Section 3.2, supply the J4--axis grease bath with the

specified grease.
10 While referencing Chapter 5, perform mastering.

J4--axis motor

Bolt:M6×14 (3pcs)

Washer : (3pcs)

O--ring

J3 casing

Fig 6.7 Replacing the J4--axis motor

Gear J4--1

M5 Spring washer

Nut

Loctite

6 COMPONENT REPLACEMENT

AND ADJUSTMENTS

6.8

REPLACING THE
J4--AXIS GEARBOX

MAINTENANCE

1 Turn off the controller power.
2 According to Section 8.2, remove the cables that run from the

J3--/J4--axismotor connectorsthrough the clampsonthe J3 casingand

in the J3 arm tothe J6--axis motor inthe J6 housing, and takethemout

from the J3 arm unit.
3 Suspend the J3 arm throughan M6eye bolt with acrane. Removethe

six M6×70 bolts that fasten the J3 arm to the J4 gearbox unit, and

dismount the J3 arm from the J4--axis gearbox unit. (See Fig. 6.8.)
4 Suspend the J4--axis gearbox unit above the J3 casing

(A290--7215--X401) throughanM6 eyebolt with acrane. Removethe

six M10×45 bolts that fasten the J4 gearbox unit t o the J2 arm, and

dismount the J4 gearbox unit from the J2 arm.
5 According to the procedures described in Sections 6.5, 6.6, and 6.7,

dismount the J3-- and J4--axis motors and J3--axis reducer.
6 Accordingto theproceduresdescribed inSections 6.6 and6.7, mount

the J4--axis motor and J3--axis reducer on a new J4--axis gearbox

(A05B--1215--K401).

Do not forget to insert an O--ring and gasket.
7 Fasten the J4-- axis gearbox unit mentioned in <6> with ten M 10×45

bolts (by applying Loctite 262 and tightening with a torque of [73.5

Nm]).
8 According to the procedure described in Section 6.5, mount the

J3--axis motor.
9 Suspend the J3 arm with a crane, fasten the J4--axis box with six

M6×70 bolts (by applying Loctite 262 and tightening with a torque

of [15.7 Nm]).
10 According to Section 8.2, dress the cables that run from the clamp on

the J3 casingto theJ6--axis motorin theJ6 housing through the clamp

in theJ3 arminto the previous form. Attachthe J3and J4--axis motor

connectors.
11 AccordingtoSection3.2, supply the J3--andJ4--axis greasebathswith

the specified grease.
12 While referencing Chapter 5, perform mastering.

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MAINTENANCE

6. COMPONENT REPLACEMENT AND
ADJUSTMENTS

Bolt:M6×70 (6pcs)

Loctite

Washer: M6 (6pcs)

J3 arm unit

J3 casing

J3--axis gear box

Fig 6.8 Replacing the J4--axis gearbox unit

6 COMPONENT REPLACEMENT

AND ADJUSTMENTS

6.9

REPLACING THE
J5--AXIS MOTOR M5

MAINTENANCE

1 Place the robot in a posture of J4 = --90°.
2 Turn off the controller power.
3 As shown in Fig. 6.9, remove the four M6×16 bolts, rotate the J5--2

cover (A290--7215--X502) around theJ5--axis to such a point that the
J5 motor can be taken out, and fasten it to the J3 arm
(A290--7215--X402) temporarily.

4 While referencing Section 8.2, detach the clamp (A290--7215--X525)

from the inside of the J3 arm, and take out inline cable connectors
M5M1 and M5P1.

5 Remove the four M5×12 bolts with a washer that fasten the J5--axis

motor to the J3 arm, and dismount the motor from the J3 arm.

6 Remove the two M3×4 setscrews that fasten the J5--1 gear

(A290--7215--X511) to the motor shaft, and pull out the gear. Also
detach the leads from the motor.

7 Bond a newkey (JB--HKY--3×3×8A) to anewmotor(with two axes

equippedwithabrake(A06B--0115--B075#0008) orsix axesequipped
with abrake (A06B--0115--B275#0008)) with Loctite 675, mount the
J5--1gear,andfasten them withsetscrews M3×4(by applyingLoctite

242). Be careful not to allow the key to stick out from the gear when

bonding it.
8 Attach the leads that were detached at <6> to the motor.
9 Attach a new gasket (A98L--0040--0042#07) to themotor flangewith

Alvania grease, fasten the motor to the J3arm with four new M5×12

seal bolts with a washer. Be sure to use new seal bolts. Otherwise,

grease may leak.
10 While referencing Section 8.2, attach the inline cable connectors,

attach the clamp to the inside of the J3 arm, and dress the cables into

the previous form.
11 While being careful not to allow the gasket (A290--7215--X527) to

stick out or to be twisted and not to have non--bound cable portions

caught between the gasket and motor flange, fasten the J5--2 cover

with fourM6×16 bolts (by applying Loctite242 and tightening with

a torque of [15.7 Nm]).
12 According to Section 3.2, supply the J5--axis grease bath with the

specified grease.
13 While referencing Chapter 5, perform mastering.

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Connector of cable relay

ClampinJ3arm

MAINTENANCE

6. COMPONENT REPLACEMENT AND
ADJUSTMENTS

Cover J 5--2

Fixing bolt : M6×16 (4pcs)

Loctite

Washer: M6 (4pcs)

Seal bolt with washer : M5×12 (4pcs)

Leads attached
to the motor

Set screw : M3×4 (2pcs)
Loctite

Packing

Fig 6.9 Replacing the J5--axis motor

J5--axis motor

key

Loctite

Gear

6 COMPONENT REPLACEMENT

AND ADJUSTMENTS

6.10

REPLACING THE
J5--AXIS GEAR

MAINTENANCE

1 To replace the J5--1 gear, follow the motor replacement procedure

stated in Section 6.9.
2 Place the robot in a posture of J4 = +90° andJ5=0°.
3 Turn off the controller power.
4 According to Section 6.9, dismount the J5--axis motor.
5 As shown in Fig. 6.10, remove the nine M5×10 flat--head bolts, and

dismount the J5--1 cover (A290--7215--X524).
6 Remove the fourM5×12 sealbolts with awasher that fasten the gear

2 assembly (A290--7215--V501), and dismount the gear 2 assembly

from the J3 arm.
7 Remove the six M5×12 seal bolts with a washer that fasten the gear

3 assembly (A290--7215--V502), and dismount the gear 3 assembly

from the J3 arm.
8 Remove the six M5×25 bolts that fasten the J5--4 gear

(A290--7215--X514), and dismount the J5--4 gear from the J3 arm.
9 Fasten a new J5--4 gear to the J3 arm with six M5×25 bolts (by

applying Loctite 262 and tightening with a torque of [9 Nm]).
10 According to the backlash adjustment procedure described in Section

5.7, make backlash adjustments on a new gear 3 assembly, and fasten

it to the J3 arm.
11 According to the backlash adjustment procedure described in Section

5.7, make backlash adjustments on a new gear 2 assembly, and fasten

it to the J3 arm.
12 Once the backlash adjustments described in Section 5.7 are

completed, fasten the J5--1 cover to the J3 arm with nine M5×10

flat--head bolts by tightening them with a torque of [4 Nm].
13 According to Section 3.2, supply the J5--axis grease bath with the

specified grease.
14 While referencing Chapter 5, perform mastering.

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Gear2 assembly

J3 arm

MAINTENANCE

6. COMPONENT REPLACEMENT AND
ADJUSTMENTS

Gear

Bolt with washer (6pcs)

Gear 3 assembly

Loctite 262

Seal bolt with washer

Plane washer

(4pcs)

Low head bolt

(4pcs)

Seal bolt with washer

(9pcs)

Cover

Gear 3 assembly

Reference bolt

(Do not remove the bolt. Just loosen it.
Be sure to replace it with a new one after
adjustmentsare completed.)

Fig 6.10 Replacing the J5--axis gear

6 COMPONENT REPLACEMENT

AND ADJUSTMENTS

6.1 1

REPLACING THE
J6--AXIS MOTOR M6
AND REDUCER

MAINTENANCE

1) Replacing the J6--axis motor M6
1 Place the robot in a posture of J4 = --90° andJ5=0°.
2 Turn off the controller power.
3 While referencing Section 8.2, dismount the J5--2 cover, remove

the two M4×6 seal bolts that fasten the J5--2 clamp
(A290--7215--X531) inthecover,andreleasetheJ5--2 clamp. Now
it is easy to take out the wrist flange. (The J5--2 clamp can move
through the J5 hollow section.)

4 As shown in Fig. 6.11 (a), remove the four M5×25 bolts, and

dismount the wrist flange from the J6 housing
(A290--7215--X501).

5 While referencing Section 8.2, remove the two M3×6 bolts that

fastentheJ6 motor connectorto theJ6 clamp (A290--7215--X534),
and dismount the clamp from the wrist flange.

6 Removethe four M5×12 boltswith awasherthatfasten the motor

to the wrist flange, and dismount the motor from the wrist flange.

7 Remove the M3×8 bolts and washers (A290--7215--X532), and

dismount the reducer wave generator from the motor.

8 Fasten the wave generator to the shaft of a new motor (with two

axes equipped with a brake (A06B--0114--B075#0008) or six axes
equipped with a brake (A06B--0114--B275#0008)) with M3×8
bolts by applying Loctite 242 and tightening with a torque of [2
Nm]. (Donot forget to insert washers[A290--7215--X532].) Also
apply a plenty of grease(Mori WhiteRE No. 00) around the wave
generator.

9 Attach a new gasket (A97L--0040--0042#07) to the motor flange

with Alvania grease, and fasten the motor to t he wrist flange with
four M5×12 bolts with a washer (by applying Loctite 262). Be
sure to use a new gasket so as to prevent grease leakage.

10 Pass a new gasket (A290--7215--X533) over the cable, and attach

the J6 clamp (A290--7215--X534) to the wrist flange with two
M3×6 bolts. Attach the motor cable connector. It will be
convenient that you hook the gasket on the parallel pins on the J6
housing.

11 After making sure that the gasket (A290--7215--X533) is placed

properly between the J6 housing and wrist flange, fasten the wrist
flangeequipped with themotorto theJ6 housingwithfourM5×25
bolts by (applying Loctite 262 and) tightening with a torque of [9
Nm]. At this point, while referencing Section 8.2, be careful to
keep non--bound movable cable portions in the J5--axis hollow
section from being caught in the J6 housing. If the robot is
assembled and put in operation with the cables caught, it is likely
that the service life of the cables may be badly shortened.

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MAINTENANCE

6. COMPONENT REPLACEMENT AND
ADJUSTMENTS

12 While referencing Section 8.2, being careful to keep the

non--bound movable cable portions in the J5--axis hollow section
from being twisted, fasten the J5--2 clamp (A290--7215--X531) to
the J5--2 cover (A290--7215--X502) with two new M4×6 seal
bolts. Be sure to use new bolts. Otherwise, the seal--ability of the
wrist section may get lower. Then, while referencing Section 6.9,
mount the J5--2 cover to the J3 arm (A290--7215--X402).

13 As describedinSection3.2, supply the J6--axisgreasebath withthe

specified grease.

14 While referencing Chapter 5, perform mastering.

2) Replacing the J6--axis reducer
1 Turn off the controller power.
2 Following procedure (1) on the previous page, remove the J5--2

cover, and dismount the wrist flange from the J6 housing
(A290--7215--X501). Also dismount the motor from the wrist
flange, then wave generator from the motor.

3 While referencing Section 8.2, remove the two M3×6 bolts that

fasten the J6 motor connector and J6 clamp (A290--7215--X534),
and dismount the J6 clamp from the wrist flange.

4 Removethe four M5×12 boltswith awasherthatfasten the motor

to the wrist flange, and dismount the motor from the wrist flange.

5 Remove M3×8 bolts and washers (A290--7215--X532), and

dismount the reducer wave generator from the motor.

6 By following procedure (1) on the previous page, mount a new

reducer wave generator to the motor, and apply a plenty of grease
around the wave generator.

7 As shown in Fig. 6.11 (b), remove the eight M3×40 bolts with a

washer that fasten the adapter (A290--7215--X543) to the
cross--roller ring, and dismount the adapter (A290--7215--X543)
from the cross--roller ring.

8 Remove the twelve M3×15 bolts with a washer t hat fasten the

circular spline, adapter B (A290--7215--X544), and the ring
(A290--7215--X545) to the adapter (A290--7215--X543), and
dismount the adapter from the circular spline. Mount and fastena
new circular spline together with adapter B (A290--7215--X543)
and the ring to the adapter (A290--7215--X543) with twelve
M3×15 bolts with a washer (by applying Loctite 262 and
tightening with a torque of [2 Nm]).

9 Remove the six M5×12 bolts that fasten the flex spline, and

dismount the flexspline from the cross--rollerring. Positiona new
flex spline with the flange (A290--7210--X524) and f3×8 parallel
pins, and fasten it with six M5×12 bolts with a washer (by
applying Loctite 262 and tightening with a torque of [9 Nm]).

10 After making sure that the O--ring (S71) is set properly in the

adapter (A290--7215--X543), mount the cross--roller ring on the
(A290--7215--X543), and fasten them with eight M3×40 bolts
with a washer (by applying Loctite 262 and tighteninga torque of
[2 Nm]).

6 COMPONENT REPLACEMENT

AND ADJUSTMENTS

MAINTENANCE

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11 While referencing (1) in Section 6.11, mount the motor, and also

mount the wrist flange to the J6 housing. Then attach the J5--2
cover.

12 According to Section 3.2, supply the J6--axis grease bath with the

specified grease.

13 While referencing Chapter 5, perform mastering.

Bolt with washer : M5×12 (4pcs)

Clamp

Packing

J6 housing

Pin

Washer

Bolt:M3×8

Loctite

Washer : M3

Fixing bolt : M3×6 (2pcs)

Packing

Ware generator

Wristflange

Bolt:M5×25 (4pcs)

Loctite

Washer: M5 (4pcs)

Fig 6.11 (a) Replacing the J6--axis motor and reducer

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MAINTENANCE

6. COMPONENT REPLACEMENT AND
ADJUSTMENTS

Packing

Wave generator

Washer

Bolt:M3×8

Loctite

Washer : M3

Packing

Ring

Adapter

Circular spline

Adapter

Bolt with washer: M3×15 (12pcs)

Loctite

O- -ring

Bolt with washer : M5×12 (6pcs)

Loctite

Flange

Flex spline
Cross roler ring

Bolt with washer : M3×40 (8pcs)

Loctite

Straight pin (2pcs)

Fig 6.11 (b) Replacing the J6--axis reducer

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7

7. PIPING AND WIRINGMAINTENANCE

PIPING AND WIRING

7. PIPING AND WIRING

MAINTENANCE

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7.1

PIPING DRAWING

Fig. 7.1 shows the diagram of piping in the mechanical unit.

Panel union
Rc 3/8 Female

Fig 7.1 Piping diagram

Panel union
Rc 3/8 Male

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7. PIPING AND WIRINGMAINTENANCE

7.2

WIRING DIAGRAMS

Controller

J1- -axis connector board

Earth

Panel union

Famale Rc 3/8

Fig. 7.2(a) andFig. 7.2 (b) show thediagramsof wiring in themechanical
unit.

Mechanical unit

J1--axis motor

Battery

Air

J2--axis motor J3- -axis motor

J4--axis motor

J5--axis motor

J6--axis motor

Panel union
Famale Rc 3/8

K102 : 5 pin
K103 : 24 pin

End effector

Fig 7.2 (a) Wiring in the mechanical unit with two axes equipped with a brake

J3--axis casing
connector board

7. PIPING AND WIRING

MAINTENANCE

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Controller

J1- -axis connector panel

Earth

Panel union

Famale Rc 3/8

Mechanical unit

J1--axis motor

Battery

Air

J2--axis motor J3- -axis motor

J4--axis motor

J5--axis motor

J6--axis motor

K105 : 5 pin
K106 : 24 pin

End effector

Panel union
Famale Rc 3/8

Fig 7.2 (b) Wiring in the mechanical unit with all axes equipped with a brake

J3--axis casing
connector panel

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7. PIPING AND WIRINGMAINTENANCE

7.3

CABLE MOUNTING
DIAGRAM

Make the following visual checks to see if there is any abnormal cable.

1) Whethertheswivelingmotionoftherobothascausedanylocaltorsion
or bending in the swiveling section.

2) Whether the cables leading to the J2-- or J3--axis sections have worn
each other during operation.

3) Whether the route of cables leading to the end effector is appropriate
for the operation of the wrist and the service operation of the robot.
Fig. 7.3 is the mounting diagram of cables in the mechanical unit.

(2--axis brake type)
(6--axis brake type)

(2--axis brake type)
(6--axis brake type)

Fig 7.3 Cables in the mechanical unit

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8

8. CABLE REPLACEMENTMAINTENANCE

CABLE REPLACEMENT

Replacethe cables ofthe robotonce every fouryears. Ifacableis broken
or damaged, replace it according to the procedure described in this
chapter.

Cautions in handling the
pulse coder cable

Whentransporting, installing, ormaintaining the robot,do not detachthe
pulse coder cables carelessly. The cables are provided with the marking
tieshownbelow. If you detachedanycablewiththemarkingtie, you need
to perform mastering for the robot.

Do not detach any connector unless you replace a motor, pulse coder,
reducer, or cable.

Fig8 Markingtie

If there is a break in or any other damage to a cable, replace the cable
according to the procedure described in this chapter. If the connector of
a pulse coder cable (K101, K102, K103, K104, K105, K106, K201, or
K202)is detached,the data about theabsolutepositionof therobot is lost.
Once any of these cables is replaced, perform simplified mastering while
referencing Section 5.3. If the data is lost because of a break in a cable,
also perform simplifiedmastering to calibratethe robotinto the previous
absolute position.

8. CABLE REPLACEMENT

MAINTENANCE

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8.1

CABLE DRESSING

After a cable is replaced individually rather than in kit, clamp it with
rubberbushingsand nylon ties(cableties) atthespecifiedpositionslisted
in Table 8.1. Otherwise, the cable may sag or become too tight, leading
to a break in the cable.

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8. CABLE REPLACEMENTMAINTENANCE

Table 8.1 Cable clamp positions

Mark

Cable clamping position Mark No.

8. CABLE REPLACEMENT

MAINTENANCE

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8.2

REPLACING CABLES

First, placethe robot inaposture of the J4--axis being at --90° and all other
axes being at 0°. Before starting cable replacement, put the controller
apart from the robot main body.

1) Replacing the cable kit
1 Cutthenylonties(cableties) for the J2--/J3--axisCornex cover,and

take out the cover from the cable kit.

2 Dismount the J1 connector board from the J1 base. (See Fig. 8.2

(a).)

3 Cut the nylon tiethatbounds therubberboot, anddetachtherubber

boot from the cable. Separate the RM1 and RP1 connectorinserts
from the connectorhousing onthe J1connector board. (Dismount
the connector housing from the J1 connector board because
otherwise the rubber boot will get caught on the housing and their
removal will be hindered.)
Dismount the terminals from t he battery box.

4 Remove the M1M, M1BK (with six axes equipped with a brake),

M2M, M2BK, M1P, and M2P connectors from the J1--/J2--axis
motor.

5 While referencing Fig. 8.2 (a), remove the two M6×6 bolts that

fastentheplate (A290--7215--X222) in theJ1 base, andpull outthe
cablefrom the inside of the J1 base toward the uppersection of the
J1 hollow pipe section. The connector inserts mentioned in <3>
tendto get caughtinsidethepipe. Do notforceit out fromthepipe.
Otherwise, a break may occur in the cable.

6 While referencing Fig. 8.2 (b), remove the two M6×10 bolts that

fasten the cable cover above the J2 base (A290--7215--X301), and
dismount the cable cover.

7 While referencing Fig. 8.2 (b), remove the two M8×10 bolts that

fasten the plate (A290--7215--X331), and dismount the plate.

8 While referencing Fig. 8.2 (b), remove the four M8×10 cable kit

mounting bolts from the J2 arm, and dismount the cable kit from
the J2 arm.

9 WhilereferencingSection6.11,dismount the J5--2 coverandwrist

flange unit, and then remove the J6--axis motor connector. Then,
as shown in Fig. 8.2 (c), cut nylon ties (cable ties) for the J6 clamp
(A290--7215--X534) and the J5--2 clamp (A290--7215--X531) [and
also for the support (A290--7215--X529)] to separate the
non--bound cables portions.

10 While referencing Fig. 8.2 (b), remove the four M6×10 bolts that

fasten the plate (A290--7215--X430) on the rear of the J3 casing.
Loosenthenut fortheresinbushing that fastenstheplate, and slide
the bushing in such a direction that the cable will become loose.

11 As shown in Fig. 8.2 (c), remove the two M5×10 bolts that fasten

theJ5--1 clamp(A290--7215--X525),and dismountthe J5--1 clamp
fromtheJ3arm,andpull itout. Then,cut the nylon ties (cableties),
and pull out the cable from the inside of the wrist toward the rear
of the J3 casing.

12 While referencing Fig. 8.2 (b), remove the two M6×10 bolt that

fastenthe plate(A290--7215--X426)ontheJ3casing,anddismount
the cable kit completely from the robot main body.

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8. CABLE REPLACEMENTMAINTENANCE

13 Mount a new cable kit by reversing the above steps. In this case,

however, do not tighten the nut for the resin bushing on the plate
(A290--7215--X430) behindtheJ3 casing. Afterpassing the cables
through the J3 arm, pass them through the J5--2 cover
(A290--7215--X502) and gasket (A290--7215--X527), and then
insert them into the J6 housing.

14 After going back to 8 on the previous page, fasten the J5--2 clamp

(A290--7215--X531) together with thesupport(A290--7215--X529)to
the non--bound cable portions. After fixing the nylon ties, do not
fasten the J5--2 clamp to the J5--2 cover immediately; keep it loose.

15 While referencing Fig. 8.2 (c), attach the J6 clamp

(A290--7215--X534) to the non--bound cable portions. Be careful
to keep non--bound twisted pairs from being twisted. Also
carefully observe a rated clamp distance of 160 mm shown in Fig.

8.2 (c).

16 After makingsure that the non--bound twisted pairsarenot twisted

inthe J5--axishollowsectionornot caught in theJ6 housing,fasten
the J6 clamp (A290--7215--X534) to the J5--2 cover with two new
M4×6 seal bolts. Then make sure that J5--1 clamp
(A290--7215--X525) is fastenedtothe inside of theJ3 armsecurely,
and mount the J5--2 cover. At this point, make sure that the
non--bound cable portions are not worn against any sheet metal
edge inside the J3 arm and that they arenot caught under the J5--2
cover when it is attached. (If it is likely that a non--bound cable
portion maybe worn against any sheet metal edge, confine it with
a nylon tie (cable tie) or take a similar measure.)

17 With the nut for the resinbushing onthe plate (A290--7215--X430)

behind the J3 casing kept loose, twist the cables passing the J4
hollow section through 90° clockwise as viewed from behind the
J3 casing (to prevent the cables from twisting when the J4--axis is
at 0°) so that t he cables will not be too tight or not sag behind the

J3 casing. Then tighten the resin nut by hand.
18 Mount the cable kit by going back from 7 to 2.
19 Attach the rubber boot to the previous place.

Beforemounting theJ1connectorboardto the J1 base,push theOT

jumperconnector into the rubber boot, and bind the opening ofthe

rubber boot for both RM1 and RP1 with a nylon tie. While being

careful not to pinch non--bound cable portions, mount the J1

connector board on the J1 base.
20 Mount the J2--/J3--axis Cornex cover on the cable kit again, and

fasten them with a nylon tie (cable tie). (Do not fasten the nylon

tie too tightly.)

8. CABLE REPLACEMENT

Connector insert

(PM1, RP1)

MAINTENANCE

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2) Replacing the cables separately
1 While referencing item (1) of S ection 8.2, dismount the cable kit

from the robot main body, and remove the J2--/J3--axis Cornex
cover.

2 While referencing Fig. 8.2 (d), dismount the clamp and grommet

from thecable kit, andreplace the cables. After cablereplacement,
mount the clamp and grommet, but do not tighten the mounting
bolts.

3 Mount the cable kit on the robot main body as before. (See (1) of

Section8.2.) Arrangethecablesinsideandoutside theJ2--/J3--axis
movable section by shifting the wires so that they are at regular
intervalsand look natural. Aftertheirlength is adjusted,tightenthe
mounting bolts for the grommet retaining clamp.

4 Mount the Cornex cover as before. (Tight the nylon tie but not

firmly.)

Rubber boot

Connector

housing
Bolt:M4×10
(8pcs)

J1 connector
board

J1 hollow pipe

Plate
A290--7215--X222
Bolt:M6×6 (2pcs)

Fig 8.2 (a) Replacing the cable kit

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8. CABLE REPLACEMENTMAINTENANCE

Plate
A290--7215--X430
Bolt:M6×10 (4pcs)

Plate
A290--7215--X426
Bolt:M6×10 (2pcs)

Cable kit

Packing
A290--7215--X527

Bolt:M8×10 (4pcs)

Plate
A290--7215--X331
Bolt:M8×10 (2pcs)

Fig 8.2 (b) Replacing the cable kit

Cover J5--2
Bolt:M6×16 (4pcs)
Washer : M6 (4pcs)

Cable cover
Bolt:M6×10 (2pcs)

J2 base

Clamp J5--2
A290--7215--X531
Seal bolt : M4×6 (2pcs)

Support
A290--7215--X529

Clamp J5--1
A290--7215--X525
Bolt:M5×10 (2pcs)

Clamp- -to--clamp distance : 160 mm

Note) Before putting on the J5--2
cover, make sure that twisted--pair
wires do not cross one another.

ClampJ6
A290--7215--X534
Bolt:M3×6 (2pcs)

Fig 8.2 (c) Replacing the cable kit (wrist section)

Wrist flange unit

8. CABLE REPLACEMENT

clamp A290- -7215--X334
grommet A290--7215--X312
Bolt:M6×10 (2pcs)

MAINTENANCE

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Outside cable

clamp A290- -7215--X334
grommet A290--7215--X312
Bolt:M6×6 (2pcs)

Inside cable

Fig 8.2 (d) Adjusting cable length

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9

9. COVER OPTION REPLACEMENTMAINTENANCE

COVER OPTION REPLACEMENT

9. COVER OPTION REPLACEMENT

MAINTENANCE

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9.1

REPLACING THE J2
COVER OPTION
(A05B--1210--J401)

Fig. 9.1 shows a method for replacing the J2 cover option.
(Replacement procedure)

1 Remove the three M6×8 button bolts that fasten the J2 cover

(A290--7210--X371), and dismount the J2 cover from the supports.

2 Remove the two M8×16 bolts that fasten the clamp (A290--7210--

X333) and supports (A290--7210--X372 and A290--7210--X373) to
the clamp (A290--7210--X333), and dismount the supports (A290-­7210--X372 and A290--7210--X373).

3 Remove the M8×10 seal bolt that fastens the support (A290--7210--

X374) to the J 2 base (A290--7210--X301), and dismount the support
(A290--7210--X374).

4 Mount the supports and J2 cover by reversingthe procedure. Toreuse

the seal bolt that was removed, wind seal tape around it.

Fig 9.1 Replacing the J2 cover option (ARC Mate 100i/M--6i)

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9. COVER OPTION REPLACEMENTMAINTENANCE

9.2

REPLACING THE J4
COVER OPTION
(A05B--1210--J402)

Fig. 9.2 shows a method for replacing the J4 cover option.
(Replacement procedure)

1 Remove the six M5×8 button bolts that fasten the J4 cover

(A290--7210--X435), and dismount the J4 cover.

2 RemovetheM6×10boltthat fastensthe support (A290--7210--X437)

to the J3 plate, and dismount the support (A290--7210--X437).

3 Remove theM6×10 bolt and the two M5×8 button bolts that fasten

the support (A290--7210--X436), and dismount the support
(A290--7210--X436).

4 Mount the supports and J4 cover by reversing the procedure.

Fig 9.2 Replacing the J4 cover option (ARC Mate 100i/M--6i)