FANUC Robot ARC Mate 100i MODEL B

FANUC Robot M-6i MODEL B

MAINTENANCE MANUAL

B--81545EN/01
B--81545EN/01 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 the specification number of the mechanical
unit.:
Mechanical unit
Model name Abbreviation
specification No.
FANUC Robot ARC Mate 100i
MODEL B A05B--1215--B201
(With J2 and J3--axis brake) ARC Mate 100i
FANUC Robot ARC Mate 100i MODEL B
MODEL B A05B--1215--B601
(With all axes brake)
FANUC Robot M--6i MODEL B
A05B--1215--B202
(With J2 and J3--axis brake)
M 6i MODEL B
M--6i
FANUC Robot M--6i MODEL B
A05B--1215--B602
(With all axes brake)
 PREFACE B--81545EN/01

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

WEIGHT
CONTENTS MODEL TYPE No. DATE
(Without controller)
FANUC Robot ARC Mate 100i
A05B--1215--B201 184 kg
MODEL B (2--axis brake)
FANUC Robot ARC Mate 100i PRINT
A05B--1215--B601 PRINT 138 kg
MODEL B (6--axis brake) PRODUCTION
LETTERS SERIAL
FANUC Robot M--6i MODEL B YEAR AND
A05B--1215--B201 NO. 184 kg
(2--axis brake) MONTH
FANUC Robot M--6i MODEL B
A05B--1215--B601 138 kg
(6--axis brake)
B--81545EN/01 PREFACE

Specification

Item R--2000i/165F
Type Articulated type
Controlled axes 6 axes (J1, J2, J3, J4, J5, J6)
Installation Floor, Upside--dowm (Wall & Angle mount) (Note 1)
Motion range
g J1 axis rotation 340° (5.93rad)
(Maximum speed) 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)
Maximum speed
p 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)
Max. load capacity at wrist 6kg
Max. load capacity on J3 catting 12kg
Allowable load moment at wrist J4 axis 15.7N·m (1.8kgf·m)
J5 axis 9.8N·m (1.0kgf·m)
J6 axis 5.9N·m (0.5kgf·m)
Allowable load inertia at wrist 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)
Drive method Electric servo drive by AC servo motor
Repeatability 0.06mm
Weight of mechanical unit 134kg (2--axis brake type)
138kg (6--axis brake type)
Installation environment Ambient temperature : 0 -- 45°C
Ambient humidity : Normally :75%RH or less
: Short time 95%RH or less
(within 1 month)
(No dew or frost allowed)
Vibration : 0.5G (4.9m/s2) or less

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

Safety handbook B--80687EN Intended readers :

All persons who use FANUC Robot, system designer
All persons who use the FANUC Robot and system de- Topics :
signer must read and understand thoroughly this handbook Safety items for robot system design, operation, maintenance
R--J3i MODEL B controller Setup and Operations Intended readers :
manual Operator, programmer, maintenance person, system designer
Topics :
SPOT TOOL Robot functions, operations, programming, setup, interfaces, alarms
B--81464EN--1 Use :
HANDLING TOOL Robot operation, teaching, system design
B--81464EN--2
ARC TOOL
B--81464EN--3
SEALING TOOL
B--81464EN--4
Maintenance manual Intended readers :
B--81465EN Maintenance person, system designer
Topics :
B--81465EN--1 Installation, connection to peripheral equipment, maintenance
(European Use :
specification) Installation, start--up, connection, maintenance
Mechanical unit Maintenance manual Intended readers :
FANUC Robot ARC Mate Maintenance person, system designer
100i B Topics :
M--6i B Installation, connection to the controller, maintenance
B--81545EN 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 SPECIFICATIONS 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 M1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
6.2 REPLACING THE J1--AXIS REDUCER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
6.3 REPLACING THE J2--AXIS MOTOR M2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
6.4 REPLACING THE J2--AXIS REDUCER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
6.5 REPLACING THE J3--AXIS MOTOR M3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
6.6 REPLACING THE J3--AXIS REDUCER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
TABLE OF CONTENTS B--81545EN/01

6.7 REPLACING THE J4--AXIS MOTOR M4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

6.8 REPLACING THE J4--AXIS GEARBOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
6.9 REPLACING THE J5--AXIS MOTOR M5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
6.10 REPLACING THE J5--AXIS GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
6.11 REPLACING THE J6--AXIS MOTOR 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

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 SYSTEM VARIABLES 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
B--81545EN/01 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
B--81545EN/01 MAINTENANCE 1. CONFIGURATION

1
CONFIGURATION

Fig. 1 shows the configuration of the mechanical unit.

AC servo motor for J4--axis (M4) J3--axis arm

AC servo motor for J5--axis (M5)

AC servo motor for J6--axis (M6)

AC servo motor for J3--axis (M3)
Wrist unit

J3--axis casing

J2--axis arm

AC servo motor for J1--axis (M1)

AC servo motor for J2--axis (M2)

J2--axis base

J1--axis base

Fig 1 Mechanical unit configuration

1. CONFIGURATION MAINTENANCE B--81545EN/01

1.1 Fig. 1.1 shows the J1--axis drive mechanism.

The J1--axis drive mechanism is configured in such a way that the J2--axis
J1--AXIS DRIVE base is rotated by reducing the rotation speed of an AC servo motor with
MECHANISM 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

B--81545EN/01 MAINTENANCE 1. CONFIGURATION

1.2 Fig. 1.2 shows the J2--axis drive mechanism. The J2--axis drive
mechanism is configured in such a way that the J2--axis arm is rotated by
J2--AXIS DRIVE reducing the rotation speed of an AC servo motor with a reducer.
MECHANISM The J2--axis arm is supported on the J2--axis base through the reducer.

J2--axis AC servo motor J2--axis arm

J2--axis base

J2--axis reducer

Fig 1.2 J2--axis drive mechanism

1. CONFIGURATION MAINTENANCE B--81545EN/01

1.3 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
J3--AXIS DRIVE by reducing the rotation speed of an AC servo motor with a reducer.
MECHANISM 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

B--81545EN/01 MAINTENANCE 1. CONFIGURATION

1.4 Fig. 1.4 shows the J4--axis drive mechanism. The J4--axis drive
mechanism is configured in such a way that the J3--axis arm is rotated by
J4--AXIS DRIVE reducing the rotation speed of an AC servo motor with a two--stage gear.
MECHANISM

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 B--81545EN/01

1.5 Fig. 1.5 shows the J5-- and J6--axis drive mechanisms. The J5--axis drive
mechanism is configured in such a way that the J6--axis unit is rotated by
J5-- AND J6--AXIS reducing the rotation speed of an AC servo motor with a three--stage gear.
DRIVE MECHANISMS The J6--axis drive mechanism is configured in such a way that the output
flange is rotated by reducing the rotation speed of an AC servo motor with
a reducer.

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

Output flange

Input gear
Final gear J6--axis reducer
Second gear

Third gear

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

B--81545EN/01 MAINTENANCE 1. CONFIGURATION

1.6 1) Motors
SPECIFICATIONS OF ARC Mate 100i MODEL B
(two--axis, equipped with a brake): A05B--1215--B201
THE MAJOR M--6i MODEL B
MECHANICAL UNIT (two--axis, equipped with a brake): A05B--1215--B202
COMPONENTS Specification Axis Remark

A06B-0223-B005 J1 α 4/4000i

A06B-0223-B605 J2 α 4/4000i Equipped with a brake

A06B-0202-B605 J3 α 1/5000i Equipped with a 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 with a brake

A06B-0223-B605 J2 α 4/4000i Equipped with a brake

A06B-0202-B605 J3 α 1/5000i Equipped with a brake

A06B-0202-B605 J4 α 1/5000i Equipped with a 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 B--81545EN/01

4) Gears
Specification Axis

A290-7215-X511 J5

A290-7215-V501 J5

A290-7215-V502 J5

A290-7215-X514 J5

5) Stoppers
Specification Axis

A290-7215-X241 J1 Note) 330° stopper

A290-7215-X323 J2

A290-7215-X324 J3
B--81545EN/01 MAINTENANCE 2. PREVENTIVE MAINTENANCE

2
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 B--81545EN/01

2.1 Clean and maintain each component of robots during everyday system
operations. At the same time, check the components to see if there is a
DAILY INSPECTION 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 Make a pneumatic pressure

check check, using the three--piece
pneumatic option shown in Fig.
2.1.
If the measured pneumatic pres-
sure does not fall in the range
between 0.5 and 0.7 MPa (5 and
7 kg/cm2), make adjustments,
using the regulator pressure set-
ting handle.

2 Check on the amount of Put the pneumatic pressure sys-

oil mist tem in operation and check the
For amount of oil dripping. If the
machines measured amount of oil dripping
with a does not meet the rating (one
three--piece drop/10 to 20 seconds), make
pneumatic adjustments, using the oil ad-
option justment knob. The oiler be-
comes empty after 10 to 20 days
of normal operation.

3 Check on the amount of Check to see if the amount of oil

oil in the three--piece option is with-
in the rated level shown in Fig.
2.1.

4 Check for leakage from Check to see if a joint or hose

the piping leaks.
If you find a problem, tighten the
joint or replace any defective
component.

5 Whether cables are abnormal See Chapter 8.

Mechanical unit

6 Battery voltage check Make sure that when the power

is turned on, the BLAL alarm has
not been raised. If the BLAL
alarm has been raised, replace
the battery as directed in Sec-
tion 3.3.

7 Whether there is any abnormal vibra- Check that each axis is running
tion, noise, or heat generation in motors smoothly.

8 Whether there is a change to positioning Check to see if there is any dis-

precision placement from the previous
position and there are variations
in the stop position.
B--81545EN/01 MAINTENANCE 2. PREVENTIVE MAINTENANCE

No. Inspection item Inspection procedure

9 Reliable operation of peripheral equip- Check to see if the machine op-

ment erates exactly according to
directions from the robot and pe-
ripheral equipment.

10 Check on the operation of the J2-- and See Section 4.2.

J3--axis brakes.

Oiler’s oil inlet Oiler adjustment knob

Check oiler’s oil level

Oiler
Pressure gauge
Filter Regulator pressure setting handle

Fig 2.1 Three--piece pneumatic option

b) After automatic operation

Once you are finished with automatic operation, bring the robot to its
reference position, and turn it off.
No. Inspection item Inspection procedure

1 Component cleaning Clean and maintain each component. At the

and inspection same time, check the components to see if
there is a crack or break in them.
2. PREVENTIVE MAINTENANCE MAINTENANCE B--81545EN/01

2.2 Inspect the following items at regular intervals of three months. Increase
the locations and the frequency of inspection if the conditions under
QUARTERLY which the robot is used and the environment in which it runs require so.
INSPECTION
No. Inspection item Inspection procedure

1 Loose connector Check that the motor connectors or other con-

nectors are not loose.

2 Loose bolt Check that the cover retaining bolts or external

bolts are not loose.

3 Debris removal Remove any spatter, debris, and dust from the
mechanical unit.
B--81545EN/01 MAINTENANCE 2. PREVENTIVE MAINTENANCE

2.3 Inspect the following item at regular intervals of one year.

YEARLY INSPECTION No. Inspection item Inspection procedure

1 Greasing See Section 3.1.

2. PREVENTIVE MAINTENANCE MAINTENANCE B--81545EN/01

2.4 Perform the following inspection/maintenance item at regular intervals of

one year and half.
ONE-- AND
HALF--YEAR No. Inspection item Inspection procedure

PERIODIC 1 Battery replacement Replace the battery in the mechanical unit.

INSPECTION (See Section 3.3.)
B--81545EN/01 MAINTENANCE 2. PREVENTIVE MAINTENANCE

2.5
THREE--YEAR No. Inspection item Inspection procedure
PERIODIC 1 Grease replacement See Section 3.2.
INSPECTION
2. PREVENTIVE MAINTENANCE MAINTENANCE B--81545EN/01

2.6 You should have the following instruments and tools ready for
maintenance.
MAINTENANCE
TOOLS a) Measuring instruments
Instrument Condition Use

Dial gauge 1/100mm For positioning precision 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
B--81545EN/01 MAINTENANCE 3. PERIODIC MAINTENANCE

3
PERIODIC MAINTENANCE
3. PERIODIC MAINTENANCE MAINTENANCE B--81545EN/01

3.1 When greasing the robot, keep its power turned off.
GREASING 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

Amount
Greasing Specified
No. of Greasing method
point grease
grease

1 J6--axis Mori White 40cc J6--axis grease inlet and out-

reducer RE No.00 let, and attach the supplied
(Specification: grease nipple to the grease in-
A97L-0040-0119) let. After greasing, 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.
B--81545EN/01 MAINTENANCE 3. PERIODIC MAINTENANCE

Low head bolt and seal

washer at the grease outlet
for the J5-axis reducer
Grease nipple at the Low head bolt and seal
grease inlet for the washer at the grease outlet
J4-axis reducer for the J6-axis reducer
Grease nipple at the Low head bolt and seal
grease inlet for the washer at the grease out-
J3-axis reducer let 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
Seal bolt at the
grease outlet for the
J1-axis reducer Grease nipple at the grease inlet
for the J2-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 MAINTENANCE B--81545EN/01

3.2 Follow the procedure stated below to replace the grease in the J1--, J2--,
and J3--axis reducers and the J4-- and J5--axis gearboxes once every three
GREASE years or after 11,520 hours of operation. See Fig. 3.1 for greasing points.
REPLACEMENT 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 the grease nipples at the J1--, J2--, J3--, and J4--axis grease inlets.
Remove the flat--head bolt from the 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
grease nipples. Keep greasing until the new grease pushes out the old
grease and comes out from each grease outlet. Ensure that 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 tape 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 the J4-- and J5--axis
sealing washers to the respective grease inlets and outlets.
Table. 3.2 Grease to be replaced at regular intervals of three years

Specified grease Amount of Robot pos-

grease to be ture when
Kyodo Yushi applied (cc) greased

J1--axis reducer Mori White RE No.00 About 1100 --

(Specification:
J2--axis reducer A98L-0040-0119#2.4KG) About 570 --

J3--axis reducer About 300 --

J4--axis gearbox About 700 --

J5--axis gearbox About 400 J4=+90°

B--81545EN/01 MAINTENANCE 3. PERIODIC MAINTENANCE

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 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.
If you cannot avoid using it, observe a greasing speed of 15
cc/s or lower and a pressure of 75 kgf/cm2 or lower.
4 Be sure to use the specified grease. Otherwise, damage to
reducers or a similar abnormality may occur.
5 Before capping the grease outlets, make sure that a grease
flow from the grease outlet has stopped (the remaining
pressure has been released).
6 Wipe off any grease from the floor and robot completely, so
no one will slip on it.
3. PERIODIC MAINTENANCE MAINTENANCE B--81545EN/01

When replacing or supplying grease, keep the robot in the posture shown
in Fig. 3.2.

Axis Posture

Free

Fig 3.2 Robot posture for greasing

B--81545EN/01 MAINTENANCE 3. PERIODIC MAINTENANCE

3.3 A backup battery is used to keep the reference--position data for each axis
of the robot.
BATTERY The battery needs to be replaced at regular intervals of one year and half.
REPLACEMENT 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 battery into the battery case while paying attention to the
polarity of the battery.
5) Cap the battery case.

Cap

Battery case Battery specifications : A98L--0031--0005

(1.5V size--D 4pcs)

Fig 3.3 Battery replacement

B--81545EN/01 MAINTENANCE 4. TROUBLESHOOTING

4
TROUBLESHOOTING
4. TROUBLESHOOTING MAINTENANCE B--81545EN/01

4.1 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
OVERVIEW 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.
B--81545EN/01 MAINTENANCE 4. TROUBLESHOOTING

4.2 Table 4.2 (a) lists the major troubles in the mechanical unit and their
causes. If you cannot find a cause accurately or do not know what measure
TROUBLES AND to take, please contact FANUC.
CAUSES 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)

Symptom Cause Measure Remark

BZAL alarm issued The voltage of the memory Replace the battery, and per- See Section 3.3.
(battery zero) backup battery has dropped. form simplified mastering. See Section 5.3.

Broken pulse coder signal Replace the cable, and per- See Section 8.2.
cable form simplified mastering. See Section 5.3.

Incorrect positioning Something hit the robot. Correct the taught point.

The robot is not firmly fixed. Fix it. See Section 3.2 of Part II,
“Connection”.

Peripheral equipment has Fix it.

shifted.

Load too heavy Reduce the load. Load on the wrist:

Limit the operating condition. Refer to “Descriptions”.
Peripheral equipment:
See Section 2.2 of Part II,
“Connection”.

Incorrect parameter setting Correct it. Refer to “Operator’s Manual”.

Broken cable Replace the cable. See Section 8.2.

Pulse coder error Replace the motor. See Sections 6.1 to 6.11.

Backlash in the mechanical

unit ---- see the next section.
4. TROUBLESHOOTING MAINTENANCE B--81545EN/01

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

Symptom Cause Measure Remark

Vibration The robot is not firmly fixed. Fix it. See Section 3.2 of Part II,
“Connection”.

The floor is vibrating (espe- Re--examine the location of

cially when the robot is installation.
installed on the second floor
or above).

Load too heavy Reduce the load. Load on the wrist:

Limit the operating condition Refer to “Descriptions”.
Peripheral equipment:
See Section 2.2 of Part II,
“Connection”.

Servo maladjustment Adjust the servo section. Contact FANUC.

Broken cable Replace the cable. See Section 8.2.

Robot not grounded Ground the robot. Refer to “Maintenance Manu-

al for the Controller”.

Defective motor Replace the motor. See Sections 6.1 to 6.11.

Defective axis printed--circuit Replace the axis printed--cir- Refer to “Maintenance Manu-
board cuit board. al for the Controller”.

Defective reducer Replace the reducer. See Sections 6.2 to 6.11.

Invalid time constant setting Change the time constant. Refer to “Operator’s Manual”.

Backlash in the mechanical

unit ---- see the next section.

Backlash or wobbling Loose screw or pin Tighten it (and apply Loctite

to it if specified so)

Defective reducer Replace the reducer. See Sections 6.2 to 6.11.

Gear maladjustment Adjust the gear. See Section 5.7.

Worn gear Adjust or replace the gear. Contact FANUC.

Worn bearing Replace the bearing. Contact FANUC.

Broken casting or other part Replace the broken compo- Contact FANUC.
nent.

Abnormal sound Insufficient grease for gear or Apply grease. See Sections 3.1 and 3.2.
reducer

Foreign matter in gear or re- Wash the gear or reducer and See Sections 6.2 to 6.11, 3.1,
ducer apply grease. and 3.2.

Gear maladjustment Adjust the gear. Contact FANUC.

Worn gear Adjust or replace the gear. Contact FANUC.

Worn bearing Replace the bearing. Contact FANUC.

Servo section maladjustment Adjust the servo section. Contact FANUC.

B--81545EN/01 MAINTENANCE 4. TROUBLESHOOTING

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

Symptom Cause Measure Remark

Abnormal heat generation Insufficient grease for gear or Apply grease. See Sections 3.1 and 3.2.
reducer

Non--specified grease used Replace the grease. See Sections 3.1 and 3.2.

Load too heavy Reduce the load. Load on the wrist:

Limit the operating condition. Refer to “Descriptions”.
Peripheral equipment:
See Section 2.2 of Part II,
“Connection.”

Gear maladjustment Adjust the gear. Contact FANUC.

Invalid time constant setting Change the time constant Refer to “Operator’s Manual”.
setting.

Arm drop at power turn--off Too large a brake gap Replace the motor. See Sections 6.1 to 6.11.

Brake drive relay contact de- Replace the relay Refer to “Maintenance Manu-
position al for the Controller”.

Grease leakage Deteriorated or broken Replace the O--ring, oil seal, Contact FANUC.
O--ring, oil seal, or gasket or gasket.

Broken casting or other part Replace the broken compo- Contact FANUC.
nent.

Loose screw Tighten it.

Table 4.2 (b) Allowable backlash level for each axis

J1 J2 J3 J4 J5 J6

Backlash in term of 2.5 2.5 2.5 3.0 4.5 3.0

angle (min)

Backlash in term of 0.95 0.44 0.44 0.17 0.2 0.17

displacement (mm) (1300) (600) (600) (200) (200) (200)

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 5mm

At emergency stop time 5mm

4. TROUBLESHOOTING MAINTENANCE B--81545EN/01

4.3 Adjustments are needed after a component is replaced.

The following table lists components and the adjustment items that must
COMPONENT be made after their replacement. After replacing a component, make
REPLACEMENT AND necessary adjustments according to this table.
ADJUSTMENT ITEMS Component replacement or
Adjustment item
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 Replace the battery with the power

(The battery should be replaced once kept on.
a year.) No adjustment is needed.
B--81545EN/01 MAINTENANCE 5. ADJUSTMENTS

5
ADJUSTMENTS

Each part of the mechanical units of a robot is set to the best condition
before the robot is shipped to the customer. The customer does not need
to make adjustments on the robot when it is delivered.
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 B--81545EN/01

5.1 1) Reference position and operation limit

REFERENCE Each controlled axis is provided with a reference position and
operation limit.
POSITION AND A state in which a controlled axis has reached its operation limit is
MOVING RANGE 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
encounter a servo section error or system error that causes a reference
position to be lost, the robot is controlled in such 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

Stroke end Stroke end

Mechanical stopper Mechanical stopper

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

Note)Motion limit is restricted by the Stroke

position of the J3--axis

Mechanical Stroke end

stopper

Stroke end
Mechanical stopper

Fig 5.1 (b) J2--axis rotation

B--81545EN/01 MAINTENANCE 5. ADJUSTMENTS

Note)Motion limit is restricted by the

position of the J2--axis Stroke

Stroke end

Mechanical
stopper
Mechanical
stopper

Stroke end

Fig 5.1 (c) J3--axis rotation

Stroke end Stroke end

Note) The mechanical stopper are not provided for J4--axis

Fig 5.1 (d) J4--axis rotation

Stroke end
Mechanical stopper
Stroke

Mechanical stopper
Stroke end

Fig 5.1 (e) J5--axis wrist rotation

5. ADJUSTMENTS MAINTENANCE B--81545EN/01

Stroke end Stroke end

Stroke

Fig 5.1 (f) J6--axis wrist rotation

Mechanical stopper
Stroke end

J3--axis arm

Interference
angle 170°

J2--axis arm
Interference angle 10°

Stroke end
Mechanical stopper

Fig 5.1 (g) J2/J3 limit interference angle

B--81545EN/01 MAINTENANCE 5. ADJUSTMENTS

Fig 5.1 (h) Operation directions of each axis

5. ADJUSTMENTS MAINTENANCE B--81545EN/01

5.2 The term simplified mastering refers to a procedure for resuming the
previous position completely after a pulse coder battery backup is
SIMPLIFIED disconnected because of cable replacement.
MASTERING Simplified mastering cannot be used if the pulse coder phase has changed
mechanically because of a motor or reducer having been replaced. To
calibrate the robot position accurately, perform the jig--based mastering
described in Section 5.4.
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
described in Section 8.2.
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 for each 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). Load the system variable $DMR_GROUP.$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 in the list to 1. Press the F1 key TYPE and
select MASTER / CAL.
10 Select The system calibration menu from the system positioning
menu, and press the FA key YES to perform simplified mastering.
Now the mastering data obtained from the pulse coder counter
value is set in the system variable $DMR_GRP.MASTER_COUN,
and the system variable $DMR_GRP.MASTER_DONE
(mastering completion flag) is set to “TRUE”.
B--81545EN/01 MAINTENANCE 5. ADJUSTMENTS

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
$PARAM_GROUP.$SV_OFF_ENB for each axis to the previous
value, turn off the power, and then perform a cold start.
Once mastering is completed, update the data sheet supplied together with
the robot with the new mastering data ($DMR_GROUP.$MASTER_
COUN[1] to [6]).

J4--axis J5--axis

J6--axis

J3--axis

J2--axis

J1--axis

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

5. ADJUSTMENTS MAINTENANCE B--81545EN/01

5.3 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
MASTERING BY at the zero--degree position. If the markings get misaligned because of
ZERO POSITION motor or reducer replacement, the following procedure can be used for
MARK ALIGNMENT 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_ENB to “FALSE” for all 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 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.
4 By performing an individual--axis feed command for each 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 in the list to 1. Press the F1 key TYPE and
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_
COUN is set with the mastering data obtained from the pulse 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 F4 key YES. Now positioning is carried out, and teaching
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.
Once mastering is completed, update the data sheet supplied together with
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 mastering procedure. New position information for that axis
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.
B--81545EN/01 MAINTENANCE 5. ADJUSTMENTS

2) Procedure (single--axis mastering)

1 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.
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 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.
4 By performing an individual--axis feed command for a desired axis,
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_ENB value in the list to 1. Press the F1 key TYPE, and
select MASTER/CAL.
7 Select SINGLE AXIS MASTER from the system positioning
menu. A setting menu for each axis appears. 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) in 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 F4 key YES. Now positioning is carried out, and teaching
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.
Once mastering is completed, update the data sheet supplied together with
the robot with the new mastering data ($DMR_GROUP.$MASTER_
COUN[1] to [6]).
5. ADJUSTMENTS MAINTENANCE B--81545EN/01

5.4 If the current--position value stored through the pulse coder becomes
different from the actual position of each axis because a major component
JIG--BASED of the mechanical unit of the robot is replaced, mastering is performed by
MASTERING 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 robot is being subjected to mastering, it does not
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), attach mastering jig B to mastering jig
C.

Mastering jig B

Mastering jig C

Bolt : M5×16 (3pcs)

Washer : M5 (3pcs)

Fig 5.4 (a) Assembling the jib base

B--81545EN/01 MAINTENANCE 5. ADJUSTMENTS

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
3.0 mm, and fix the dial gauges with M5 bolts. (Be careful when
tightening the bolts. Tightening them too firmly can break the
dial gauges.)

Calibration block

Dial gauge
(6pcs)
(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

5. ADJUSTMENTS MAINTENANCE B--81545EN/01

iii) Attaching to the robot main body

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

Pin A
Bolt : M12×25 (2pcs)
A290-7215-X955
Pin B Washer : M12 (2pcs)
A290-7215-X956

J1 base

Fig 5.4 (c) Attaching to the robot main body

B--81545EN/01 MAINTENANCE 5. ADJUSTMENTS

iv) Attaching the jig to the wrist

Manually move the wrist 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
described in Section 5.3.
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 then select
SYSTEM from the menu. Press the F1 key TYPE, and select
the system variable. For $DMR_GROUP.$MASTER_DONE
(simplified mastering completion flag), 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 B--81545EN/01

Mastering posture

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
the system variable. In the list, 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 the mastering data obtained
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 Once you are finished with mastering, reset the system variable
$MASTER_ENB value to 0.
9 To enable brake control, re--set the $PARARM_GROUP.$SV_
OFF_ENB to the previous value for all axes, turn off the power,
and perform a cold start.
B--81545EN/01 MAINTENANCE 5. ADJUSTMENTS

Once mastering is completed, update the data sheet supplied together with
the robot with the new mastering data ($DMR_GROUP.$MASTER_
COUN[1] to [6]).
If you want to perform mastering for a specific axis, take note of the value
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 B--81545EN/01

5.5 1) Confirming that mastering was performed normally

CONFIRMING Usually, positioning is performed automatically when the power is
turned on. To confirm that mastering was performed normally, check
MASTERING 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 raised if the voltage of the pulse coder backup battery
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
check whether the current--position data is correct, using a method
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.
B--81545EN/01 MAINTENANCE 5. ADJUSTMENTS

5.6 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
J5--AXIS GEAR adjustments, using this procedure. (See Fig. 5.6.)
BACKLASH 1 Place the robot in a posture of J4 = +90° and J5 = J6 = 0°.
ADJUSTMENTS 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)
Gear 2 assembly
Loctite
Gear 3 assembly
Seal bolt with washer :
M5×12 (4pcs)
Seal bolt with washer :M5×12 (6pcs)
Plane washer (4pcs)
Low head bolt : M5×10 (9pcs)
Cover J5--1

Reference bolt
(Do not remove the bolt. Just loosen it.
Be sure to replace it with a new one after
adjustments are 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
gear 2 assembly (A290--7215--V501) to such a point that it will not
be engaged with the gear 3 assembly (A290--7215--V502).
5. ADJUSTMENTS MAINTENANCE B--81545EN/01

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, loosening it impairs its ability to seal. 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.
After you have fixed the gear 3 assembly temporarily, rotate the J6
housing (output gear) in both positive and negative 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 Once you have completed adjustments, fix the J3 arm with 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 the gear 2 assembly to the J3 arm with four
M5×12 seal bolts with a washer.
2 Rotate the gear 2 assembly, and check the operation of the J5--axis
by operating it within its stroke (--140° to +140°). Repeat step 1
for reducing the backlash until the gears will not interfere with each
other.
Fix the gear 2 assembly temporarily in the same manner as stated
in (1). Once you have completed adjustments, mount the assembly
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 specified grease to the J5--axis gearbox by following the
grease replacement procedure stated in Section 3.2.
6 Perform mastering as stated in Sections 5.3 and 5.4.
B--81545EN/01 MAINTENANCE 5. ADJUSTMENTS

5.7 When the robot power is off, the brakes of the robot can be released using
the brake release unit (option). In this case, the robot can be put in a
BRAKE RELEASE different posture. Observe Notes 1 to 4 given below.

NOTE
1 When releasing the brakes of the J2--axis or J3--axis motor
(M2 or M3), suspend the robot with a crane as shown in Fig.
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 B--81545EN/01

Fig 5.7 Releasing the brakes of the J2--axis motor

 6. COMPONENT REPLACEMENT AND
B--81545EN/01 MAINTENANCE ADJUSTMENTS

6
COMPONENT REPLACEMENT AND ADJUSTMENTS

Adjustments are needed after a component is replaced.

The following table lists components and the adjustment items that must
be made after the components are replaced. After replacing a component,
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 very careful when dismounting and mounting 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 31kg

Fig. 6.6.)

All components from J2--axis arm to wrist unit (See Fig. 38.7kg
6.4. (a).)

All components from J2--axis base to wrist unit (See 69.4kg

Fig. 6.2 (a) and (b).)
6 COMPONENT REPLACEMENT
AND ADJUSTMENTS MAINTENANCE B--81545EN/01

6.1
REPLACING THE 1 Turn off the controller power.
J1--AXIS MOTOR M1 2 Remove the J1--axis motor connector.
3 Remove the four M8×20 motor mounting bolts. Dismount the motor
from the J1--axis unit. When dismounting the motor, be careful of the
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 nut from the motor shaft, and pull out the
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 equipped with 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 specified torque
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.

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.
 6. COMPONENT REPLACEMENT AND
B--81545EN/01 MAINTENANCE ADJUSTMENTS

Bolt : M8×20 (4pcs)

Washer : M8 (4pcs)

J1--axis motor

Gear

M10 Screw washer

M10 hex agonal nut

Loctite

O--ring

J2 base

Fig 6.1 Replacing the J1--axis motor

6 COMPONENT REPLACEMENT
AND ADJUSTMENTS MAINTENANCE B--81545EN/01

6.2
REPLACING THE 1 Put the robot in such a posture that the J2 base and the portions above
it can be suspended with a crane or the like (hereafter abbreviated as
J1--AXIS REDUCER 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 As shown in Fig. 6.2 (b), remove the four M4×10 bolts that fasten the
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
reducer to a new J1 base with 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 motor 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.
 6. COMPONENT REPLACEMENT AND
B--81545EN/01 MAINTENANCE ADJUSTMENTS

J1--axis motor
Bolt : M10X50 (8pcs)
Loctite

Washer : M10 (8pcs)

O--ring

Bearing
Bolt : M12×80 (6pcs) O--ring
Loctite

Washer : M12 (6pcs) Center gear

J1--axis reducer

O--ring

O--ring

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

J1 reducer

O--ring

Pipe

Bolt (4pcs)
Washer (4pcs)
Fig 6.2 (b) Replacing the J1--axis reducer
6 COMPONENT REPLACEMENT
AND ADJUSTMENTS MAINTENANCE B--81545EN/01

6.3
REPLACING THE 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
J2--AXIS MOTOR M2 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 the input 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 draw bolt 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 (if the spline is engaged correctly, 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.
 6. COMPONENT REPLACEMENT AND
B--81545EN/01 MAINTENANCE ADJUSTMENTS

Draw bolt
Loctite

Input spline

M6 Spring washer

J2--axis motor M6 nut

Loctite

O--ring

Bolt : M8×20 (4pcs)

Washer : M8 (4pcs)

J2 base

Fig 6.3 Replacing the J2--axis motor

6 COMPONENT REPLACEMENT
AND ADJUSTMENTS MAINTENANCE B--81545EN/01

6.4
REPLACING THE 1 Put the robot in such a posture that the J2 arm (A290--7215--X302) and
the components on it can be suspended with a crane, and then turn off
J2--AXIS REDUCER the controller power.
2 Suspend the J2 arm and the components on it with a crane so that they
will not drop when the J2 arm is dismounted.
3 As shown in Fig. 6.4 (a), remove the ten M10×50 bolts that fasten the
J2 arm, dismount the J2 arm and plate (A290--7215--X321) from the
J2--axis reducer, and then dismount adapter 1 (A290--7210--X321). Be
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 attaching adapter 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.
 6. COMPONENT REPLACEMENT AND
B--81545EN/01 MAINTENANCE ADJUSTMENTS

Adapter

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 B--81545EN/01

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 the surface completely with a cloth dampened
with solvent. Do not spray solvent directly onto the
surface.
3) Wipe off any solvent from the surface with a dry cloth.
Make sure that no solvent is left in the tap or on any other
portion.
4) Always use a new surface of a cloth so that the grease
once wiped up with the cloth will not get on the degreased
surface.
2 Allowing time during which the sealant can cure
To let the applied sealant cure, avoid running the 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.
 6. COMPONENT REPLACEMENT AND
B--81545EN/01 MAINTENANCE ADJUSTMENTS

6.5
REPLACING THE 1 Push the J3--axis section to the mechanical stopper, or fix it in such a
way that it will not swivel when the motor is dismounted, for example,
J3--AXIS MOTOR M3 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
is a danger that J3--axis section will swivel when the J3--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 four M6×14 bolts that fasten the J3--axis motor to the J3
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 Attach a new gasket (A98L--0040--0042#03), and insert the motor into
the reducer. Keep the J3--axis degrease outlet on the J2 arm side open
(see Fig. 3.1), and look into the outlet to make sure that the input spline
has settled in the correct place. Even one teeth of a shift in engagement
can cause vibration. (If the input spline is engaged correctly, the motor
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 to 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 MAINTENANCE B--81545EN/01

Packing

J3--axis motor

M5 nut
Loctite

M5 Spring washer

Input gear

Draw bolt
Loctite
J3--axis casing
Bolt : M6×14 (4pcs)
Washer : M6 (4pcs)

Fig 6.5 Replacing the J3--axis motor

 6. COMPONENT REPLACEMENT AND
B--81545EN/01 MAINTENANCE ADJUSTMENTS

6.6
REPLACING THE 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
J3--AXIS REDUCER controller power.
2 While referencing Section 8.2, remove the cable from the J2 arm
section.
Suspend the J3--axis section and the components on it with a crane so
that they will not drop when the reducer is dismounted from the J2 arm.
Be careful not to allow an excessive load to be put on the cable
(because the cables are left 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 the J3--axis reducer from the J3
casing, and remove the O--ring from the J3--axis reducer.
6 Attach an O--ring (SO120) to a new reducer (A97L--0218--0295#161),
mount the reducer on the J3 casing, and fasten them with ten M6×30
bolts (by applying Loctite 262 and tightening with a torque of [15.7
Nm]).
7 While referencing Section 6.5, mount the J3--axis motor on the J3 arm
unit.
8 Remove the O--ring from the J2 arm, degrease both the J2 arm and the
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--axis section and the 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 Section 8.2, dress the cable into the previous form.
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 MAINTENANCE B--81545EN/01

Bolt : M10×45 (6pcs)

Loctite

Washer : M10 (6pcs) J3 casing

Plate

Adapter

O--ring

Packing

O--ring

J3--axis reducer J3--axis motor

Bolt : M6×30 (10pcs)

Loctite

Washer : M6 (10pcs)

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

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

 6. COMPONENT REPLACEMENT AND
B--81545EN/01 MAINTENANCE ADJUSTMENTS

6.7
REPLACING THE 1 Place the robot in a posture of J4 = --90°. Keep this condition until step
<10> (mastering). Note that if the operation for setting the
J4--AXIS MOTOR M4 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 motor to the J3 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
and M5 spring washer.
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)), apply Loctite 242 to the threaded portion of the
motor shaft, and fasten them with a nut (A290--7215--X412) by
tightening with a torque of [9 Nm]. (Be very careful when tightening
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 where the 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.
Gear J4--1

M5 Spring washer

J4--axis motor Nut

Loctite

Bolt : M6×14 (3pcs)

Washer : (3pcs)

O--ring

J3 casing

Fig 6.7 Replacing the J4--axis motor

6 COMPONENT REPLACEMENT
AND ADJUSTMENTS MAINTENANCE B--81545EN/01

6.8
REPLACING THE 1 Turn off the controller power.
J4--AXIS GEARBOX 2 According to Section 8.2, remove the cables that run from the
J3--/J4--axis motor connectors through the clamps on the J3 casing and
in the J3 arm to the J6--axis motor in the J6 housing, and take them out
from the J3 arm unit.
3 Suspend the J3 arm through an M6 eye bolt with a crane. Remove the
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) through an M6 eyebolt with a crane. Remove the
six M10×45 bolts that fasten the J4 gearbox unit to 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 According to the procedures described in Sections 6.6 and 6.7, 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 M10×45
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 casing to the J6--axis motor in the J6 housing through the clamp
in the J3 arm into the previous form. Attach the J3 and J4--axis motor
connectors.
11 According to Section 3.2, supply the J3-- and J4--axis grease baths with
the specified grease.
12 While referencing Chapter 5, perform mastering.
 6. COMPONENT REPLACEMENT AND
B--81545EN/01 MAINTENANCE 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 MAINTENANCE B--81545EN/01

6.9
REPLACING THE 1 Place the robot in a posture of J4 = --90°.
J5--AXIS MOTOR M5 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 the J5--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 new key (JB--HKY--3×3×8A) to a new motor (with two axes
equipped with a brake (A06B--0115--B075#0008) or six axes equipped
with a brake (A06B--0115--B275#0008)) with Loctite 675, mount the
J5--1 gear, and fasten them with setscrews M3×4 (by applying Loctite
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 the motor flange with
Alvania grease, fasten the motor to the J3 arm 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 four M6×16 bolts (by applying Loctite 242 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.
 6. COMPONENT REPLACEMENT AND
B--81545EN/01 MAINTENANCE ADJUSTMENTS

Cover J5--2

Fixing bolt : M6×16 (4pcs)

Loctite
Connector of cable relay
Washer : M6 (4pcs)

Clamp in J3 arm

Seal bolt with washer : M5×12 (4pcs)

J5--axis motor
Leads attached
to the motor
key

Loctite
Set screw : M3×4 (2pcs)
Gear
Loctite
Packing

Fig 6.9 Replacing the J5--axis motor

6 COMPONENT REPLACEMENT
AND ADJUSTMENTS MAINTENANCE B--81545EN/01

6.10
REPLACING THE 1 To replace the J5--1 gear, follow the motor replacement procedure
stated in Section 6.9.
J5--AXIS GEAR
2 Place the robot in a posture of J4 = +90° and J5 = 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 four M5×12 seal bolts with a washer 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.
 6. COMPONENT REPLACEMENT AND
B--81545EN/01 MAINTENANCE ADJUSTMENTS

J3 arm

Gear

Bolt with washer (6pcs)

Gear2 assembly Loctite 262
Gear 3 assembly
Seal bolt with washer (4pcs)
Seal bolt with washer
Plane washer (4pcs)
Low head bolt (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
adjustments are completed.)
Fig 6.10 Replacing the J5--axis gear
6 COMPONENT REPLACEMENT
AND ADJUSTMENTS MAINTENANCE B--81545EN/01

6.11
REPLACING THE 1) Replacing the J6--axis motor M6
J6--AXIS MOTOR M6 1 Place the robot in a posture of J4 = --90° and J5 = 0°.
AND REDUCER 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) in the cover, and release the J5--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
fasten the J6 motor connector to the J6 clamp (A290--7215--X534),
and dismount the clamp from the wrist flange.
6 Remove the four M5×12 bolts with a washer that fasten 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]. (Do not forget to insert washers [A290--7215--X532].) Also
apply a plenty of grease (Mori White RE 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 the 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
flange equipped with the motor to the J6 housing with four M5×25
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.
 6. COMPONENT REPLACEMENT AND
B--81545EN/01 MAINTENANCE 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 described in Section 3.2, supply the J6--axis grease bath with the
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 Remove the four M5×12 bolts with a washer that fasten 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 that 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 fasten a
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 flex spline from the cross--roller ring. Position a 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 tightening a torque of
[2 Nm]).
6 COMPONENT REPLACEMENT
AND ADJUSTMENTS MAINTENANCE B--81545EN/01

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

Fixing bolt : M3×6 (2pcs)

Packing
Packing

Ware generator
Wrist flange

Washer

J6 housing
Bolt : M3×8
Loctite
Pin
Washer : M3
Bolt : M5×25 (4pcs)
Loctite

Washer : M5 (4pcs)

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

 6. COMPONENT REPLACEMENT AND
B--81545EN/01 MAINTENANCE ADJUSTMENTS

Bolt with washer : M5×12 (6pcs)

O--ring
Loctite
Ring
Flange
Adapter
Wave generator
Flex spline

Circular spline Cross roler ring

Packing
Adapter

Washer

Bolt with washer : M3×40 (8pcs)

Bolt : M3×8
Loctite
Loctite

Washer : M3 Packing Straight pin (2pcs)

Bolt with washer: M3×15 (12pcs)

Loctite

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

B--81545EN/01 MAINTENANCE 7. PIPING AND WIRING

7
PIPING AND WIRING
7. PIPING AND WIRING MAINTENANCE B--81545EN/01

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

Panel union
Rc 3/8 Female

Panel union
Rc 3/8 Male

Fig 7.1 Piping diagram

B--81545EN/01 MAINTENANCE 7. PIPING AND WIRING

7.2 Fig. 7.2 (a) and Fig. 7.2 (b) show the diagrams of wiring in the mechanical
unit.
WIRING DIAGRAMS

Controller Mechanical unit

J1--axis connector board J1--axis motor J2--axis motor J3--axis motor

J4--axis motor

J5--axis motor

J6--axis motor

K102 : 5 pin
K103 : 24 pin
Earth Battery
End effector
Panel union
Air Panel union
Famale Rc 3/8
Famale Rc 3/8

J3--axis casing
connector board

Fig 7.2 (a) Wiring in the mechanical unit with two axes equipped with a brake
7. PIPING AND WIRING MAINTENANCE B--81545EN/01

Controller Mechanical unit

J1--axis connector panel J1--axis motor J2--axis motor J3--axis motor

J4--axis motor

J5--axis motor

J6--axis motor

K105 : 5 pin
K106 : 24 pin
Earth Battery
End effector
Panel union
Air Panel union
Famale Rc 3/8
Famale Rc 3/8

J3--axis casing
connector panel

Fig 7.2 (b) Wiring in the mechanical unit with all axes equipped with a brake
B--81545EN/01 MAINTENANCE 7. PIPING AND WIRING

7.3 Make the following visual checks to see if there is any abnormal cable.
CABLE MOUNTING 1) Whether the swiveling motion of the robot has caused any local torsion
or bending in the swiveling section.
DIAGRAM
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

B--81545EN/01 MAINTENANCE 8. CABLE REPLACEMENT

8
CABLE REPLACEMENT

Replace the cables of the robot once every four years. If a cable is broken
or damaged, replace it according to the procedure described in this
chapter.

Cautions in handling the When transporting, installing, or maintaining the robot, do not detach the
pulse coder cable pulse coder cables carelessly. The cables are provided with the marking
tie shown below. If you detached any cable with the marking tie, you need
to perform mastering for the robot.
Do not detach any connector unless you replace a motor, pulse coder,
reducer, or cable.

Fig 8 Marking tie

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 the absolute position of the robot 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 simplified mastering to calibrate the robot into the previous
absolute position.
8. CABLE REPLACEMENT MAINTENANCE B--81545EN/01

8.1 After a cable is replaced individually rather than in kit, clamp it with
rubber bushings and nylon ties (cable ties) at the specified positions listed
CABLE DRESSING in Table 8.1. Otherwise, the cable may sag or become too tight, leading
to a break in the cable.
B--81545EN/01 MAINTENANCE 8. CABLE REPLACEMENT

Table 8.1 Cable clamp positions

Mark Cable clamping position Mark No.

8. CABLE REPLACEMENT MAINTENANCE B--81545EN/01

8.2 First, place the robot in a posture of the J4--axis being at --90° and all other
axes being at 0°. Before starting cable replacement, put the controller
REPLACING CABLES apart from the robot main body.
1) Replacing the cable kit
1 Cut the nylon ties (cable ties) for the J2--/J3--axis Cornex 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 tie that bounds the rubber boot, and detach the rubber
boot from the cable. Separate the RM1 and RP1 connector inserts
from the connector housing on the J1 connector 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 the 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
fasten the plate (A290--7215--X222) in the J1 base, and pull out the
cable from the inside of the J1 base toward the upper section of the
J1 hollow pipe section. The connector inserts mentioned in <3>
tend to get caught inside the pipe. Do not force it out from the pipe.
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 While referencing Section 6.11, dismount the J5--2 cover and wrist
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.
Loosen the nut for the resin bushing that fastens the plate, 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
the J5--1 clamp (A290--7215--X525), and dismount the J5--1 clamp
from the J3 arm, and pull it out. Then, cut the nylon ties (cable ties),
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
fasten the plate (A290--7215--X426) on the J3 casing, and dismount
the cable kit completely from the robot main body.
B--81545EN/01 MAINTENANCE 8. CABLE REPLACEMENT

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) behind the J3 casing. After passing 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 the support (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 making sure that the non--bound twisted pairs are not twisted
in the J5--axis hollow section or not caught in the J6 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 fastened to the inside of the J3 arm securely,
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 are not caught under the J5--2
cover when it is attached. (If it is likely that a non--bound cable
portion may be 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 resin bushing on the 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 the 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.
Before mounting the J1 connector board to the J1 base, push the OT
jumper connector into the rubber boot, and bind the opening of the
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 MAINTENANCE B--81545EN/01

2) Replacing the cables separately

1 While referencing item (1) of Section 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 the cable kit, and replace the cables. After cable replacement,
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
Section 8.2.) Arrange the cables inside and outside the J2--/J3--axis
movable section by shifting the wires so that they are at regular
intervals and look natural. After their length is adjusted, tighten the
mounting bolts for the grommet retaining clamp.
4 Mount the Cornex cover as before. (Tight the nylon tie but not
firmly.)

Connector insert
(PM1, RP1)
Rubber boot

Connector
housing J1 hollow pipe
Bolt : M4×10
(8pcs)

J1 connector
board
Plate
A290--7215--X222
Bolt : M6×6 (2pcs)

Fig 8.2 (a) Replacing the cable kit

B--81545EN/01 MAINTENANCE 8. CABLE REPLACEMENT

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

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

Cable kit

Bolt : M8×10 (4pcs) Cable cover

Bolt : M6×10 (2pcs)

Plate
A290--7215--X331 J2 base
Bolt : M8×10 (2pcs)

Fig 8.2 (b) Replacing the cable kit

Cover J5--2
Bolt : M6×16 (4pcs) Clamp J5--2
Packing Washer : M6 (4pcs) A290--7215--X531
A290--7215--X527 Seal bolt : M4×6 (2pcs)

Support
A290--7215--X529

Clamp J5--1 Clamp--to--clamp distance : 160 mm

A290--7215--X525
Bolt : M5×10 (2pcs) Note) Before putting on the J5--2
cover, make sure that twisted--pair Wrist flange unit
wires do not cross one another.

Clamp J6
A290--7215--X534
Bolt : M3×6 (2pcs)

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

8. CABLE REPLACEMENT MAINTENANCE B--81545EN/01

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

Inside cable

Outside cable

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

Fig 8.2 (d) Adjusting cable length

B--81545EN/01 MAINTENANCE 9. COVER OPTION REPLACEMENT

9
COVER OPTION REPLACEMENT
9. COVER OPTION REPLACEMENT MAINTENANCE B--81545EN/01

9.1 Fig. 9.1 shows a method for replacing the J2 cover option.
REPLACING THE J2 (Replacement procedure)
COVER OPTION 1 Remove the three M6×8 button bolts that fasten the J2 cover
(A05B--1210--J401) (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 J2 base (A290--7210--X301), and dismount the support
(A290--7210--X374).
4 Mount the supports and J2 cover by reversing the procedure. To reuse
the seal bolt that was removed, wind seal tape around it.

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

B--81545EN/01 MAINTENANCE 9. COVER OPTION REPLACEMENT

9.2 Fig. 9.2 shows a method for replacing the J4 cover option.
REPLACING THE J4 (Replacement procedure)
COVER OPTION 1 Remove the six M5×8 button bolts that fasten the J4 cover
(A05B--1210--J402) (A290--7210--X435), and dismount the J4 cover.
2 Remove the M6×10 bolt that fastens the support (A290--7210--X437)
to the J3 plate, and dismount the support (A290--7210--X437).
3 Remove the M6×10 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)

 10. M--6i PACKAGES WITH REINFORCED
DUST--PROOF AND DRIP--PROOF
B--81545EN/01 MAINTENANCE CHARACTERISTICS

M--6i PACKAGES WITH REINFORCED DUST--PROOF

10 AND DRIP--PROOF CHARACTERISTICS

The M--6i packages with reinforced dust--proof and drip--proof

characteristics have been reinforced for dust--proof and drip--proof
characteristics so that they enable the robot to withstand harsh
environments. They are also rust--proof so that the robot can be used for
a long period.
Specifications
M--6i mechanical unit
(with two axes equipped with a brake): A05B--1210--B202
M--6i mechanical unit
(with six axes equipped with a brake): A05B--1210--B602

NOTE
The packages with reinforced dust--proof and drip--proof
characteristics are available only for the M--6i; they are
unavailable for the ARC Mate 100i.
10. M--6i PACKAGES WITH REINFORCED
DUST--PROOF AND DRIP--PROOF
CHARACTERISTICS MAINTENANCE B--81545EN/01

10.1 The following table lists the dust--proof and drip--proof performance of
the M--6i packages with reinforced dust--proof and drip--proof
DUST--PROOF AND characteristics according to JIS C0920.
DRIP--PROOF
Packages with reinforced dust--proof
PERFORMANCE OF and drip--proof characteristics
THE PACKAGES
Wrist section and J3 arm section IP67
WITH REINFORCED
DUST--PROOF AND Main body IP55

DRIP--PROOF
CHARACTERISTICS

Fig 10.1 Dust--proof and drip--proof performance of the M--6i packages

with reinforced dust--proof and drip--proof characteristics
 10. M--6i PACKAGES WITH REINFORCED
DUST--PROOF AND DRIP--PROOF
B--81545EN/01 MAINTENANCE CHARACTERISTICS

10.2 The following table lists the major differences between the M--6i standard
specification and the M--6i packages with reinforced dust--proof and
CONFIGURATION OF drip--proof characteristics.
THE PACKAGES
Package with reinforced
WITH REINFORCED Standard specification dust--proof and drip--proof
DUST--PROOF AND characteristics

DRIP--PROOF Coating Polyurethane enamel coating Polyurethane enamel coating

CHARACTERISTICS or melamine enamel coating

Bolt and washer Blackened steel bolt FR--coated bolt

Blackened washer Stainless bolt
Black chromated washer

Cover J1 cover
J2 cover
J4 cover
Battery box cover

EE connector Non--waterproof connector Waterproof connector

Others Sealing gasket for the

connector box
Sealed tap
Rust--proof grease coating
10. M--6i PACKAGES WITH REINFORCED
DUST--PROOF AND DRIP--PROOF
CHARACTERISTICS MAINTENANCE B--81545EN/01

Fig 10.2 Configuration of the package with reinforced dust--proof and drip--proof characteristics
 10. M--6i PACKAGES WITH REINFORCED
DUST--PROOF AND DRIP--PROOF
B--81545EN/01 MAINTENANCE CHARACTERISTICS

10.3
CAUTIONS IN 1) The following fluids can deteriorate or corrode the rubber components
(such as gaskets, oil--seals, and O--rings) of the robot. So the packages
SELECTING THE with reinforced dust--proof and drip--proof characteristics cannot be
PACKAGES WITH used in environments with these fluids.
REINFORCED a) Organic solvent
DUST--PROOF AND b) Chlorine or gasoline coolant
DRIP--PROOF c) Corrosive fluids (such as acid and alkaline), and fluids or solutions
CHARACTERISTICS that can cause rust
d) Any other fluid or solution to which nitrile rubber (NBR) is not
resistant
2) When the robot is used in an environment where water or any other
fluid splashes onto the robot, be sure to drain under the J1 base. A
trouble can occur if the J1 base is kept in fluid constantly.
10. M--6i PACKAGES WITH REINFORCED
DUST--PROOF AND DRIP--PROOF
CHARACTERISTICS MAINTENANCE B--81545EN/01

10.4
REPLACING THE 1) Replacing the J1 cover
COMPONENTS OF 1 Cut the nylon tie that fastens Cornex motor cover 6
(A290--7210--X288), and dismount motor cover 6.
THE PACKAGES
2 Remove the ten M6×10SUS bolts that fasten motor cover 3
WITH REINFORCED (A290--7210--X285), and dismount motor cover 3.
DUST--PROOF AND 3 Dismount the connector box from the J1 base.
DRIP--PROOF 4 Remove the M6×10SUS bolt that fastens motor cover 4
CHARACTERISTICS (A290--7210--X286) and motor cover 5 (A290--7210--X287), and
the one that fastens motor cover 1 (A290--7210--X283) and motor
cover 5 (A290--7210--X287).
5 Dismount motor covers 4 and 5 from motor cover 2
(A290--7210--X284).
6 By reversing the procedure, mount motor covers 1 to 6 and the
connector box.

Fig 10.4 (a) Replacing the J1 cover

2) Replacing the J2 cover

Replace the J2 cover according to Section 9.1.
3) Replacing the J4 cover
Replace the J4 cover according to Section 9.2.
4) Replacing the battery
1 Turn off the robot power by pressing the EMERGENCY STOP
button to disable the robot from moving.
2 Remove the five M8×12SUS bolts that fasten cover 1
(A290--7210--X280/A290--7210--X282).
3 Uncap the battery case, and take out the battery.
4 Insert a new battery into the battery case while pay attention to the
polarity of the battery.
5 By reversing the procedure, cap the battery case, and attach cover 1.
 10. M--6i PACKAGES WITH REINFORCED
DUST--PROOF AND DRIP--PROOF
B--81545EN/01 MAINTENANCE CHARACTERISTICS

Fig 10.4 (b) Replacing the battery

5) Replacing the K101 cable
1 Remove all connectors from the connector box.
2 Remove the J2 cover according to Section 9.1.
3 Remove the J4 cover according to Section 9.2.
4 While referencing Fig. 10.4 (c), remove the five M8×12SUS bolts
that fasten cover 1 (A290--7210--X280/A290--7210--X282) and
cover 2 (A290--7210--X281).
5 Uncap the battery case, and remove the two screws
(A6--SSA--4X10S) that fasten the battery case to cover 2.
6 Remove the GB1 crimp terminals of the K101 cable
(A660--8012--T043/A660--8012--T044) from the battery case.
7 Remove the uniseal of the K101 cable from cover 2, and pull out
the K101 cable from cover 2.
8 According to 3 and below in Section 8.2, replace the K101 cable.
The J1 cover need not be removed.

Fig 10.4 (c) Replacing the K101 cable (M--6i package with reinforced dust--proof and drip--proof characteristics)
II. CONNECTION
 1. ROBOT OUTLINE DRAWING AND
B--81545EN/01 CONNECTION OPERATION AREA DIAGRAM

ROBOT OUTLINE DRAWING AND OPERATION AREA

1 DIAGRAM
1. ROBOT OUTLINE DRAWING AND
OPERATION AREA DIAGRAM CONNECTION B--81545EN/01

1.1 Fig. 1.1 (a) shows the outline drawing and operation area diagram of a
robot with a separate controller.
OUTLINE DRAWING When installing a peripheral device, be careful not to let it interfere with
AND OPERATION the robot main body. While referencing Section 3.2, use 4--φ18 through
AREA DIAGRAM holes in the base to install the peripheral device.
Fig. 1.1 (b) and (c) show the operation diagrams of the robot.

Motion range of
J5--axis rotation center

J5--axis rotation center

Fig 1.1 (a) Outline drawing and operation area diagram of a robot with a separate controller
 1. ROBOT OUTLINE DRAWING AND
B--81545EN/01 CONNECTION OPERATION AREA DIAGRAM

Fig 1.1 (b) Operation diagram of a robot with a separate controller (No. 1)
1. ROBOT OUTLINE DRAWING AND
OPERATION AREA DIAGRAM CONNECTION B--81545EN/01

Fig 1.1 (c) Operation diagram of a robot with a separate controller (No. 2)
 2. MOUNTING DEVICES
B--81545EN/01 CONNECTION ON THE ROBOT

2
MOUNTING DEVICES ON THE ROBOT
2. MOUNTING DEVICES
ON THE ROBOT CONNECTION B--81545EN/01

2.1
WRIST SECTION END 1) Mounting surface for an ISO flange--type end effector (standard)
EFFECTOR Fig. 2.1 (a) sows the end effector mounting surface at the tip of the
wrist. The end effector is engaged using a φ50h7 spigot or φ25H7
MOUNTING socket, positioned using a 1--φ6H8 reamed hole, and fastened using
SURFACE four M6 self--tapping screws. As for the M6 self--tapping screws,
select those not longer than the tapping depth (10 mm).

depth
on pitch

Depth
equally spaced on
circumference
Fig 2.1 Mounting surface for the ISO flange type end effector
 2. MOUNTING DEVICES
B--81545EN/01 CONNECTION ON THE ROBOT

2.2 As shown in Fig. 2.2 (a), there are two device mounting surfaces.
DEVICE MOUNTING
NOTE
SURFACES 1 Keep the gravity center of devices mounted on device
mounting surfaces A and B within the area shown by
hatching in Fig. 2.2 (b).
2 The mass of each device mounted on a device mounting
surface shall satisfy the following condition:
1) W + A + B ≦ 18 (kg)
where W : Mass (kg) of the device on the end effector
mounting surface
A : Mass (kg) of the device on device
mounting surface A
B : Mass (kg) of the device on device
mounting surface B

J4--axis rotation
center

J3--axis rotation Depth

center 10

Equipment mounting face A

Depth
J3--axis rotation 10
center

Equipment mounting face B

Fig 2.2 (a) Device mounting surface dimensions

2. MOUNTING DEVICES
ON THE ROBOT CONNECTION B--81545EN/01

Equipment mounting face A

Equipment mounting face B

Fig 2.2 (b) Dimensions of the gravity center position of the device on the device mounting surfaces
 2. MOUNTING DEVICES
B--81545EN/01 CONNECTION ON THE ROBOT

2.3 Setting up appropriately the load conditions, such as mass, moment, and
inertia, of the wrist section and hand mounted on the J3--axis arm of a
SETTING THE robot enables effective use of the robot.
SYSTEM VARIABLES
FOR
SHORTEST--TIME
CONTROL

Wrist axis load moment Load the following system variables with the wrist section load moment
represented using an integer (kgf--m).
[Input examples]
$PARAM_GROUP.$AXISMOMENT[4]: 160 (J4--axis load moment)
$PARAM_GROUP.$AXISMOMENT[5]: 100 (J5--axis load moment)
$PARAM_GROUP.$AXISMOMENT[6]: 60 (J6--axis load moment)

Wrist axis load inertia Load the following system variables with the wrist section load inertia
represented using an integer (kgf--cm--s2).
[Input examples]
$PARAM_GROUP.$AXISINERTIA[4]: 640 (J4--axis load inertia)
$PARAM_GROUP.$AXISINERTIA[5]: 220 (J5--axis load inertia)
$PARAM_GROUP.$AXISINERTIA[6]: 62 (J6--axis load inertia)

Mass of the loads Load the following system variable with the mass of the loads mounted
mounted on the J3--axis on the J3--axis arm and J2--axis base represented using an integer (kg)
arm and J2--axis base [Input examples]
$PARAM_GROUP.$ARM_LOAD[1] : 12.25 (mass of the load on the
J3--axis arm)
$PARAM_GROUP.$ARM_LOAD[2] : 0 (mass of the load on the
J2--axis base)

Operation performance The operation performance screens include the list screen, load setting
screens screen, and device setting screen. These screens are used to set up
information about loads and that about devices on the robot.
1 Press the screen selection key to display the screen menu.
2 Select SYSTEM on the next page.
3 Press F1 TYPE. The screen switching menu appears.
4 Press F1 Motion Performance. The list screen appears.
2. MOUNTING DEVICES
ON THE ROBOT CONNECTION B--81545EN/01

MOTION PERFORMANCE 10%

Group1
No. PAYLOAD[kg] Comment
1 6.34 [ ]
2 0.00 [ ]
3 0.00 [ ]
4 0.00 [ ]
5 0.00 [ ]
6 0.00 [ ]
7 0.00 [ ]
8 0.00 [ ]
9 0.00 [ ]
10 0.00 [ ]

Active PAYLOAD number = 1

[ TYPE ] GROUP DETAIL ARMLOAD SETIND >
>

5 On this screen, you can set up ten different types of load information
(condition No. 1 to No. 10). Place the cursor on the line of a desired
condition number, and press F3 DETAIL. The load setting screen
appears.

MOTION PAYLOAD SET JOINT 10%

Group 1
Schedule No[ 1]:[Comment ]
1. PAYLOAD [kg] 6.34
2. PAYLOAD CENTER X [cm] -7.99
3. PAYLOAD CENTER Y [cm] 0.00
4. PAYLOAD CENTER Z [cm] 6.44
5. PAYLOAD INERTIA X [kgfcms^2] 0.13
6. PAYLOAD INERTIA Y [kgfcms^2] 0.14
7. PAYLOAD INERTIA Z [kgfcms^2] 0.07

[ TYPE ] GROUP NUMBER DEFAULT HELP

6 On this screen, specify the mass and gravity center position of the load
and the inertia around the gravity center. The X, Y, and Z directions
displayed on the screen correspond to the standard tool coordinates
(with no tool coordinate system set up). When you enter values, the
confirmation message “Path and Cycletime will change. Set it?”
appears. Select F4 YES or F5 NO.
7 Pressing F3 NUMBER brings you to the load setting screen for
another condition number. In a multigroup system, pressing F2
GROUP brings you to the setting screen for another group.
8 Press the previous page key to return to the list screen. Press F5
SETIND, and enter a desired load setting condition number.
9 On the list screen, pressing F4 ARMLOAD brings you to the device
setting screen.
 2. MOUNTING DEVICES
B--81545EN/01 CONNECTION ON THE ROBOT

MOTION ARMLOAD SET JOINT 10%

Group 1
1 ARM LOAD AXIS #1 [kg] 0.00
2 ARM LOAD AXIS #3 [kg] 12.25

[ TYPE ] GROUP DEFAULT HELP

10 Specify the mass of the loads on the J2--axis base and J3--axis arm.
When you enter
ARMLOAD AXIS #1[kg] : Mass of the load on the J2--axis base and
ARMLOAD AXIS #3[kg] : Mass of the load on the J3--axis arm,
the confirmation message “Path and Cycletime will change. Set it?”
appears. Select F4 YES or F5 NO.
Once the mass of a device is entered, it is put in effect by turning the
power off and on again.
2. MOUNTING DEVICES
ON THE ROBOT CONNECTION B--81545EN/01

2.4 Fig. 2.4 is the allowable load curves of the wrist of the robot.
Use the robot with the load conditions kept within the range shown on the
WRIST LOAD graph.
CONDITIONS

The load inertia is the sum of the offset inertia from the
center of each axis section to the gravity center of the
workpiece and the shape inertia around the gravity center
of the workpiece.
Keep the total load inertia including the shape inertia at or
below the values listed below.

Inertia around the X--axis

Inertia around the Y--axis

Fig 2.4 Wrist section allowable load conditions

 2. MOUNTING DEVICES
B--81545EN/01 CONNECTION ON THE ROBOT

2.5 If you select cables (A05B--1215--H203, --H204, --H603, and --H604) in

the mechanical unit with a pneumatic option, an air pipe whose inlet is on
END EFFECTOR AIR the J1--axis connector panel and outlet is behind the J3 casing is provided.
PIPING See Fig. 7.1 of Part I, “Maintenance,” for explanations about the piping
routes. The joint diameter for the air pipe inlet and outlet is RC3/8 female.
No joint is supplied together with the option. The customer shall arrange
for the joints that match the tubes to be used.
2. MOUNTING DEVICES
ON THE ROBOT CONNECTION B--81545EN/01

2.6 There are end effector connectors for connecting peripheral devices
behind the J3 casing. Fig. 2.6 (a) and Fig. 2.6 (b) show the pin
END EFFECTOR arrangement of end effector connectors. Refer to “R--J3i MODEL B
INPUT SIGNALS Controller Maintenance Manual” for details of input--common settings.
(RDI/RDO)
Mechanical unit (K102, K105)

End effector

Fig 2.6 (a) End effector signal arrangement

(one RDI signal and one RDO signal)

Mechanical unit (K103, K106)

End effector

Fig 2.6 (b) End effector signal arrangement (eight RDI signals and eight RDO signals)
 2. MOUNTING DEVICES
B--81545EN/01 CONNECTION ON THE ROBOT

2.7 Table 2.7 (a) lists the makers and models of the connectors used on the
robot mechanical unit. Table 2.7 (b) lists the makers and models of the
CONNECTOR connectors to be used on user--prepared devices.
SPECIFICATIONS
Table 2.7 (a) Connector specifications (on the mechanical unit side)

Output side
Cable name Maker
(J3--axis casing)

RDI/O×1 JMWR1305F Daiichi Denshi Kogyo K.K.

RDI/O×8 JMWR2524F Daiichi Denshi Kogyo K.K.

Table 2.7 (b) Connector specifications (on the user side)

Output side
Cable name Maker
(J3--axis casing)

RDI/O×1 JMSP1305M Daiichi Denshi Kogyo K.K.

RDI/O×8 JMSP2524M Daiichi Denshi Kogyo K.K.

NOTE
For detailed descriptions of the dimensions of the
connectors, contact FANUC or refer to the respective
catalogs available from the maker.
 3. TRANSPORTATION AND
B--81545EN/01 CONNECTION INSTALLATION

3
TRANSPORTATION AND INSTALLATION
3. TRANSPORTATION AND
INSTALLATION CONNECTION B--81545EN/01

3.1
TRANSPORTATION 1) Installation procedure
1 Release the transportation stopper (red).
2 Using JOINT, feed the J2-- and J3--axis sections in the positive
direction to such a position that the J2-- and J3--axis transportation
stoppers can be released.
3 Remove the J2-- and J3--axis transportation stoppers(red).
4 Remove the two M10 eyebolts from the J2 base. Now you are
ready to install the robot.

NOTE
If an overtravel alarm is issued at 2, hold down the shift key
and press the alarm reset key. Then, while holding down the
shift key, feed the J2-- and J3--axis sections to such a
position, using JOINT, that the overtravel condition is
released.

2) Carrying the robot with a crane

The robot can be carried by suspending it with a crane. To hoist the
robot, hook rope on the two M10 eyebolts. Once the robot is installed,
release the transportation stoppers. (See Fig. 3.1.)
These stoppers are bolts for preventing the swiveling axes of the robot
from moving during its transportation. The stoppers are pained or
plated in red. Before starting to operate the robot, be sure to remove
these stoppers.
Be careful not to let the suspending sling get caught on the connectors
of the motors; the connectors may be damaged if the sling get caught
on it.

NOTE
When transporting a robot having two axes that are
equipped with a brake while leaving an end effector
mounted on its wrist, be sure to place soft material such as
sponge rubber between the J2 and J3 arms previously so
that the J4--axis section will not swing. Otherwise, the end
effector or the robot main body may be damaged if the
J4--axis section swings to let the end effector hit the robot
main body during transportation. If the J4--axis section is
caused to rotate beyond its operation range, a break may
occur in the cable.
 3. TRANSPORTATION AND
B--81545EN/01 CONNECTION INSTALLATION

Position during shipment

Note) 1. Machine weight : 138 kg
J1--axis
2. Eyebolts complied with JIS B1168.
J2--axis [Load capacity : 150 kg/1]
J3--axis
3. Quantity Eyebolt :2
J4--axis Sling :2
J5--axis
J6--axis
Crane
Load capacity : 300 kg

Sling
Load capacity : 250 kg

M10 Eye bolt

Center
of gravity

Fig 3.1 Carrying the robot with a crane

3. TRANSPORTATION AND
INSTALLATION CONNECTION B--81545EN/01

3.2 When storing the robot, keep it in the posture shown in Fig. 3.1.
Be very careful when the robot is in any other posture, because it can fall
STORING THE down.
ROBOT
 3. TRANSPORTATION AND
B--81545EN/01 CONNECTION INSTALLATION

3.3 Fig. 3.3 (a) shows the dimensions of the base of the robot main body.
INSTALLATION

4--φ18 through
φ26 facing depth 5
Mounting face

Front

J1 rotation center
Mounting face
4--φ18 through
φ26 facing depth 5

Fig 3.3 (a) Dimensions of the base of the robot main body
3. TRANSPORTATION AND
INSTALLATION CONNECTION B--81545EN/01

Fig. 3.3 (b) shows an example of installing the robot. In this example, the
sole plate is fixed with four M20 chemical anchors (in strength category
4.8), and the robot base is fastened to the sole plate with four M16×35
bolts (in strength category 12.9). If compatibility must be maintained in
teaching the robot after the robot mechanical unit is replaced, use the butt
surface.

NOTE
The customer shall arrange for the positioning pin, anchor
bolts, and sole plate.

4--φ24 through

Mounting face

J1 rotation center

Mounting face

4--M16 through

Robot J1 base
Installation Plate
Robot fixing bolt
Chemical anchor M16×35 (4)
Strength class : 12.9
M20 (4) Tightening torque : 314 Nm
Strength class : 4.8
Tightening torque : 186 Nm

Fig 3.3 (b) Example of installing the robot

 3. TRANSPORTATION AND
B--81545EN/01 CONNECTION INSTALLATION

Fig. 3.3 (c) and Table 3.3 explain what load is put on the J1 base when the
robot is at a rest, accelerating or decelerating, and at an emergency stop.

Fig 3.3 (c) Load and moment applied to the J1 base

Table 3.3 Load and moment applied to the J1 base

Bending moment Vertical load Torsion moment Horizontal load

State
MV[kgfm](Nm) FV[kgf](N) MH[kgfm](Nm) FH[kgf](N)

At a rest [56](549) [230](2254) [0](0) [0](0)

Accelerating or [189](1852) [297](2911) [61](598) [105](1029)

decelerating

At an emergency stop [724](7095) [677](6635) [231](2264) [252](2470)

3. TRANSPORTATION AND
INSTALLATION CONNECTION B--81545EN/01

3.4 Fig. 3.4 (a) shows the clearance required in maintaining the robot.
MAINTENANCE
CLEARANCE

Mastering area

Maintenance area

Fig 3.4 (a) Maintenance clearance layout

 3. TRANSPORTATION AND
B--81545EN/01 CONNECTION INSTALLATION

The robot must be kept in the posture shown in Fig. 3.4 (b) during
mastering. Provide such a clearance around the robot that the robot can
take a posture of J1 = 0°.

Mastering posture

Mastering jig

Fig 3.4 (b) Robot posture for mastering

3. TRANSPORTATION AND
INSTALLATION CONNECTION B--81545EN/01

3.5 If a separate controller is selected for the robot, the robot connection
cables are detached from the connector board of the mechanical unit (they
ASSEMBLING THE are left connected to the controller) when the robot is shipped. When
ROBOT FOR installing the robot, attach the cables to the connector board of the
INSTALLATION mechanical unit shown in Fig. 3.5.
When attaching the connectors, be careful not to pull the cables that have
HARTING connectors.
The customer shall arrange for installation of cable ducts between the
robot main body and its controller.

Fig 3.5 Cable connection panel for the robot mechanical unit
 3. TRANSPORTATION AND
B--81545EN/01 CONNECTION INSTALLATION

3.6 Fig. 3.6 (a) shows the air piping of the robot.
If the three--piece pneumatic option is selected, it comes with the air pipe
AIR PIPING to be installed between it and the mechanical unit. To use the option, the
customer shall arrange for a three--piece pneumatic option mounting
section that has the self--tapping screw holes whose dimensions and
layout are specified in Fig. 3.6 (b) and for its installation.

Elbow nipple

Straight nipple

In dotted line :
optional ports

Air control set Air hose 3 m

Outer 12 mm Inner 8 mm

Note
Hose used in the mechanical unit has an outer diameter of 12 mm and
an inner diameter of 8 mm.
You can use a different size hose outside the mechanical unit.

Fig 3.6 (a) Air piping

3. TRANSPORTATION AND
INSTALLATION CONNECTION B--81545EN/01

Fill the oiler in the three--piece pneumatic option with any turbine oil
between #90 and #140 to the specified level.
The customer shall arrange for mounting bolts.

Air filter Lubricator

Fig 3.6 (b) Three--piece pneumatic option

 3. TRANSPORTATION AND
B--81545EN/01 CONNECTION INSTALLATION

3.7 Table 3.7 lists the installation conditions for the robot.
INSTALLATION Table 3.7 Installation conditions

CONDITIONS Item Specification

Pneumatic Supply air 0.5 to 0.7 MPa (5 to 7 kg/cm2)

pressure pressure (set at 0.5 MPa (5 kg/cm2))

Consumption Maximum instantaneous amount: 150 NI/min

(Note 1)

Mechanical unit mass About 134 kg: Type having two axes equipped
with a brake
About 138 kg: Type having six axes equipped
with a brake

Allowable ambient 0 to 45°C

temperature

Allowable ambient humidity Regularly: 75%RH or below

Short period (within one month):
95%RH (maximum) or below
No condensation is allowed.

Atmosphere There shall be no corrosive gas (Note 2).

Vibration 0.5 G or less

NOTE
1 This is the capacity of the three--piece pneumatic option.
Use the robot at or below this value.
2 If you cannot avoid using the robot in an adverse
environment with respect to vibration, dust, or coolant,
contact FANUC.
APPENDIX
B--81545EN/01 APPENDIX A. SPARE PARTS LISTS

A
SPARE PARTS LISTS

Table A (a) Cables

A) Two axes equipped with a brake (with no RDI/O signal and without
pneumatic option)
A05B-1215-H201
Cable Specification Remark

K101 A05B-1215-D001 J1, J2, J3, J4, J5, and J6 power cables
J1, J2, J3, J4, J5, and J6 pulse coder cables

K201 A660-4004-T115 J5 power and pulse coder inline connector cable

A660-2005-T088 OT jumper connector

B) Two axes equipped with a brake (with one RDI/O signal and without
pneumatic option)
A05B-1215-H202
Cable Specification Remark

K102 A05B-1215-D002 J1, J2, J3, J4, J5, and J6 power cables
J1, J2, J3, J4, J5, and J6 pulse coder cables

K201 A660-4004-T115 J5 power and pulse coder inline connector cable

A660-2005-T088 OT jumper connector

C) Two axes equipped with a brake (with one RDI/O signal and with
pneumatic option)
A05B-1215-H203
Cable Specification Remark

K102 A05B-1215-D002 J1, J2, J3, J4, J5, and J6 power cables
J1, J2, J3, J4, J5, and J6 pulse coder cables

K201 A660-4004-T115 J5 power and pulse coder inline connector cable

A660-2005-T088 OT jumper connector

D) Two axes equipped with a brake (with eight RDI/O signals and
pneumatic option)
A05B-1215-H204
Cable Specification Remark

K103 A05B-1215-D003 J1, J2, J3, J4, J5, and J6 power cables
J1, J2, J3, J4, J5, and J6 pulse coder cables

K201 A660-4004-T115 J5 power and pulse coder inline connector cable

A660-2005-T088 OT jumper connector

A. SPARE PARTS LISTS APPENDIX B--81545EN/01

E) Six axes equipped with a brake (with no RDI/O signal and without
pneumatic option)
A05B-1215-H601
Cable Specification Remark

K104 A05B-1215-D004 J1, J2, J3, J4, J5, and J6 power cables
J1, J2, J3, J4, J5, and J6 pulse coder cables

K202 A660-4004-T116 J5 power and pulse coder inline connector cable

A660-2005-T088 OT jumper connector

F) Six axes equipped with a brake (with one RDI/O signal and without
pneumatic option)
A05B-1215-H602
Cable Specification Remark

K105 A05B-1215-D005 J1, J2, J3, J4, J5, and J6 power cables
J1, J2, J3, J4, J5, and J6 pulse coder cables

K202 A660-4004-T116 J5 power and pulse coder inline connector cable

A660-2005-T088 OT jumper connector

G) Six axes equipped with a brake (with one RDI/O signal and with
pneumatic option)
A05B-1215-H603
Cable Specification Remark

K105 A05B-1215-D005 J1, J2, J3, J4, J5, and J6 power cables
J1, J2, J3, J4, J5, and J6 pulse coder cables

K202 A660-4004-T116 J5 power and pulse coder inline connector cable

A660-2005-T088 OT jumper connector

H) Six axes equipped with a brake (with eight RDI/O signals and
pneumatic option)
A05B-1215-H604
Cable Specification Remark

K106 A05B-1215-D006 J1, J2, J3, J4, J5, and J6 power cables
J1, J2, J3, J4, J5, and J6 pulse coder cables

K202 A660-4004-T116 J5 power and pulse coder inline connector cable

A660-2005-T088 OT jumper connector

B--81545EN/01 APPENDIX A. SPARE PARTS LISTS

Table A (b) Motors

ARC Mate 100i MODEL B

(two axes equipped with a brake) A05B-1215-B201
M--6i MODEL B
(two axes equipped with a brake) A05B-1215-B202

Specification Axis Remark

A06B-0223-B005 J1 α4/4000i

A06B-0223-B605 J2 α4/4000i with a brake

A06B-0202-B605 J3 α1/5000i with a brake

A06B-0202-B005 J4 α1/5000i

A06B-0115-B075#0008 J5 βM0.5/4000

A06B-0114-B075#0008 J6 βM0.4/4000

ARC Mate 100i MODEL B

(six axes equipped with a brake) A05B-1215-B601
M--6i MODEL B
(six axes equipped with a brake) A05B-1215-B602

Specification Axis Remark

A06B-0223-B605 J1 α4/4000i with a brake

A06B-0223-B605 J2 α4/4000i with a brake

A06B-0202-B605 J3 α1/5000i with a brake

A06B-0202-B605 J4 α1/5000i with a brake

A06B-0115-B275#0008 J5 βM0.5/4000 with a brake

A06B-0114-B275#0008 J6 βM0.4/4000 with a brake

Table A (c) Reducers

Specification Axis

A97L-0218-0288#33 J1

A97L-0218-0289#153 J2

A97L-0218-0295#161 J3

A97L-0218-0224 J6

Table A (d) Motor auxiliary seals

Specification Axis

A98L-0004-0771#A03TP J1/J2

A98L-0004-0771#A01TP J3/J4
A. SPARE PARTS LISTS APPENDIX B--81545EN/01

Table A (e) J4--axis gearbox

Specification Axis

A05B-1215-K401 J4

Table A (f) Gears

Specification Axis

A290-7215-X511 J5

A290-7215-V501 J5

A290-7215-V502 J5

A290-7215-X514 J5

Table A (g) Cover

Specification Remark

A05B-1215-H351 J2--axis cable protect cover

Table A (h) Battery

Specification Remark Quantity

A98L-0031-0005 R20 (1.5 V) 4

Table A (i) Grease

Name Specification

Mori White RE No. 00 A98L-0040-0119#2.4KG

Table A (j) Grease nipples

Name Specification Axis

Grease nipple (1/8) A97L-0218-0013#A110 J2/J3

Grease nipple [elbow type] (1/8) A97L-0218-0013#C110 J1

Grease nipple (M6) A97L-0218-0013#A610 J4/J5/J6

B--81545EN/01 APPENDIX A. SPARE PARTS LISTS

Table A (k) O--ring

Specification Location of use

A98L--0001--0347#S150 J1RV output

A98L--0001--0347#S100 J1RV output

A290--7207--X342 J1RV input

JB--OR1A--G60 J1 pipe

JB--OR1A--G105 J1 motor

JB--OR1A--G115 J2 motor

A98L--0001--0347#S135 J2RV output

A98L--0040--0041#258 J2RV input

A98L--0001--0347#S135 J2RV output

A98L--0001--0347#S100 J3RV output

A98L--0001--0347#S120 J3RV input

JB--OR1A--G75 J4 motor

A98L--0001--0347#S65 J3 arm mounting section

A98L--0001--0347#S71 J6 cross roller mounting section

Table A (l) Gaskets

Specification Location of use

A98L--0040--0042#03 J4 motor

A98L--0040--0042#07 J5/J6 motor

A290--7215--X527 J5--2 (X502) cover mounting section

A290--7215--X533 Wrist flange mounting section

Table A (m) Stoppers

Specification Axis

A290--7215--X241 J4 Note) 330° stopper

A290--7215--X323 J4

A290--7215--X324 J4

Table A (n) Seal bolts

Specification Remark

A97L--0218--0417#081010 J1/J2/J3 grease outlet

A97L--0218--0621#051212 J5--axis motor and J5 gear unit mounting

(with a washer)
 B. INTRA--MECHANICAL UNIT
B--81545EN/01 APPENDIX CONNECTION DIAGRAMS

B
INTRA--MECHANICAL UNIT CONNECTION DIAGRAMS
B. INTRA--MECHANICAL UNIT
CONNECTION DIAGRAMS APPENDIX B--81545EN/01

Fig B (a) Intra--mechanical unit circuit diagram

(two axes with a brake, separate controller)
 B. INTRA--MECHANICAL UNIT
B--81545EN/01 APPENDIX CONNECTION DIAGRAMS
B. INTRA--MECHANICAL UNIT
CONNECTION DIAGRAMS APPENDIX B--81545EN/01

Fig B (b) Intra--mechanical unit circuit diagram

(six axes with a brake, separate controller)
 B. INTRA--MECHANICAL UNIT
B--81545EN/01 APPENDIX CONNECTION DIAGRAMS
B--81545EN/01 APPENDIX C. PERIODIC INSPECTION TABLE

C
PERIODIC INSPECTION TABLE

Fig C Periodic inspection table

B--81545EN/01 APPENDIX D BOLT MOUNTING TORQUE LIST

D
BOLT MOUNTING TORQUE LIST
D BOLT MOUNTING TORQUE LIST APPENDIX B--81545EN/01

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

table.
Recommended bolt tightening torque Unit: Nm (kgf--cm)

Hexagon socket head boss bolt

Hexagon socket head bolt (steel Hexagon socket head bolt
Hexagon socket head flush bolt
in strength category 12.9) (stainless)
(steel in strength category 12.9)
Nominal
diameter
Tightening torque Tightening torque Tightening torque

Upper limit Lower limit Upper limit Lower limit Upper limit Lower limit

M3 1.8(18) 1.3(13) 0.76(7.7) 0.53(5.4) — —

M4 4.0(41) 2.8(29) 1.8(18) 1.3(13) 1.8(18) 1.3(13)

M5 7.9(81) 5.6(57) 3.4(35) 2.5(25) 4.0(41) 2.8(29)

M6 14(140) 9.6(98) 5.8(60) 4.1(42) 7.9(81) 5.6(57)

M8 32(330) 23(230) 14(145) 9.8(100) 14(140) 9.6(98)

M10 66(670) 46(470) 27(280) 19(195) 32(330) 23(230)

M12 110(1150) 78(800) 48(490) 33(340) — —

(M14) 180(1850) 130(1300) 76(780) 53(545) — —

M16 270(2800) 190(1900) 120(1200) 82(840) — —

(M18) 380(3900) 260(2700) 160(1650) 110(1150) — —

M20 530(5400) 370(3800) 230(2300) 160(1600) — —

(M22) 730(7450) 510(5200) — — — —

M24 930(9500) 650(6600) — — — —

(M27) 1400(14000) 940(9800) — — — —

M30 1800(18500) 1300(13000) — — — —

M36 3200(33000) 2300(23000) — — — —

B--81545EN/01 Index
≪A≫ INSTALLATION CONDITIONS, 130
INTRA--MECHANICAL UNIT CONNECTION DIAGRAMS,
ADJUSTMENTS, 32 139
AIR PIPING, 128
ASSEMBLING THE ROBOT FOR INSTALLATION, 127

≪J≫
J1--AXIS DRIVE MECHANISM, 4
≪B≫ J2--AXIS DRIVE MECHANISM, 5
BATTERY REPLACEMENT, 25 J3--AXIS DRIVE MECHANISM, 6
BOLT MOUNTING TORQUE LIST, 145 J4--AXIS DRIVE MECHANISM, 7
BRAKE RELEASE, 50 J5-- AND J6--AXIS DRIVE MECHANISMS, 8
J5--AXIS GEAR BACKLASH ADJUSTMENTS, 48
JIG--BASED MASTERING, 41
≪C≫
CABLE DRESSING, 83
CABLE MOUNTING DIAGRAM, 81 ≪M≫
CABLE REPLACEMENT, 82 M--6i PACKAGES WITH REINFORCED DUST--PROOF AND
DRIP--PROOF CHARACTERISTICS, 93
CAUTIONS IN SELECTING THE PACKAGES WITH
REINFORCED DUST--PROOF AND DRIP--PROOF MAINTENANCE CLEARANCE, 125
CHARACTERISTICS, 97
MAINTENANCE TOOLS, 18
COMPONENT REPLACEMENT AND ADJUSTMENT
ITEMS, 31 MASTERING BY ZERO POSITION MARK ALIGNMENT, 39

COMPONENT REPLACEMENT AND ADJUSTMENTS, 52 MOUNTING DEVICES ON THE ROBOT, 107

CONFIGURATION, 3
CONFIGURATION OF THE PACKAGES WITH
REINFORCED DUST--PROOF AND DRIP--PROOF
CHARACTERISTICS, 95
≪O≫
CONFIRMING MASTERING, 47 ONE-- AND HALF--YEAR PERIODIC INSPECTION, 16

CONNECTOR SPECIFICATIONS, 117 OUTLINE DRAWING AND OPERATION AREA DIAGRAM,

104
COVER OPTION REPLACEMENT, 90
OVERVIEW, 27

≪D≫ ≪P≫
DAILY INSPECTION, 12 PERIODIC INSPECTION TABLE, 144
DEVICE MOUNTING SURFACES, 109 PERIODIC MAINTENANCE, 19
DUST--PROOF AND DRIP--PROOF PERFORMANCE OF PIPING AND WIRING, 77
THE PACKAGES WITH REINFORCED DUST--PROOF
AND DRIP--PROOF CHARACTERISTICS, 94 PIPING DRAWING, 78
PREVENTIVE MAINTENANCE, 11

≪E≫
END EFFECTOR AIR PIPING, 115 ≪Q≫
END EFFECTOR INPUT SIGNALS (RDI/RDO), 116 QUARTERLY INSPECTION, 14

≪G≫ ≪R≫
GREASE REPLACEMENT, 22 REFERENCE POSITION AND MOVING RANGE, 33
GREASING, 20 REPLACING CABLES, 85
REPLACING THE COMPONENTS OF THE PACKAGES
WITH REINFORCED DUST--PROOF AND DRIP--PROOF
CHARACTERISTICS, 98
≪I≫ REPLACING THE J1--AXIS MOTOR M1 , 53
INSTALLATION, 122 REPLACING THE J1--AXIS REDUCER, 55
INDEX B--81545EN/01

REPLACING THE J2 COVER OPTION (A05B--1210--J401), SPECIFICATIONS OF THE MAJOR MECHANICAL UNIT
91 COMPONENTS, 9
REPLACING THE J2--AXIS MOTOR M2 , 57 STORING THE ROBOT, 121

REPLACING THE J2--AXIS REDUCER, 59

REPLACING THE J3--AXIS MOTOR M3 , 62
REPLACING THE J3--AXIS REDUCER, 64 ≪T≫
REPLACING THE J4 COVER OPTION (A05B--1210--J402), THREE--YEAR PERIODIC INSPECTION, 17
92
TRANSPORTATION, 119
REPLACING THE J4--AXIS GEARBOX, 67
TRANSPORTATION AND INSTALLATION, 118
REPLACING THE J4--AXIS MOTOR M4 , 66 TROUBLES AND CAUSES, 28
REPLACING THE J5--AXIS GEAR, 71 TROUBLESHOOTING, 26
REPLACING THE J5--AXIS MOTOR M5 , 69

REPLACING THE J6--AXIS MOTOR M6 AND REDUCER,

73
≪W≫
ROBOT OUTLINE DRAWING AND OPERATION AREA
DIAGRAM, 103 WIRING DIAGRAMS, 79
WRIST LOAD CONDITIONS, 114
WRIST SECTION END EFFECTOR MOUNTING SURFACE,
108
≪S≫
SETTING THE SYSTEM VARIABLES FOR
SHORTEST--TIME CONTROL, 111
SIMPLIFIED MASTERING, 37 ≪Y≫
SPARE PARTS LISTS, 133 YEARLY INSPECTION, 15
 Revision Record

FANUC Robot ARC Mate 100i MODEL B / M--6i MODEL B MAINTENANCE MANUAL (B--81545EN)

01 Sep., 2001

Edition Date Contents Edition Date Contents