Manipulator (NG3)

No.
1L11444A-E-2
series
INSTRUCTION MANUAL
MANIPULATOR
( NG3 )
Read and follow these instructions and all safety blocks carefully.
Have only trained and qualified persons install, operate, or service this unit.
Give this manual to the operator.
For help, call your distributor.

Be Sure to Read Instruction Manuals Before Use
Thank you for selecting DAIHEN arc welding robot Almega series.
Please be sure to read the instruction manuals listed below (including this manual) and the instruction manuals
provided with the equipment, and use all the products correctly.
In particular, please be sure to read "Chapter 1 Safety Precautions" in the "Quick Start" instruction manual before
starting to use the products in order to ensure your safety and the safety of others. Store the instruction manual in
a safe place for future reference.
Instruction manuals related to the manipulator G series, and the robot control unit FD11 are as follows. Refer
to the instruction manual NB4/NV6(Model type:FD11-JV***) about the robot control unit.
Standard Manuals
Instruction
Instruction Manual Type Main Contents
Manual No.
QUICK START Point on Safety, Transportation and Installation,
1L21700A
Turning the power on/off and manual operation, etc.
SETUP Safety precautions, installing & connecting method,
1L21700B starting up, periodical inspection, solution at the time
of failure
CONTROLLER MAINTENANCE Specifications of controller, explanation of each parts
1L21700K
and maintenance, parts list, etc.
MANIPULATOR Specifications or maintenance of manipulator, parts
1L11444A
NG3 list, etc.
BASIC OPERATIONS Explanation of manual operation, teaching, automatic
1L21700C operation, file utilities, backing-up data, basic
operations of Arc/Spot welding application, etc.
EXTERNAL INPUT/OUTPUT Interfacing method with external control device, list of
1L21700H
I/O signals and start/halt the automatic operation, etc.
Software PLC Create program, Input/output relay lists, List of
1L21700J
command words, etc.
CONTROL AND MAINTENANCE Edit logging, User Check, Troubleshooting, etc.
1L21700L
FUNCTION
Application Manuals
Instruction
Instruction Manual Type Main Contents
Manual No.
APPLICATION MANUAL Basic settings, functions for arc welding, teaching
1L21700F
(ARC WELDING) technique, etc.
APPLICATION MANUAL Basic settings, functions for arc welding, teaching
1L21700E
(SPOT WELDING) technique, etc.
Instruction manuals are available other than the above for each optional function that you have purchased.
[Notes] 1. Specifications and information contained in these manuals are subject to change at any time without notice.
2. The screen display of a teach pendant shown in the manual are described as examples, which may be different from the actual
ones.
3. Although we cautiously compiled this standard specifications to eliminate as much error as possible, we do not take any
responsibility for damages resulting from neither direct nor indirect errors.
4. The manual is a part of robot products. When transferring or selling off a robot, be sure to append the manual.
5. No part of this manual may be reproduced without permission.
6. Prohibited altering or remodeling
- Do not alter or remodel our products.
- You may get injured or have your equipment damaged because of fire, failure or malfunction caused by altering or
remodeling the product.
- The warranty does not cover any altered or remodeled products.
-1-
Notice
Notes on Safety
The instructions that you are required to obey in order to prevent injury or physical damage to the operator or other
nearby persons are classified and explained as shown below in the provided instruction manuals (including this
manual).
Cases in which death or serious injury are assured if handed incorrectly, and which
avoidance of such dangers is also considered extremely difficult.
DANGER
Cases in which death or serious injury can be expected if handled incorrectly.

WARNING
Cases in which injury or physical damage can be expected if handled incorrectly.

CAUTION
The following symbols are also used for important checkpoints:
A particularly important checkpoint is shown.

IMPORTANT
INFO.
Useful information is shown.
POINT Info for deeper understanding for the main text is shown.
Note that even the matters which are described as CAUTION can result in serious accident depending on the
conditions. Be sure to keep the safety notes since they describe very important matters.
The meanings of Serious injury, Minor injury, and Damage described above are as follows.
Injury which has the aftereffect by loss of eyesight, an injury, the burn (high/low
Serious injury temperature), an electric shock, fracture, poisoning, etc. and that which requires
hospitalization and long-term treatment as an outpatient.
Injury which does not require either hospitalization or long-term treatment as an

Minor injury
outpatient, a burn (high temperature, low temperature), and an electric shock.
Direct and indirect damage in connection with damage of property and

Damage
equipment.
-2-
Table of Contents
Table of Contents
G-type Manipulator
Chapter 1 Specifications of G-Type Manipulator
1.1 Manipulator model .................................................................................................................. 1-1-2
1.2 Basic Specifications ................................................................................................................ 1-1-3
1.3 Outside Dimensions and Working Range ............................................................................... 1-1-4
1.4 Description on Each Part of Manipulator ................................................................................ 1-1-5

1.4.1 Allowable Load on Wrist Axis .......................................................................................... 1-1-5
1.4.2 Flange Dimensions of Wrist Axis .................................................................................... 1-1-6
1.4.3 Mounting Equipment on Revolving Frame...................................................................... 1-1-7
1.4.4 Restrictions of Working Range ....................................................................................... 1-1-8
1.4.5 Instrument Connecting Cables and Gas (Air) Piping ...................................................... 1-1-8
1.4.6 Link Movement ............................................................................................................... 1-1-9
1.4.7 Motion Warning Lamp (option) ..................................................................................... 1-1-10
1.4.8 Holding Brake ............................................................................................................... 1-1-10
1.5 Reference Position of Moving Axis ....................................................................................... 1-1-11
1.5.1 Angular Reference Position of Each Joint in the Working Range................................. 1-1-11
1.5.2 Angular Reference Position of Each Joint in the Starting Area ..................................... 1-1-12
1.6 Motion Direction of Each Axis ............................................................................................... 1-1-13
1.6.1 Motion of Each Axis ...................................................................................................... 1-1-13
1.6.2 Motion in the Cartesian Coordinate .............................................................................. 1-1-13
1.7 Changing Working Range ..................................................................................................... 1-1-17
1.7.1 Changing Working Range of Axis J1 ............................................................................ 1-1-17
1.7.2 Changing Working Range of Axis J2 and J3 (with the option mounted)....................... 1-1-18
1.8 Option ................................................................................................................................... 1-1-19
Chapter 2 Foundation Work and Installation
2.1 Safety Measures Relating to Installation ................................................................................. 1-2-2
2.2 Installation Locations and Ambient Conditions ....................................................................... 1-2-5
2.3 Notes on Interference by Electromagnetic Noise.................................................................... 1-2-6
2.4 Accessories ............................................................................................................................. 1-2-7
2.5 Transport Method .................................................................................................................... 1-2-8
2.6 Installation of Manipulator ..................................................................................................... 1-2-10

2.6.1 Installation Method ........................................................................................................ 1-2-10
2.6.2 Installing Manipulator and Jigs on Common Frame Base ............................................ 1-2-11
2.6.3 Using Optional Manipulator Stand ................................................................................ 1-2-12
2.6.4 Maximum Manipulator Generative Force ..................................................................... 1-2-13
2.7 Note on Emergency stop of Manipulator ............................................................................... 1-2-14
1
Table of Contents
Chapter 3 Periodic Inspection
3.1 Periodic Inspection .................................................................................................................. 1-3-2

3.1.1 Safety Measures for Inspection, Maintenance, Adjustments and Repairs of the Manipulator ....... 1-3-2
3.1.2 Periodic Inspection Schedule ......................................................................................... 1-3-4
3.1.3 Notes on Periodic Inspection .......................................................................................... 1-3-4
3.1.4 Deadline for Supplying/ Repairing the Robot Maintenance Parts ................................... 1-3-4
3.2 List of Maintenance Items ....................................................................................................... 1-3-5
3.2.1 NG3 Manipulator ............................................................................................................. 1-3-5
Chapter 4 Maintenance
4.1 Grease Replacement and Replenishment of Reduction Gears ................................................. 4-4

4.1.1 Grease Replacement Procedure for Axis J1, J2 and J3 Reduction Gears ........................ 4-4
4.1.2 Grease Replacement Procedure for Axis J3, J4 and J5 Reduction Gears ........................ 4-7
4.2 Grease Replenishment for Cross Roller Bearing....................................................................... 4-8
4.2.1 Grease Replenishment Procedure for Cross Roller Bearing of J2-3 Axis Joint .......................... 4-8
4.2.2 Grease Replenishment Procedure for Axis J3 Cross Roller Bearing ................................ 4-9
4.3 Battery ...................................................................................................................................... 4-10
4.3.1 Function of Battery ........................................................................................................... 4-10
4.3.2 Specification of Battery .................................................................................................... 4-10
4.3.3 Replacing Battery............................................................................................................. 4-10
4.3.4 Notes on Battery Safekeeping ......................................................................................... 4-11
4.4 Replacing Internal Wires .......................................................................................................... 4-12
Chapter 5 Parts List
5.1 Parts List .................................................................................................................................... 5-2

5.1.1 NG3 ................................................................................................................................... 5-2
5.2 Location and List of Warning Label............................................................................................ 5-4
Chapter 6 Internal Wires
6.1 Wiring Connection Figure .......................................................................................................... 6-2

6.1.1 Wiring Connection Figure for NG3 .................................................................................... 6-2
2
Table of Contents
3
G-type Manipulator
Capter 1 Specifications of G-Type Manipulator
Capter 2 Foundation Work and Installation
Capter 3 Periodic Inspection
Capter 4 Maintenance
Capter 5 Parts List
Capter 6 Internal Wires

Chapter 1 Specifications of G-Type Manipulator
This chapter describes the specifications of G-type manipulator.
1.1 Manipulator model................................................................................... 1-1-2

1.2 Basic Specifications................................................................................. 1-1-3
1.3 Outside Dimensions and Working Range................................................ 1-1-4
1.4 Description on Each Part of Manipulator ................................................. 1-1-5
1.4.1 Allowable Load on Wrist Axis............................................................. 1-1-5
1.4.2 Flange Dimensions of Wrist Axis ....................................................... 1-1-6
1.4.3 Mounting Equipment on Revolving Frame......................................... 1-1-7
1.4.4 Restrictions of Working Range .......................................................... 1-1-8
1.4.5 Instrument Connecting Cables and Gas (Air) Piping ......................... 1-1-8
1.4.6 Link Movement .................................................................................. 1-1-9
1.4.7 Motion Warning Lamp (option) ........................................................ 1-1-10
1.4.8 Holding Brake .................................................................................. 1-1-10
1.5 Reference Position of Moving Axis ........................................................ 1-1-11
1.5.1 Angular Reference Position of Each Joint in the Working Range .... 1-1-11
1.5.2 Angular Reference Position of Each Joint in the Starting Area ........ 1-1-12
1.6 Motion Direction of Each Axis................................................................ 1-1-13
1.6.1 Motion of Each Axis ......................................................................... 1-1-13
1.6.2 Motion in the Cartesian Coordinate ................................................. 1-1-13
1.7 Changing Working Range ..................................................................... 1-1-17
1.7.1 Changing Working Range of Axis J1 ............................................... 1-1-17
1.7.2 Changing Working Range of Axis J2 and J3 (with the option mounted) 1-1-18
1.8 Option.................................................................................................... 1-1-19
1-1-1
1.1 Manipulator model
1.1 Manipulator model
The following section shows the nomenclature of manipulator model.
Classification by overseas
N No support standard support
F Floor-installed Classification by mount type
J Domestic specification Classification by shipment

E Overseas specification destination
N Standard specification
Classification by design No.
Manipulator series No.
Manipulator name
1-1-2
1.2 Basic Specifications
1.2 Basic Specifications

Item Specifications
Name NG3
Structure Horizontal articulated type
Number of axes 5
Max. payload capacity 3 kg
Positional repeatability +/-0.08 mm (Note 1)
Drive system AC servomotor
Drive capacity 1500W
Position feedback Absolute encoder
J1 (Revolving 1) +/- 170
Arm J2 (Upper and Lower) +/- 50
Working
range
J3 (Revolving 2) +/- 150

J4 (Revolving) +/- 210
Wrist
J5 (Bending) +/- 130
J1 (Revolving 1) 2.09 rad/s120/s
Max. velocity
Arm J2 (Up and Down) 2.79 rad/s160/s

J3 (Revolving 2) 4.19rad/s240/s
J4 (Revolving) 9.42 rad/s540/s
Wrist
J5 (Bending) 9.42 rad/s540/s
Allowable J4 (Revolving)
Wrist load
Moment J5 (Bending) 2.5 N*m

2
Allowable J4 (Revolving) 0.074 kg*m
moment of 2
inertia J5 (Bending) 0.037 kg*m
Arm operation cross-sectional area 0.69 m340
0 ~ 45C, 20 ~ 80 %RH
Ambient temperature and humidity
(No condensation)
Mass (weight) 144 kg
Revolving frame payload capacity 40 kg
Installation type Floor type
Paint color White (Munsell 10GY9/1)
Note) 1. The value of the positional repeatability is at the tool center point (TCP) compliant to ISO 9283
IMPORTANT
1. The positional repeatability is a measured value obtained when the robot operating conditions are stabilized after
times of the automatic operation.
2. The positional data of absolute encoder is backed up by the battery. The battery backup period with the primary power
OFF is approx. 3 years.
Exceeding this period will require the battery replacement and the absolute offset adjustments.
3. The battery backup period may be shorter depending on the environmental conditions, the use conditions and so on.
4. A holding brake is provided in all axes.
5. The robot itself or peripheral jigs can be cause of interference according to their postures. Please be careful about any
interference when you teach the robot.
6. The above specifications are subject to change without notice.
1-1-3
1.3 Outside Dimensions and Working Range
1.3 Outside Dimensions and Working Range
170
116 430 130 500 300 300

418
150
R4
06
46
R5
300
R532
150
6
47
R1
TCP Working Range 170

TCP
145
686
50
986
345
TCP Working Range

300
50
TCP

TCP
626
526
858
766
471
944 532
Fig. 1.2.0.1 Outside Dimensions and Working Range (unit : mm)

Note) This figure does not demonstrate the working range of the equipment-mounted robot.
When equipments and tools are mounted, the robot may interfere with itself. Therefore, before
performing operations, be sure that the robot does not come in contact with itself.
Approaching the operating robot may result in a fatal injury. Keep out of the robot
working range whenever the power is ON.
WARNING
1-1-4
1.4 Description on Each Part of Manipulator
1.4.1 Allowable Load on Wrist Axis

The payload of NG3 manipulator must not exceed max. payload capacity (3kg), including a welding torch, a
chucking tool in handling and a workpiece.
Mounting a standard welding torch does not cause any problems to the manipulator, but both the moment and the
moment of inertia must be within the allowance stated in the table below when the manipulator is used for
handling or any other similar purposes.
Also, when a load is imposed not in the form of mass but force, a wrist axis must not be used with these maximum
allowable values exceeded.
Table 1.4.1.1 Allowable Load on Wrist Axis

Axis Name Allowable Moment Allowable Moment of Inertia
J4 0.074kg*m2
J5 2.5N*m 0.037kg*m2
86.5
Distance from Axis J4

Rotation Center
J4
272 192 157
(mm) 300 200 100
J5
3 kg
Distance from Axis J5
85
100
2 kg
127
Rotation Center
1 kg 192
200
(mm)
Fig. 1.4.1.1 Allowable Load on Wrist Axis
Fig. 1.4.1.2 Wrist Load Conditions
1-1-5
1.4.2 Flange Dimensions of Wrist Axis
Fig. 1.4.2.1 shows the flange dimensions of wrist axis. Fit a tool using the flange spigot (40h7). To fix the tool in
position, use 6XM5 tapping holes.
The length of M5 bolts must be shorter than 8 mm so that it fits the tapping hole of the flange part on wrist axis.
P.
C. 3.5
A D.
32
45
40 h7
6xM5 8 deep
45
86.5 (82)
View A
A
Fig. 1.4.2.1 Flange Dimensions of Wrist Axis (unit : mm)
To avoid damaging to the motors or the reduction gears due to overload, be sure to keep
the allowable load on the wrist axis.
CAUTION
Use a specified tightening torque (Strength grade 12.9 : 7.25 N*m) for firmly tightening
M5 bolts so that tools are prevented from falling off or forcibly flown off.
WARNING Note that M5 bolts must be fit into a tapping hole (8 mm deep) in the wrist axis flange.
1-1-6
1.4.3 Mounting Equipment on Revolving Frame

The top of the revolving frame is provided with the face to mount the equipment such as a wire feeding unit, gas
solenoid valve etc. To mount the equipment, use 6XM8 holes provided. (The face for mounting is the same
plane.)
(a) Restriction of the maximum mountable mass on the revolving frame.

Max. wrist payload capacity (kg) : Max. 3 kg
Mountable mass on the revolving frame (kg) : Max. 40 kg
(b) The center-of-gravity position for mounting an equipment on the revolving frame must be within a radius of 200mm
from J1 axial rotation center. Show in Fig. 1.4.3.1.
6xM8 12 deep
12
25
10
50
R200
25
Rotation Center
90 170

View A
A
A
Fig. 1.4.3.1 Equipment Mounting Position on Revolving Frame (unit: mm)
To avoid damaging to the motors or the reduction gears due to overload, be sure to keep
the maximum mountable mass on the revolving frame.
CAUTION
Use a specified tightening torque (Strength grade 12.9 : 28.4 N*m) for firmly tightening
M8 bolts so that tools are prevented from falling off or forcibly flown off.
WARNING
1-1-7
1.4.4 Restrictions of Working Range

Each axis of the manipulator has a limit in its working range for safety management and interference prevention.
The limit of working range set by the program in the robot controller is called Soft Limit.
In addition, the manipulator is usually equipped with an overrun limit switch and/or mechanical stoppers in case
that the manipulator moves beyond the Soft Limit.
NG3 manipulator has the working range restrictions as shown in the table 1.4.4.1 below.
Table 1.4.4.1 Restrictions of Working Range on Each Axis

Axis Overrun Limit Mechanical
Soft Limit
Name Switch Stopper
J1
J2 *
J3 *
J4
J5
: Standard equipment
: Optional equipment (Refer to the 1.8 Option)
: Unequipped
Fig. 1.4.4.1 Limit of Working Range Fig. 1.4.4.2 Arrangement of Axis J1 Limit Switch
1.4.5 Instrument Connecting Cables and Gas (Air) Piping

Inside the manipulator, the instrument connecting cables and a gas (air) hose are built in for a wire feeding unit
mounted on top of the revolving frame and for driving or signaling instruments such as a gas solenoid valve.
The max allowable pressure of a gas (air) hose is 1.0MPa or less(At 20).

MAX PRESSURE
1.0 MPa (145psi)
GAS
CN1 CN2 CN4
Rc3/8 (PT3/8) 9/16-18UNF
Fig. 1.4.5.1 Instrument Connecting Cables and Gas (Air) Piping
1-1-8
For welding application, Fig. 1.4.5.2 below shows the wiring diagram of the built-in cables in the manipulator.
Base Side Electrical Connection of Manipulator Revolving Frame Side
CN4 CN29
White
Red
Yellow,Blue,Green Wire Feed Device(Encorder)
Orange
SRCN6A25-16S
SRCN2A25-16P
CN41
Gray
Black SOL Gas Solenoid Valve
CN26
Yellow
Blue
Others
White
CN27
Red
Black Wire Feed Device(Motor)
CN28
Green
Voltage Detection Line(+)
CN2
MOLEX 58691-0020
Yellow
Blue Warning Lamp
Red
White
Shock Sensor LS
Fig. 1.4.5.2 Cable Wiring (for welding application)
When using these built-in cables for applications other than welding, prepare the counter-connectors shown in
Fig. 1.4.5.1.
1.4.6 Link Movement
Link Bar is to keep Axis J3 to the tip horizontally. Fig. 1.4.6.1 indicates movement of the Link Bar.
Link Bar

Fig. 1.4.6.1 Link Movement
It might hurt you if you bring your fingers to the working parts like linked parts.
WARNING
1-1-9
1.4.7 Motion Warning Lamp (option)

A manipulator is provided with a connector for the motion warning lamp. This warning lamp is optionally available
to indicate Servo ON, Automatic Operation and so on.
Refer to the 1.8 Option for more details.
Fig. 1.4.7.1 Motion Warning Lamp (option)
1.4.8 Holding Brake

All the motors of G-type manipulator have built in holding brakes respectively.
A holding brake is intended to prevent the manipulator arm from falling when the control power is OFF or when
the servo power is OFF due to an emergency stop.
(Note: These brakes will be released only when the servo power is turned on.)
1-1-10
1.5 Reference Position of Moving Axis
The angular reference position of each joint in the working range and the starting area of NG3 manipulator is as
follows:
1.5.1 Angular Reference Position of Each Joint in the Working Range
Axis J1
Axis J3

Axis J4

Reference Position of Axis J1, J3 and J4

Reference Position of Axis J5 Reference Position of Axis J2

Axis J1 : 0 deg. is at front position.

Axis J2 : 0 deg. is at horizontal position.
Axis J3 : 0 deg. is the position where the Axis J1 and J3 are laid in a straight line.
Axis J4 : 0 deg. is the position where the Axis J4 is turned 90 deg. in a clockwise from the front when viewed from
the top.
Axis J5 : 0 deg is at vertical position.
Fig. 1.5.1.1 Reference Position of Moving Axis (in the Working Range)
1-1-11
1.5.2 Angular Reference Position of Each Joint in the Starting Area
Axis J1
Axis J3

Axis J4

Reference Position of Axis J1, J3 and J4

Reference Position of Axis J5 Reference Position of Axis J2

Axis J1 : 0 deg. is at front position.

Axis J2 : 0 deg. is at horizontal position.
Axis J3 : 0 deg. is the position where the Axis J1 and J3 are laid in a straight line.
Axis J4 : 0 deg. is the position where the Axis J4 is turned 90 deg. in a clockwise from the front when viewed from
the top.
Axis J5 : 0 deg is at vertical position.
Fig. 1.5.2.1 Reference Position of Moving Axis (in the Starting area)
1-1-12
1.6 Motion Direction of Each Axis
1.6.1 Motion of Each Axis

The axis corresponding to each axis key on Teach pendant can move independently as shown in the figure.
Axis Name Movement Keys on Teach Pendant

Revolving 1 J2
(Left-right)
1
Arm
(Up-Down) J3
( J1
Revolving 2
(Left-right)
2
Wrist J4
(Swing)
()
Wrist
(Bending)
() J5
Fig. 1.6.1.1 Name of the Motion Axis
1.6.2 Motion in the Cartesian Coordinate

The moving directions of each axis for the base coordinate system and the tool coordinate system are as follows.
The motion in the Cartesian coordinate contain the body axis movement for torch tip position and the wrist axis
movement for torch angle.
The movement of wrist axis does not depend on the system configuration set by Teach pendant, but depends on
the movement described in 1.6.2 Cartesian movement (2) Movement of wrist axis (Base coordinate system).
(1) Body Axis Movement (Base Coordinate System)
Fig. 1.6.2.1 Body Axis Movement in the Base Coordinate System
1-1-13
(2) Wrist Axis Movement (Base Coordinate System)
Axis J4 Movement
A torch rotates around the vertical line with the torch tip fixed.
Z-Axis
Z
Fig. 1.6.2.2 Axis J4 Moving Direction
Axis J5 Movement
A torch rotates over the horizontal line of Axis J5 with the torch tip fixed.
Fig. 1.6.2.3 Axis J5 Moving Direction
1-1-14
(3) Body Axis Movement (Tool Coordinate System)
Direction that the wire retracts from the torch is Axis X. Reference Position of Axis J4 angle display
indecates Axis Y. The Axis which cross Axis Z perpendiculary over the Axis J5 horizontally line in Axis X.
This coordinate system has dependence on the torch position: each moving changes as the position does.
Z-Axis
Z
Y-Axis X-Axis
Y X
Fig. 1.6.2.4 Body Axis Movement in Tool Coordinate System
Fig. 1.6.2.5 Body Axis Movement in the Tool Coordinate System when the Posture of the Manipulator Changes
1-1-15
WANNING
Movement Around the Singular Point in Cartesian Coordinate
Performing the manual operation in Cartesian coordinate or linear/circular interpolation movement around the
singular point may result in danger, causing abrupt movement of an unexpected axis. Therefore, when the
manipulator needs to work around the singular point, be sure to manually operate each axis.
In addition, teach a robot in such a manner that a linear/circular trajectory will not pass near the singular point.
Teaching otherwise provides no guarantee of the set velocity and the trajectory accuracy for the taught point.
NG3 have the following two postures referred to as Singular Point.
Singular Point: the position that rotation Axis J1, J3 and J4 are all in a same vertical plane.
1.6.2.6 Posture Near the Singular Point
1-1-16
1.7 Changing Working Range
1.7.1 Changing Working Range of Axis J1

Axis J1 can be changed its working range according to the ambient condition, which is available by changing the
setting position of stopper bolt as shown in the figure below. Also modify the Soft Limit area at this time.
Stopper Bolt

1.Remove Stopper Bolt 2.Install Stopper Bolt

Fig.1.7.1.1 Changing Working Range of Axis J1
Note that it must be set within +170 ~ -170 since the working range in excess of +/-170 cannot be set. In
addition, the arm must face the front of the robot in the working range. Select the working range from the + side
and the - side in Fig.1.7.1.2
The stopper bolts are mounted at +/-170 at factory shipment.
Stopper Bolt
Axis J1 (Fixed Side)
Rotary
Direction
J1
Arm
- Stopper
(Movable Side)
Arm Front

Axis J1
Rotary
Direction
J1

+
Fig.1.7.1.2 Stopper Bolt Setting Position
1-1-17
1.7.2 Changing Working Range of Axis J2 and J3 (with the option mounted)
For the axis J2 and J3, the working range can be changed by installing the optional Dog and Limit Switch.
At this time, modify the Soft Limit area as well. The installation position and the adjustment angle of Limit Switch
in each manipulator is shown in the figure below. When setting the dog, select a single position in each (+) and (-)
side in the desired working range.
Axis J2
Limit Switch

Axis J2 Rotary
Direction

Vertical Position
0

Axis J2 Rotary
Direction

Fig. 1.7.2.1 Dog Setting Position on Axis J2
Axis J3 Rotary
Direction

Front
0

Axis J3 Rotary
Direction

Axis J3
Limit Switch

Fig. 1.7.2.2 Dog Setting Position on Axis J3
1-1-18
1.8 Option
1.8 Option
(1) Parts to restrict the workings areas of Axes J2 and J3
The following parts can restrict the working areas of Axes J2 and J3 electrically.
DAIHEN Part No.. Name Specifications
L7403N00 Dog accessories Dog parts for working restriction of Axis J2 and J3.
L7400Q00 Cable assembly LS2 Limit switch parts for working restriction of Axis J2 and J3.
(2) Warning lamp
The warning lamp lights up while the robot is working (the servo power is ON).
This is mounted on the center of Axis J3 (on H/D Housing).
L6600R00 Warning lamp Coloramber
L6600S Warning lamp Colorred
(3) Manipulator stand
A manipulator stand is available by option.

For details, refer to 2.6.3 Using optional manipulator stand in this instruction manual.
L-3573 Stand For NG3 Stand height1200mm
Do not alter or remodel our products.

You may get injured or have your equipment damaged because of fire,
failure or malfunction caused by altering or remodeling the product.
DANGER The warranty does not cover any altered or remodeled products.
1-1-19
Chapter 2 Foundation Work and Installation
This chapter provides the instructions for the foundation work and installation.
2.1 Safety Measures Relating to Installation ................................................. 1-2-2

2.2 Installation Locations and Ambient Conditions ........................................ 1-2-5
2.3 Notes on Interference by Electromagnetic Noise .................................... 1-2-6
2.4 Accessories ............................................................................................. 1-2-7
2.5 Transport Method .................................................................................... 1-2-8
2.6 Installation of Manipulator ..................................................................... 1-2-10
2.6.1 Installation Method .......................................................................... 1-2-10
2.6.2 Installing Manipulator and Jigs on Common Frame Base ............... 1-2-11
2.6.3 Using Optional Manipulator Stand ................................................... 1-2-12
2.6.4 Maximum Manipulator Generative Force......................................... 1-2-13
2.7 Note on Emergency stop of Manipulator ............................................... 1-2-14
1-2-1
2.1 Safety Measures Relating to Installation
Measures to Ensure the Safety of Personnel Entering inside the Operating

Range of the Robot
While the robot is operating, there is a danger that the operators will come into contact
with the robot. For this reason, erect a guarding fence to ensure that the operators will
be kept at a distance from the robot. Accidents may occur if operators or other
DANGER individuals gain admittance inside the operating range of the robot by mistake.
Guarding fence
ISO 13857:2008 Safety of machinery - Safety distances to prevent hazard zone
being reached by the upper and lower limbs.
The guarding fence must be constructed in such a way that it cannot be easily climbed
over or easily moved. If the guarding fence is too low, individuals may climb over it and
enter inside the operating range of the robot, leading to accidents.
DANGER
Provide a door in the guarding fence to allow access in and out of the operating range.
Be absolutely sure to install a safety plug in the door, and construct the door in such a
way that it will not open unless the plug is removed. The entry of an individual inside the
CAUTION guarding fence can be detected by means of the signals from the safety plug.
Take steps to provide an interlock so that the servo power (motor power) of the robot
is turned off when the safety plug has been removed or ensure that the motor power
is turned off while the guarding fence is open. The robot can be stopped automatically
when an individual has made an attempt to enter inside the guarding fence. (The
CAUTION robot controller has a safety plug input.)
1-2-2
Provide the emergency stop button of the robot in a location where it can be pressed
immediately by the operator.
Accidents may occur since the emergency stop operation cannot be initiated
CAUTION immediately. (The robot controller has an external emergency stop input.)
If it is not possible to erect a guarding fence, install photoelectric switches, mat switches,
etc. in every location where individuals can enter inside the operating range of the robot
in place of the safety plug. The robot can be stopped automatically when an individual
DANGER has entered inside the operating range of the robot.
Color-code the floor so that the danger area (operating range of the robot) can be easily
identified visually.
CAUTION
Safety measures for positioning the robot and its peripheral devices
Do not position the operation and adjustment controls inside the operating range of the
robot. The robot may cramp the access to these controls.
Place the robot control panel, interlock panel and all other operation panels in positions
DANGER where they can be operated outside the guarding fence.
If an operation stand is to be provided, provide it with an emergency stop button as well.

Emergency stop can be initiated immediately even when fault occurs during operation
using the operation stand.
CAUTION
Do not route the wires and hoses between the robot body and the control panel,
inter-lock panel, etc. in such a way that the operators will trip over them or the forklift
trucks will run straight over them. Otherwise, operators may fall over, wires may break or
WARNING become disconnected, causing accidents.
Do not place the control panel, interlock panel, operation stand, etc. in positions where
the movements of the robot body are not visible.
If the robot movements cannot be seen, the operator will be slow to respond even when
fault has occurred, and this may lead to a serious accident. Accidents may also be
DANGER caused if the presence of the operators cannot be verified.
Place restrictions on the operating range of the robot if the necessary work range of the
robot is smaller than the range in which the robot can be operated. Restrictions can be
placed using limit switches and mechanical stoppers. Even if the robot has moved out of
CAUTION the normal work range due to a fault, for instance, it can be stopped ahead of time.
(Refer to 1.6 Changing Working Range .)
1-2-3
In the range where the movements of the robot body can be seen satisfactorily, install
light-shielding boards, covers, etc. in the directions where operators may be exposed to
spatter while welding is in progress. Operators may be injured by the light emitted during
CAUTION welding, by spatter, etc.
Ensure that the display of the automatic and manual modes indicating the operating
status of the robot is large and conspicuous enough to enable the modes to be easily
recognizable from a distance. The use of a buzzer, alarm or other warning to signal the
start of auto operation is also effective. This will enable the fact that auto operation is
WARNING underway to be easily verified from a distance.
Minimize the number of protruding parts on the devices around the robot.
If necessary, place covers over them. Protruding parts are dangerous when they are
touched by the operator even under normal circumstances, and they constitute a hazard
as well if the robot should suddenly move, surprising and possibly knocking over the
CAUTION operator in the process.
Avoid the kind of layout where operators need to put their hands inside the fenced
area to load and unload the work pieces. The robot may move to the place where an
operator has placed his or her hands inside the fenced area.
DANGER
Safety Precautions for Installation Work
In installing the robot, it is important to position the robot where the operator will not be
cramped. While tools are still installed on the robot, the robot must not be operated in its
maximum operating range so that it touches its peripheral devices.
WARNING
The designated method for installing the robot must be followed without fail. Following a
method which is not designated may cause the robot to move or topple over during
operation which is extremely dangerous.
WARNING
Before proceeding to connect the wires between the robot and the robot controller or
peripheral devices, ensure that the connection methods are thoroughly understood.
Faults may be caused in the operation of the robot by taking the wrong steps.
WARNING
Ensure that the grounding work is done properly. If there are any welders or other
devices that generate significant levels of noise, proceed with the designated
grounding work for them.
WARNING
When moving the robot into position and installing it, be very careful not to damage the
wiring. Furthermore, after having positioned the units, take protective measures such as
providing protective covers to ensure that the wiring will not be damaged by the
WARNING operators and other individuals or by the forklift truck.
1-2-4
2.2 Installation Locations and Ambient Conditions
2.2 Installation Locations and Ambient Conditions
(1) The ambient temperature must be in the 0 to 45 degrees Celsius range.

(2) The ambient relative humidity must be in the 20 to 85%RH range, and there must be no condensation.
(3) The amounts of dust, dirt, oily vapors, water, etc. must be minimal.
(4) There must be no flammable or corrosive liquids or gases present.
(5) There must be no major sources of impact or vibration.
(6) No major sources of electrical noise must be in the vicinity of the robot.
2
(7) The vibration level must be less than 0.5G (4.9m/s ).
(8) Avoid direct sunlight.
1-2-5
2.3 Notes on Interference by Electromagnetic Noise
2.3 Notes on Interference by Electromagnetic Noise

A high-frequency arc starting unit, an inverter-type welding power supply and other units that generate
electromagnetic noises may cause an adverse effect on the robot system, such as malfunction.
To prevent this effect, select a proper installation location and install them in a most appropriate manner
1-2-6
2.4 Accessories
2.4 Accessories
NG3 manipulator is provided with the following standard accessories.
Table. 2.4.0.1 Standard Accessories (L7700D)
Name Specifications Qt. Remarks

Hexagon Socket Head For fixing the main body
M16X50 4
Cap Screw (Strength grade: 10.9)
Spring Washer M16 4 For fixing the main body
NG3 can be provided with the following parts as optional accessories.
Table. 2.4.0.2 Optional Accessories
Name Specifications Qt. Remarks

Allen Wrench Set L7096B 1 Tool
Point Mark Assembly L7096C 1 For origin confirmation
Arrow Indicator Plate NB10107A 1set 12 pcs / set
1-2-7
2.5 Transport Method

Use a crane or a forklift to transport the manipulator for unpacking or installing. The manipulator must be
transported at the factory-configured posture as shown in Fig. 2.5.0.1 and Fig. 2.5.0.2.
When transporting the manipulator with a crane, hook a rope on the M12 eyebolts (2 pcs.) of manipulator using
shackles and lift it up as shown in Fig. 2.5.0.1.
When transporting the manipulator with a forklift, secure the manipulator onto a pallet as shown in Fig. 2.5.0.2 in
order to prevent it from overturning. The weight of a single NG3 manipulator is 144 kg. Use a pallet strong
enough to withstand that load.
Be sure to prevent impacts especially against the encoder of J2 and J3 motor during
transport. It may cause damage to the motor or encoder.
WARNING
When transporting or installing the manipulator, take ample care not to apply load by
such as putting your weight on or pulling the Axis J4 or J5 part, etc.
WARNING
Axis J3 Arm
Encoder of Axis J2 motor

Revolving Frame
Wire Rope

Withstand Loadmin. 800kg
Length min. 1.5m

Encoder of Axis J3 motor

3
Shackles

Prepare shackles that meet
the following requirements.
ModelSC-12
Withstand Load0.9t

Center of
Gravity
J4 Unit

(268)
J5 Unit
(198) (12)
Note) Center of gravity position is reference.

Fig. 2.5.0.1 Transport Method for Manipulator (by crane)
Table. 2.5.0.1 Axis Angle in the Transport Posture by Installation Type

Axis J1 Axis J2 Axis J3 Axis J4 Axis J5
0 45 -145 -35 -130
1-2-8
Protector

Fixing Rope
or
Belt
Pallet Forklift

Fig. 2.5.0.2 Transport Method for Manipulator (by forklift)
Ensure that the manipulator is moved into position by individuals who have acquired
the permits or licenses needed for carrying out slinging work, operating cranes,
driving forklift trucks, etc. The weights of the robot and the robot controller are given
in the Operation Manual and Maintenance Manual. After checking the weights, adopt
WARNING handling procedures which are commensurate with these weights.
When hoisting the manipulator and/or the robot controller, follow the method set forth
in this manual or in the Maintenance Manual. Moving the robot into position using a
method not specified by the manufacturer may cause the robot to topple over or fall,
WARNING which may lead to accidents.
Take more than enough care to ensure that the wiring is not damaged during the
moving and installation processes. After having positioned the units, take protective
measures such as providing protective covers to ensure that the wiring will not be
WARNING damaged by the operators, other individuals or the forklift trucks.
1-2-9
2.6
2.6 Installation of Manipulator
2.6.1 Installation Method

Large reaction force will be applied to the revolving base from all directions when the manipulator works at an
adjustable speed. Considering this mentioned above, the base needs to tolerate not only the static load but also
the reaction force at adjustable speed. Install the manipulator with its revolving base stable.
A
300
4xM12
240
4x18
242
300
310
180
RP 180 325
RP RP :Reference Plane
Fig. 2.6.1.1 Manipulator Installation Dimensionsunit : mm
1-2-10
2.6.2 Installing Manipulator and Jigs on Common Frame Base

Movements of the manipulator cause a large force of inertia, requiring the installation floor to be strong and rigid.
Therefore, when the manipulator and jigs are to be mounted together on the same common frame base, the
frame base must be at least 20 mm in thickness and the manipulator must be firmly fixed using four pieces of
hexagon socket head cap screws (M16) and spring washer with a tightening torque of 216 N*m. For the
mounting method of the manipulator on the base, see Fig. 2.6.2.1.
Spring Washer Hexagon Socket Head

Cap Screw(M16)

Robot-side Base

Common Frame Base

Fig. 2.6.2.1 Installing the Manipulator Directly on Common Frame Base
1-2-11
2.6
2.6.3 Using Optional Manipulator Stand

Movements of the manipulator cause a large force of inertia, requiring the installation floor to be strong and
rigid. When the concrete floor thickness is more than 200 mm, use anchor bolts (M16) shown in Fig. 2.6.3.1
for installation.
If the floor is not strong enough, use J-type anchor bolts as shown in Fig. 2.6.3.1 for installation.
The anchor Installation must be in conformity with the manufacturer indicator.
(The concrete anchors, J-type anchor bolts and jack bolts or the like must be prepared by a user.)
If the thickness of a concrete base is 200mm or less, form the foundation in advance after an enough review.
Jack Bolt (M12)

M12
Anchor Bolt (M16)
M16
Lock Nut Lock Nut(M16)
(Tightening Torque: 107.8 Nm)
(M12) M16
107.8 Nm
M12
Spring Washer (M16)
M16
420
4xM12 Flat Washer (M16)
320 M16
4x18
Manipulator Stand

Supporting Plate
420
Foundation

500
Fig. 2.6.3.1 Using an Optional Manipulator Stand for Installation (unit: mm)
1-2-12
2.6.4 Maximum Manipulator Generative Force

Movements of the manipulator may cause a large force as shown in Table 2.6.4.1.
Please design the common frame base that has an enough safety factor to the force shown below.
Table. 2.6.4.1 Maximum Manipulator Generative Force

Maximum vertical Maximum horizontal Maximum vertical Maximum horizontal
Name
generative force FV generative force FH generative moment MV generative moment MH
NG3 4500 N 3100 N 2800 N*m 2300 N*m
Fig 2.6.4.1 Maximum Manipulator Generative Force
1-2-13
2.6
2.7 Note on Emergency stop of Manipulator
Table 2.7.0.1 shows the length of time from Emergency stop SW pressed to the robot stopped and the
angles of each axis to move. For designing a work cell etc., these values shall be considered.
Table 2.7.0.1 Emergency stop of Manipulator

Stop Time Stop Angle
Model Axis No.
ms deg
Axis J1 600 27.2
Axis J2 600 33.7
NG3 Axis J3 570 34.8
Axis J4 580 73.0
Axis J5 590 78.8
1-2-14
Chapter 3 Periodic Inspection
This chapter provides the instructions on the periodic inspection.

3.1 Periodic Inspection ................................................................................................... 1-3-2
3.1.1 Safety Measures for Inspection, Maintenance,Adjustments and Repairs of the Manipulator 1-3-2
3.1.2 Periodic Inspection Schedule................................................................................ 1-3-4
3.1.3 Notes on Periodic Inspection ................................................................................ 1-3-4
3.1.4 Deadline for Supplying/ Repairing the Robot Maintenance Parts..................... 1-3-4
3.2 List of Maintenance Items ...................................................................................... 1-3-5
1-3-1
3.1 Periodic Inspection
3.1.1 Safety Measures for Inspection, Maintenance, Adjustments and Repairs of the Manipulator
To perform inspection, maintenance, adjustments, repairs or other similar work on the manipulator, access to the
robot working range may be required, or work with the primary-side power or the servo power turned on may be
necessary. In any case, be sure to observe the following precautions for inspection, maintenance, adjustments
and repairs.

You may get injured or have your equipment damaged because of fire, failure or
malfunction caused by altering or remodeling the product.
Whenever the power is ON, never enter the robot working range.
Approaching the operating robot may result in a fatal injury.
WARNING
Never touch any charged parts.

Touching any charged part may result in a fatal electric shock hazard or burn.
WARNING
Never put your hand, finger, hair, clothes or the like close to any rotating section.
Putting your hand, finger, hair or clothes close to the wire feed roll of the wire feed
unit may cause you to get caught, resulting in a serious injury.
Similarly, putting your hand, finger, hair or clothes close to the rotating section of a
WARNING cooling fan may cause you to get caught and hurt.
(1) Prior to carrying out robot inspection, maintenance, adjustments, repairs, etc., be sure to wear a helmet,
safety shoes, gloves and other protective means that may be deemed necessary, as specified by law.
To be more specific, wear clothes that are suited to each specific work.
(2) Prior to initiating work, press the EMERGENCY Stop button or the Stop button to check if the robot system
stops instantly. Furthermore, if a safety plug, a dead man switch or other protective devices are added to the
robot system, they must be checked for proper operation. Should any fault be detected, stop the inspection
work, turn off the primary power immediately, check for causes and take necessary countermeasures
accordingly.
(3) Ensure that personnel who are not operating the robot must not approach the guarding fence.
(4) Prior to starting work, put up a sign Under Inspection

at a visible place to let people around the robot system
know that inspection is now being carried out. Under Inspection
(5) Do not use any equipment that may generate electromagnetic noises, in and around the place where
inspection is being performed.
(6) At least two workers should be involved in the inspection or maintenance work, one performing actual work
and the other serving as a watcher.
(7) Personnel to be involved in robot inspection, maintenance, adjustment and/or repairs should receive
instructions and training on robot functions, operation and maintenance. In addition, if special equipment or
facilities are provided in the robot system, then their entire mechanism must also be fully understood.
(8) Robot inspection, maintenance, adjustment and repairs must be performed by only those who are qualified by
receiving special training. Furthermore, even if they have received such special training, they are not allowed
to perform inspection, maintenance, adjustment or repairs of other machinery that they are not fully familiar
with.
1-3-2
(9) Any sign that may be given to workers, watchmen and/or operators of related machines must be in conformity
with the Customers safety management standards.
(10) The watcher must observe the following. He shall:
(A) Stand at a place that commands a view of the entire robot working range, and devote himself to the duty
of watching the work.
(B) Always hold the EMERGENCY Stop button, and press it immediately whenever any abnormality occurs.
(C) Make sure that people other than those who are involved in inspection, etc. do not come close to the
robot working range.
(11) The workers to be involved in inspection or other work must observe the following.
(A) If work can be carried out outside the robot working range, specify the work details prior to starting the
work. In any case, be sure that work is done outside the robot working range.
(B) In principle, perform inspection, etc., with the robot stopped. However, if such inspection or other work is
inevitably required during robot operation, then be sure to report this to the responsible safety manager,
and with permission obtained, perform the work outside the robot working range.
(C) If the robot is required to be in an operable condition when performing inspection work or the like, specify
the work procedure details beforehand so that safe work can be efficiently proceeded with. Furthermore,
if work is not particularly required to be performed in the robot operable condition, carry out the work with
the robot controller, the welding power supply and/or other input-side power supplies all turned off. If no
special safety procedure is required, be sure to turn off such input-side power supplies for jigs and
peripheral equipment or to make them inactive.
(D) When working in the robot working range, be sure you are always in a ready-to-act posture so that you
can immediately press the EMERGENCY Stop button just in case of robot malfunction.
(E) Carefully check your footing before starting work. Be sure to avoid an unstable scaffold or a scaffold
provided at an elevated position (more than 2 meters high).
(F) When you are in the robot working range, do not perform work with your back facing the manipulator.
(G) To replace PCBs provided in the robot controller or the teach pendant, take anti-static electricity
countermeasures including anti static electricity sheets.
(12) If any abnormal condition has occurred during work, carefully perform the following procedure.
(A) If any malfunction is observed on the robot system, immediately press the EMERGENCY Stop button.
(B) Immediately report this to the watcher, turn off the control power
Do not Switch ON
of the robot controller, then put up a sign Do not switch on.
(C) Be sure to check that all the related machines are stopped.
(D) When necessity arises to go inside the guarding fence, be sure that the person who is going to enter pulls
out the safety plug himself, carries it with him and proceeds with the work concerned.
(E) Even when the robot has automatically stopped due to a fault in supply voltage to the robot system,
hydraulic pressure or air pressure of related equipment, make sure that it is at a complete stop, then
investigate causes to take necessary countermeasures.
(F) If the EMERGENCY Stop switch or other safety devices should have failed to operate, immediately turn
off the primary power, investigate causes and take necessary countermeasures.
(G) To restart the robot after stopping it by pressing the EMERGENCY Stop button, investigate causes, take
necessary countermeasures, replace the safety plug, then restart it from outside the guarding fence.
(13) To end the work, carefully check that the necessary connectors, covers, panels, etc. have been all correctly
mounted and wired.
1-3-3
3.1.2 Periodic Inspection Schedule

The periodic inspection is indispensable in order to continue operating Almega series in a safe and an efficient
manner. Perform the periodic inspection in accordance with the following schedule.
Be sure to overhaul in either a period of whole 6 years or 30,000 cumulative operating hours after delivery,
whichever is shorter.
The inspection and maintenance period is estimated, supposing the manipulator only for Arc welding use. For
more frequent use such as handling operation, that period may be shorter.
Contact to our engineers for details.
3yrs
Maintenance
1yr 1yr 1yr
Inspection Inspection Inspection
3mths 3mths 3mths 3mths 3mths 3mths 3mths 3mths 3mths 3mths 3mths 3mths
Inspection Inspection Inspection Inspection Inspection Inspection Inspection Inspection Inspection Inspection Inspection Inspection
Daily Inspection
0 3mths 6mths 9mths 1yr 15mths 18mths 21mths 2yrs 27mths 30mths 33mths 3yrs
3.1.3 Notes on Periodic Inspection
(1) Periodic inspection must be performed by those who have received the special training program by the
Government or DAIHEN Corporation and maintenance instructions offered by DAIHEN Corporation, or at
their presence (Under the Regulations on Industrial Robots: Article 19 and Paragraph 32 of Article 36).
(2) Prior to performing inspection or maintenance, be sure to turn off the external breaker.
Note that, with turning off only the non-fuse breaker of the robot controller, the primary side of the non-fuse
breaker is still being applied with voltage.
In order to show that inspection or maintenance is underway, hang a noticeable sign on the switch of the
external breaker.
WARNING
ELECTRIC SHOCK

can kill.
Do not touch live electrical
Never touch the charged parts.

parts.
Disconnect all power
before installing or servicing.

Multiple sources of voltage
WARNING

may exist inside this
enclosure.
NK3637
3.1.4 Deadline for Supplying/ Repairing the Robot Maintenance Parts
Deadline for supplying the robot maintenance parts is guaranteed for 7 years from the discontinuation date of the
product, and that for repairing is for 10 years.
For the detailed information about discontinuation date of the product, please see the guidance on the
maintenance parts in our homepage: http://www.daihen.co.jp/ .
Repair of the maintenance parts is provided for the above period of time in principle, however, we will support
our customers as long as the stock is available.
We will make our every effort to secure the required maintenance parts. However, please note that it may be
occasionally unavailable due to the external factors such as the market situation even during the guaranteed
period.
1-3-4
3.2 List of Maintenance Items
3.2.1 NG3 Manipulator

Mainten
Inspection
-ance
No
Location Item Corrective Action
. 3 1 3 6
Daily
mths yr yrs yrs
Entire Outer Attached spatter, dust
1 Visual check and cleaning
appearance or other foreign matter
2 Matchmark panel Peeling, soiling Visual check
External cable Scratches, soiling and
3 Visual check
Lead wire loose connectors
Check with torch
Cracks, chipping and
4 Torch mount positioning gauge
bending
Replacing the parts
Visual check with origin
5 Torch aiming point Deviation
checking program.
Looseness at cable
connection Retightening
Worn tip Replacing tip
6 Welding torch Attached spatter on
Cleaning or replacing
nozzle
Attached spatter on
Cleaning
torch mounted section
Visual check, inspection
Worm feed roll
and replacing if needed.
7 Wire feed unit
Attached oil or dust on
Cleaning
strainer and feed roll
Scratched or bent
Coaxial power Visual check, inspection
cable
cable and replacing if needed.
Worn or bent coil liner
Gas hose
8 Damaged hose, gas Check with soapy water
Welding power
leakage applied and replacing
cable
Conduit cable Looseness at cable
Retightening
connection
9 Base bolts Looseness Retightening
Connector housing
10 Looseness Retightening
Base portion
No noise and vibration by
servo ON.
11 Brake Brake operating
No falling of the arm with
the servo OFF.
Damaged cable
Check visually and
Loose connectors
12 Internal wires retighten if necessary.
Bolt for mounting
Replacement Replacement
Bearing check by moving
13 Link mechanism Visual and touch check
Axis J2 arm up and down
Grease replenishment
Reduction gear See Chapter 4.1
14 Abnormality in the
(Axis J1, J2) Replacing if the reduction
reduction gear
gear is abnormal
Reduction gear See Chapter 4.1
15 Abnormality in the
(Axis J3, J4, J5) Replacing if the reduction
reduction gear
gear is abnormal
Cross roller bearing Grease replenishment
(See Chapter 4.2)
16 (J2-J3 axis joint and Abnormality in the
Replacing if the cross roller
Axis J3) Cross roller bearing
bearing is abnormal
Replacement
17 Battery Replacement
See Chapter 4.2
18 Overhaul
Inspection
Replacement
1-3-5
14 7
16
8 3
1
9
15
16
15 6
2
4
15
17
10
14
12
Fig. 3.2.0.1 Check Points of Manipulator
WARNING
ELECTRIC SHOCK

can kill.
Do not touch live electrical
Never touch live electrical parts.

parts.
Disconnect all power
before installing or servicing.

Multiple sources of voltage
WARNING

may exist inside this
enclosure.
NK3637
1-3-6
This chapter provides the instructions on the maintenance of robots.

4.1 Grease Replacement and Replenishment of Reduction Gears ............. 1-4-4
4.1.1 Grease Replacement Procedure for Axis J1, J2 and J3 Reduction Gears 1-4-4
4.1.2 Grease Replacement Procedure for Axis J3, J4 and J5 Reduction Gears 1-4-7
4.2 Grease Replenishment for Cross Roller Bearing ................................... 1-4-8
4.2.1 Grease Replenishment Procedure for Cross Roller Bearing of J2-3 Axis Joint .. 1-4-8
4.2.2 Grease Replenishment Procedure for Axis J3 Cross Roller Bearing ........ 1-4-9
4.3 Battery ................................................................................................. 1-4-10
4.3.1 Function of Battery ................................................................................... 1-4-10
4.3.1 Specification of Battery............................................................................. 1-4-10
4.3.2 Replacing Battery ..................................................................................... 1-4-10
4.3.3 Notes on Battery Safekeeping ................................................................. 1-4-11
4.4 Replacing Internal Wires...................................................................... 1-4-12
1-4-1
This chapter provides the instructions on the maintenance of robots.
To perform inspection, maintenance, adjustment, repairs or other similar works on the robot system, access to
the robot working range may be required, or work with the primary-side power or the servo power turned on
may be necessary. In any case, be sure to observe the following precautions for inspection, maintenance,
adjustments and repairs.

You may get injured or have your equipment damaged because of fire,
failure or malfunction caused by altering or remodeling the product.
Whenever the power is ON, never enter the robot working range.
Approaching the operating robot may result in a fatal injury.
WARNING
Never touch any live electrical parts.

Touching any live electrical parts may result in a fatal electric shock hazard or a burn.
WARNING
Never put your hand, finger, hair, clothes or the like close to any rotating section.
Bringing hands, fingers, hair or clothes close to the wire feed roll of the wire feed unit
may cause an injury by being caught by it.
Bringing hands, fingers, hair or clothes close to the rotating section of a cooling fan may
WARNING cause an injury by being caught by it.
(1) Before carrying out robot inspection, maintenance, adjustments, repairs, etc., be sure to wear a helmet,
safety shoes, gloves and other protective means that may be deemed necessary, as specified by law.
To be more specific, wear clothes that are suited to each specific work.
(2) Before operation, be sure to check that the robot can certainly stop when needed by testing the
emergency stop or temporary stop. Also, check that the fail-safe devices such as the safety plug or
enable SW, if equipped, properly work. If errors occur, stop the operation and immediately shut off the
power supply. Then, inspect the cause of trouble to take remedies appropriate to the situation.
(3) Ensure that personnel who are not operating the robot must not approach the guarding fence.
(4) Before starting work, put up a sign Under Inspection Under Inspection
at a visible place to notify people around the robot system
that the inspection is now underway.
(5) Do not use any devices that may generate electromagnetic noises in and around the place where the
inspection is being conducted.
(6) At least two workers should be involved in the inspection or maintenance work, one performing the actual
work and the other serving as a watchman.
(7) Personnel who are going to conduct the robot inspection, maintenance, adjustment and/or repairs should
receive instructions and training on robot functions, operation and maintenance. In addition, if special
devices or facilities are provided in the robot system, their entire mechanism must also be fully understood.
(8) Robot inspection, maintenance, adjustment and repairs must be performed only by qualified personnel who
have received special training. Furthermore, even if they have received such special training, they are not
allowed to perform inspection, maintenance, adjustment or repairs of machinery other than those they are
fully familiar with.
(9) Any sign that may be given to workers, watchmen and/or operators of related machines must be in
conformity with the Customers safety management standards.
1-4-2
(10) The watchman has to observe the following.
(A) Stand at a place that commands a view of the entire robot work envelope and concentrate on the duty of watching
the work.
(B) Always hold the EMERGENCY STOP button and press it immediately whenever any abnormality occurs.
(C) Keep personnel except the teaching operator away from the robot work envelope.
(11) The workers to be involved in the inspection or other works must observe the following.
(A) If work can be carried out outside the robot working range, specify the work details before starting the work and
make sure to carry out the work outside the robot working range.
(B) In principle, perform inspection, etc., with the robot stopped. However, if the inspection or other work is inevitably
required while the robot is operating, be sure to report this to the responsible safety manager, and, with permission
obtained, perform the work outside the robot working range.
(C) If the robot is required to be in an operable condition when the inspection work or the like is carried out, specify the
work procedure in detail beforehand so that work can be carried out safely and efficiently. Furthermore, if work is not
particularly required to be performed in the robot operable condition, carry out the work while the robot controller, the
welding power supply and/or other input-side power supplies are all turned off.
If no special safety procedure is required, be sure to turn off such input-side power supplies for jigs and peripheral
equipment or make them inactive.
(D) When working in the robot working range, be sure that you are always in a ready-to-act posture to be promptly able
to press the EMERGENCY Stop button in case of robot malfunction.
(E) Check your footing carefully before initiating work. Be sure to avoid an unsTable scaffold or a scaffold provided at an
elevated position (more than 2 meters high).
(F) When you are in the robot working range, do not perform work with your back facing the manipulator.
(G) When replacing PCBs provided in the robot controller or the teach pendant, take countermeasures against static
electricity, for instance by using anti-static electricity sheets.
(12) If any abnormal condition occurs during the work, follow the procedure below carefully.
(A) If any malfunction is observed in the robot system, press the EMERGENCY Stop button immediately.
(B) Report this immediately to the watchman, turn off the control
power of the robot controller, and then put up a sign
Do Not Switch On. Do Not Switch ON
(C) Make sure that all the related machines are stopped.
(D) When necessity arises to go inside the guarding fence, be sure that the person who is going to enter pulls out the
safety plug himself, carries it with him while proceeding with the work concerned.
(E) Even when the robot has automatically stopped due to a fault in supply voltage to the robot system, hydraulic
pressure or air pressure of related equipment, make sure that the robot is at a complete stop. Then, investigate
causes and take necessary countermeasures.
(F) If the EMERGENCY Stop switch or other safety devices should have failed to operate, turn off the primary power
immediately, investigate causes and take necessary countermeasures.
(G) In order to restart the robot after stopping it by pressing the EMERGENCY Stop button, investigate causes, take
necessary countermeasures, replace the safety plug, and then restart it from outside the guarding fence.
(13) To end the work, check carefully that the necessary connectors, covers, panels, etc. have been all
correctly mounted and wired.
1-4-3
4.1 Grease Replacement and Replenishment of Reduction Gears

Carry out periodical replacement and replenishment of grease for the reduction gear, referring to Table 4.1.0.1.
Table 4.1.0.1 Period of Replacement and Replenishment Grease

Axis Name Period for Replacement and Replenishment of Grease
Every one year or every 3,000 operating hours,
J1, J2 Replacement
whichever is shorter period.
Every one year or every 3,000 operating hours,
J3, J4, J5 Replenishment
whichever is shorter period.
If you request us for replacement or replenishment work, you will be charged for the work.
4.1.1 Grease Replacement Procedure for Axis J1, J2 and J3 Reduction Gears
For the location of inlet and outlet, see Fig.4.1.1.4
Use the grease gun with the filling amount check counter function.
If it is not possible to prepare the tool to check the grease filling amount, users are able to measure the difference in
the grease amount before and after the greasing work to see the amount actually injected. Injecting of grease more
than necessary may cause a grease leakage or abnormal robot operation.
When the internal pressure is at the high level such as soon after the manipulator has stopped, it is very dangerous
because the grease may spatter at the moment of removing the plug of grease inlet port and outlet port. Therefore,
take enough care in performing soon after the manipulator has stopped.
(1) Set the posture of manipulator suiTable for the work.

Table 4.1.1.1 Posture at the Grease Replacement
Axis J1 Axis J2
Any 0
TP display angle of Axis J1 and J2 is the one of the Axis J1 and J2 displayed when the
axis monitor is started with the teach pendant.
(2) Remove the orifice plug at the grease drain port (J1 axis) and the grease nipple (J2 axis).
(3) Replace the grease nipple on Axis J2 (or A-PT 1/8 type) with a plug on each axis inlet.
(4) Make sure that neither grease inlet port nor outlet port has a choke. Inject the grease for some 50mm from the
tip of the outlet hose [85, Max. length 100mm].Attach the air equipment fitting [Rc1/8,8] and the outlet
hose to the outlet port.
As the outlet port for the J1 axis is located inside the frame, attach the air equipment fitting and the hose to
the outlet port and lay it outside the frame.
Fig.4.1.1.1 Air Equipment Fitting and Outlet Hose for Choke Checking
1-4-4
(5) Prepare the grease catch container under the outlet part. Use the grease gun to inject the grease of 1.4ml
from the grease inlet port at the rate of 1.6ml/sec. or lower. And make sure that the grease comes out from the
tip of outlet hose. If not, eliminate a choke from the hole of inlet and outlet port.
Fig.4.1.1.2 Grease Catch Container
(6) Use the grease gun to inject the given amount of grease at the rate of 1.6ml/sec. or lower. At this time, make
sure that the color of grease come out is gradually going to change. In addition, be sure to observe the
injecting rate. If not, it may cause a abnormal robot operation.
Grease to use is MOLI WHITE RE00, and the filling amount is as follows.
Table 4.1.1.1 Amount of Grease
Axis J1 Axis J2
NG3 480ml 220ml
The density of MOLI WHITE RE00 is 0.9g/ml.
(7) Check the amount of grease injected and discharged when the actual injecting amount reaches the given
filling amount. As for the actual injecting amount, check the grease gun counter or the difference in the amount
before and after the greasing work. For the discharged amount on the other hand, check the grease catch
container to see the difference in the amount before and after the greasing work. When the amount of injected
and discharged becomes equal, it is considered that the grease replacement has been completed. Then, go to
the procedure (12).
(8) If the discharged amount is less than the injected amount, the difference indicates the surplus. In that case,
discharge the surplus by applying push-out air into the outlet port so that the injected and discharged amount
becomes equal.
(9) Remove the grease nipple from the inlet port, and attach the air equipment fitting [Rc1/8,8] and the outlet
hose [85, Max. length 100mm] to the inlet port.
(10) Prepare the grease catch container as shown in Fig.4.1.1.2.
(11) Make the pressure of push-out air lower than the maximum of 0.025MPa using the precision regulator.
If the grease does not come out but only air even if applying push-out air, operate the target axis at the low
speed with the posture shown in Table 4.1.1.3 and within the working range shown in Fig.4.1.1.3, applying
push-out air at the same time, to discharge the surplus. When the amount of injected and discharged
becomes equal, it is considered that the grease replacement has been completed. Then, go to the procedure
(12).
Table 4.1.1.3 Recommended Posture
Recommended Recommended
Axis posture with posture with
J1 axis at motion J2 axis at motion
Axis J1 Any Any
Axis J2 Any 0
Axis J3 Any Any
1-4-5
10
10
(a) Low Speed Working Range of J1 Axis

10
10
(b) Low Speed Working Range of J2 Axis
Fig.4.1.1.3 Low Speed Working Range in Applying Push-out Air

(12) Wipe off grease adhered to the body, and attach the plug. To attach it, wrap the seal tape around the screw
part.
When operating after grease replenishment, grease may leak from the outlet. This is just remains from
the outlet, not an abnormal thing. Wipe off leaked grease.
The Rc1/8 grease nipple, orifice plug and plug are tightened by torques of 8 N*m.
On completion of replacement, be sure to attach the plug to the grease inlet port of J1, J2 axis and fit the
removed orifice plug to the outlet port of J1 axis, grease nipple to the outlet port of J2 axis.
Axis J2 Outlet(Rc 1/8)

(Grease nipple)
(Rc 1/8)
()
Axis J1 outlet(Rc 1/8)

(Orifice plug)
(Rc 1/8)
()
Axis J2 Inlet(Rc 1/8)

(Plug)
(Rc 1/8)

Axis J1 Inlet(Rc 1/8)
(Plug)
1(Rc 1/8)
()
Fig.4.1.1.4 Location of Grease Inlet and Outlet in Axis J1 and J2 Reduction Gears
1-4-6
4.1.2 Grease Replacement Procedure for Axis J3, J4 and J5 Reduction Gears

NG3 Axis J3 Axis J4 Axis J5
Grease Harmonic SK-2 Harmonic SK-2 Harmonic SK-2
Amount 5ml 3ml 3ml
(1) Remove the plugs of grease filler port and air vent hole on the axis J3, J4 and J5.
(2) Apply grease (Harmonic SK-2) to the Axis J4, J5 and J6 using a sharpened-point tool such as an injector.
Comply with the prescription as shown inTable 4.1.2.1.
(3) After filling grease, attach the plugs (2 places each) using the tightening torque 2.5Nm.
In attaching the plugs, wrap a sealing tape around the screw part.
Axis J3 Plug
(Grease filler port)
Axis J3 Plug
M6x0.75
(Air vent hole)

()
(M6x0.75)
Axis J4 Plug

M6x0.75
Axis J4 Plug
(Air vent hole)

()
(M6x0.75)
Axis J5 Plug
(Air vent hole) Axis J5 Plug
()
(M6x0.75) M6x0.75
Fig.4.1.2.1 Plug Positions of Axis J3, J4 and J5 Reduction Gears
Do not enter the robot work area while the power is ON.
Also, never apply grease while the robot is operating.
Be sure to take out a plug and grease nipple in the outlet port, otherwise grease may
flow into the motor inside to result in damage of the motor.
Carry out the proper replacement/refill of grease, otherwise the reduction gear may
be damaged.
WARNING
When the internal pressure is at the high level such as soon after the manipulator
has stopped, it is very dangerous because the grease may spatter at the moment of
removing the plug of grease inlet port and outlet port. Therefore, take enough care
in performing soon after the manipulator has stopped.
1-4-7
4.2 Grease Replenishment for Cross Roller Bearing

Replenish the cross roller bearing with grease according to the cycle shown in Table 4.2.0.1.
Table 4.2.0.1 Grease Replenishment Cycle
Axis Name Cycle of Replenishment

J2, J3 Every one year or every 3,000 operating hours, whichever is shorter.
If you request us for replenishment work, you will be charged for the work.
4.2.1 Grease Replenishment Procedure for Cross Roller Bearing of J2-3 Axis Joint

Amount of Grease
Type TP Display Angle of Axis J2
Upside Downside
50
NG3 1ml each 1ml each
0
You are recommended to use a manual grease gun with a displacement of 1ml.
When the amount of grease is more than the specified one, the operation will not be
hindered, while the grease may leak from the rotating section.
TP display angle of Axis J2 is the one of the Axis J2 displayed when the axis monitor is
started with the teach pendant.
(1) Remove the plug at the lower grease filling port of the J2-J3 axis joint (lower one out of two places).
(2) Fill grease using the grease gun from the upper filling port. Use a grease gun to fill grease. Grease to
be used is Daphne Multilex WR No.2. Position Axis J2 at the TP display angle as shown in Table
4.2.1.1, and inject the amount specified in this Table. Before greasing, make sure that the
manipulator is servo OFF.
(3) After filling grease from the upper filling port, remove the grease nipple (A-M6F) and fit it to the lower
filling port. (To fix the nipple, tighten it by hand, and turn it around about one-sixth.)
(4) Fill grease using the grease gun from the lower filling port too, just in the same way as done from the
upper filling port.
(5) After filling grease, attach a grease nipple to filler port upside and a plug to filler port downside filler
port. In attaching the plugs, wrap a sealing tape around the screw part. The tightening torque for each
plug of Rc1/8 is specified to be 2.5 N*m. After greasing, shake down the Axis J2 after the
application to have grease spread.
D ow n si de
A xi s J 2 -J 3 j oi nt gr ea s e f il ler p ort
(P l ug :M 6 x0 .75 )

J2 -J 3
L ab el
L a be l ( : M6 x0 .7 5)

U ps id e
Ax i s J2 - J3 jo in t g re a se fi ll er po rt
( Gr ea s e ni p pl e: A-M 6F )
B
J2-J3
( :A -M 6F )
Fig.4.2.1.1 Location of Grease Inlet Plug of J2-3 Axis Joint Cross Roller Bearing
1-4-8
4.2.2 Grease Replenishment Procedure for Axis J3 Cross Roller Bearing

TP Display Angle of Amount of
Type
Axis J3 Grease
-90
0
NG3 1ml each
90
150
You are recommended to use a manual grease gun with a displacement of 1ml.
When the amount of grease is more than the specified one, the operation will not be
hindered, while the grease may leak from the rotating section.
TP display angle of Axis J3 is the one of the Axis J3 displayed when the axis monitor is
started with the teach pendant.
(1) Apply grease using a grease gun. Grease to be used is Daphne Multilex WR No.2.
Operate the Axis J3 to the TP display angle shown in Table 4.2.2.1 to apply the amount of grease shown in the
Table.
After filling grease, take out a grease nipple and put a rubber stopper once removed in (1) back on a filler port of
the cross roller bearing. Then, attach a plug. In attaching the plugs, wrap a sealing tape around the screw part.
Before greasing, make sure that the manipulator is servo OFF.
(2) After greasing, shake down the Axis J3 after the application to have grease spread.
La bel

Gre as e fi ll er por t

Fig.4.2.2.1 Location of Grease Inlet Plug of Axis J3 Cross Roller Bearing
Do not enter the robot work area while the power is ON.
Also, never apply grease while the robot is operating.
WARNING Carry out the proper replacement/refill of grease, otherwise the bearing may be
damaged.
1-4-9
4.3 Battery
4.3 Battery
4.3.1 Function of Battery

A battery is provided to back up data of each absolute encoder used in the manipulators. This battery supplies
power to the absolute encoder for data backup purpose when the control power is OFF.
If the battery voltage excessively drops, it may fail to properly store the data. Timing of replacement depends
on the use condition, however, replace all of them at once periodically once in 3 years.
The life of the battery is about three years. If more than three years have passed,
the battery has to be replaced.
This is not a rechargeable battery. If you try to charge this battery, it may be
damaged. Be sure not to try charge this battery.
WARNING
The data backup period of the absolute encoder might become shorter depending
on the environmental conditions, operating conditions, and other factors.
4.3.2 Specification of Battery

Nominal voltage: 3.6V
* The above specification is applicable when absolute encoders and other loads are connected.
4.3.3 Replacing Battery

The replacing procedure described below.see Fig.4.3.3.1
(1) Perform check go/back operation in accordance with the origin position check program <such as P9999>
and make sure that the origin position is in alignment with the matchmark <> . If that is not the case, mark
that position.
(2) Remove the upper surface cover from the manipulator.
(3) While the control power is ON, cut off the tie band that fixes the batteries and take off the battery box.
(4) Replace the used batteries in the battery case with the new one. Replace with only DAIHEN Part
No.5096-434. Be sure to replace all of them at a time. At this time, be careful at the orientation in which
batteries are inserted. If placing a battery in a wrong position, the battery may be damaged.
Disconnecting the battery with the control power OFF results in the loss of absolute
encoder data. Be sure to turn on the control power when replacing the battery.
When the power is ON, never touch any parts of the robot controller other than the
battery since doing so may result in an electric shock hazard.
Because of the possible occurrence of a fire or an electric shock hazard, never

attempt to short circuit when replacing the battery with a new one or while conveying
and scrapping it.
WARNING This battery is lithium battery. Be sure to scrap it in accordance with law or the like.
Do not dispose of batteries in fire. If the batteries are put in fire, they may explode by
rapid heating.
The replacement of the batteries should be done in principle by a trained technician.
At disposal of the batteries, insulate the terminal parts with or the like.
1-4-10
4.3 Battery
(5) Connect three new battery connectors.
(6) Fix the battery box with a tie band. At this time, be careful at the orientation of the battery box. If the orientation
is wrong, the batteries may be damaged (see Fig.4.3.3.1).
The tie band is to be prepared by a customer.
(7) Install a connector plate.
(8) Perform check go/back operation in accordance with the origin position check program <P9999>, and make
sure that the origin position will not change from that obtained in (1) above.
(9) Perform encoder reset operation at the basic posture check program <P9999>. Refer to the instruction
manual SETUP. Also, see the aforementioned section to reset the encoder if the encoder data have been
lost.
Tie Band
Battery
CN.3133
CN.2 Battery Box
CN.1 View "A"
Fig. 4.3.3.1 Battery
4.3.4 Notes on Battery Safekeeping

Store the battery in non-condensing, well ventilated locations, avoiding high temperatures and high humidity.
You are recommended to store them at room temperature(20+/-15) with minimal temperature variation and
relative humidity of 70% or below.
Note that the batteries are to be stored only for 6 months, and enforce First-in, first-out rigidly.
Because of the possible occurrence of a fire or an electric shock hazard, never

attempt to short circuit when replacing the battery with a new one or while conveying
and scrapping it.
WARNING
This battery is lithium battery. Be sure to scrap it in accordance with law or the like.
1-4-11
4.4 Replacing Internal Wires
4.4 Replacing Internal Wires

Replace the internal wires of manipulator every 3 years or every 15,000 operating hours, though the use
condition may differ in each case.
Before replacing, contact to DAIHEN.

1-4-12
Chapter 5 Parts List
This chapter provides the instructions on the Parts List.

5.1 Parts List............................................................................................... 1-5-2
5.1.1 NG3.................................................................................................... 1-5-2
5.2 Location and List of Warning Label....................................................... 1-5-4
1-5-1
5.1 Parts List
5.1 Parts List
5.1.1 NG3
Location Ref. No. Parts Name DWG. No. & Model Qty DAIHEN Part No.
AC Servomotor W-L01830 1 100-0255
RV Reduction Gear W-L00963 1 5096-244
Axis J1
Limit Switch W-35630 1 4254-101
Grease Moly White RE No.00 480ml 2670-013*
AC Servomotor W-L01830 1 100-0255
RV Reduction Gear W-L00962 1 5096-213
Axis J2 Grease Moly White RE No.00 220ml 2670-013*
Cross Roller Bearing W-L02409 1 W-L02409
Grease Daphne Multilex WR No.2 4ml 100-1491*
AC Servomotor W-L02659 1 W-L02659
Harmonic Reduction Gear W-L01430 1 5096-453
Axis J3 Grease Harmonic SK-2 5ml 2670-053*
Cross Roller Bearing W-L02409 1 W-L02409
Grease Daphne Multilex WR No.2 4ml 100-1491*
AC Servomotor L11444H00 1 L11444H00
Axis J4 Harmonic Reduction Gear W-L01426 1 5096-454
Grease Harmonic SK-2 3ml 2670-053*
AC Servomotor L11444H00 1 L11444H00
Axis J5 Harmonic Reduction Gear W-L01426 1 5096-454
Grease Harmonic SK-2 3ml 2670-053*
Battery W-L01399 3 5096-434
Cable Assembly (1)
L11444G00 1 L11444G00
(Frame rear to H/D Housing)
Internal Cable Assembly (2)
Wires (For Axis J4 and J5 of H/D L11444J00 1 L11444J00
Housing interior)
Cable Assembly (3)
(For Axis J5 of Axis J4 Shaft L7403J00 1 L7403J00
interior)
Axis J4 Unit L11444C00 1 L11444C00
Assembly
Axis J5 Unit L11444B00 1 L11444B00
Note) On January 1, 2009, for revision of the UN Recommendations on the Transport of Dangerous Goods, Model
Regulations-15th edition, Transportation regulation of Lithium battery is partially revised.
When you transport the Lithium battery by air, transport it according to providing items of the newest ICAO-TI and
IMDG Code of IMO
IMPORTANT
1. Grease: Minimum quantity for a single order of Moly White RE No.00 is about 575 ml in a 500-g can.
2. Grease: Minimum quantity for a single order of Harmonic SK-2 is about 500 ml in a 500-g can.
3. Grease: Minimum quantity for a single order of Daphne Multilex WR No.2 is 400g.
4. * mark is recommendatory spare parts.
1-5-2
5.1 Parts List
Fig. 5.1.1.1 NG3

1-5-3
5.2 Location and List
5.2 Location and List of Warning Label
Every manipulator and robot controller of Almega series is provided with warning labels (that states the special
cautions to be observed) to ensure the safe operation of the robot system.
If such warning labels have been peeled off or damaged, order them from our local distributor or our sales
office.
Table.5.2.0.1 Warning Label
Location Item Name Parts No. Qty

Manipulator Warning Label NK7248 3
NG3 Caution Label NK7024 1
Fig. 5.2.0.1 Warning Label Location
1-5-4
Chapter 6 Internal Wires
This chapter provides the instructions on the Internal Wires.
6.1 Wiring Connection Figure ........................................................................1-6-2

6.1.1 Wiring Connection Figure for NG3 .....................................................1-6-2
1-6-1
6.1 Wiring Connection Figure
6.1.1 Wiring Connection Figure for NG3
Fig. 6.1.1.1 Wiring Connection Figure for NG3
1-6-2
Fig. 6.1.1.2 Wiring Connection Figure for NG3

1-6-3

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Chapter 1 Specifications of G-Type Manipulator

1.1 Manipulator model .................................................................................................................. 1-1-2

1.2 Basic Specifications ................................................................................................................ 1-1-3

1.3 Outside Dimensions and Working Range ............................................................................... 1-1-4

1.4 Description on Each Part of Manipulator ................................................................................ 1-1-5

Chapter 2 Foundation Work and Installation

2.1 Safety Measures Relating to Installation ................................................................................. 1-2-2

2.2 Installation Locations and Ambient Conditions ....................................................................... 1-2-5

2.3 Notes on Interference by Electromagnetic Noise.................................................................... 1-2-6

2.4 Accessories ............................................................................................................................. 1-2-7

2.5 Transport Method .................................................................................................................... 1-2-8

2.6 Installation of Manipulator ..................................................................................................... 1-2-10

Chapter 3 Periodic Inspection

3.1 Periodic Inspection .................................................................................................................. 1-3-2

4.1 Grease Replacement and Replenishment of Reduction Gears ................................................. 4-4

Chapter 5 Parts List

5.1 Parts List .................................................................................................................................... 5-2

Chapter 6 Internal Wires

6.1 Wiring Connection Figure .......................................................................................................... 6-2

Capter 1 Specifications of G-Type Manipulator

Capter 2 Foundation Work and Installation

Capter 3 Periodic Inspection

Capter 5 Parts List

Capter 6 Internal Wires

This chapter describes the specifications of G-type manipulator.

1.1 Manipulator model................................................................................... 1-1-2

1.1 Manipulator model

The following section shows the nomenclature of manipulator model.

F Floor-installed Classification by mount type

J Domestic specification Classification by shipment

Manipulator series No.

1.2 Basic Specifications

J3 (Revolving 2) +/- 150

Arm J2 (Up and Down) 2.79 rad/s160/s

Moment J5 (Bending) 2.5 N*m

1.3 Outside Dimensions and Working Range

116 430 130 500 300 300

TCP Working Range 170

TCP Working Range

Fig. 1.2.0.1 Outside Dimensions and Working Range (unit : mm)

1.4 Description on Each Part of Manipulator

1.4.1 Allowable Load on Wrist Axis

Table 1.4.1.1 Allowable Load on Wrist Axis

Distance from Axis J4

Fig. 1.4.1.1 Allowable Load on Wrist Axis

Fig. 1.4.1.2 Wrist Load Conditions

1.4.2 Flange Dimensions of Wrist Axis

Fig. 1.4.2.1 Flange Dimensions of Wrist Axis (unit : mm)

1.4.3 Mounting Equipment on Revolving Frame

(a) Restriction of the maximum mountable mass on the revolving frame.

Fig. 1.4.3.1 Equipment Mounting Position on Revolving Frame (unit: mm)

1.4.4 Restrictions of Working Range

Table 1.4.4.1 Restrictions of Working Range on Each Axis