F-200iB Mechanical Unit Maintenance (B-81725EN - 01)

FANUC Robot F–200iB
MECHANICAL UNIT
MAINTENANCE MANUAL
B–81725EN/01
B–81725EN/01 SAFETY
SAFETY
FANUC is not and does not represent itself as an expert in safety systems,
safety equipment, or the specific safety aspects of your company and/or
its work force. It is the responsibility of the owner, employer, or user to
take all necessary steps to guarantee the safety of all personnel in the
workplace.
The appropriate level of safety for your application and installation can
best be determined by safety system professionals. FANUC therefore,
recommends that each customer consult with such professionals in order
to provide a workplace that allows for the safe application, use, and
operation of FANUC systems.
Additionally, as the owner, employer, or user of a robotic system, it is your
responsibility to arrange for the training of the operator of a robot system
to recognize and respond to known hazards associated with your robotic
system and to be aware of the recommended operating procedures for
your particular application and robot installation.
FANUC therefore, recommends that all personnel who intend to operate,
program, repair, or otherwise use the robotics system be trained in an
approved FANUC training course and become familiar with the proper
operation of the system. Persons responsible for programming the
system-including the design, implementation, and debugging of
application programs-must be familiar with the recommended
programming procedures for your application and robot installation.
The following guidelines are provided to emphasize the importance of
safety in the workplace.
IMPORTANT!
Before operating, servicing or in any other way handling the
robot, the “FANUC Robot SAFETY HANDBOOK (B–80687EN)”
must be thoroughly studied.
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SAFETY B–81725EN/01
Considering safety for Safety is essential whenever robots are used. Keep in mind the following
your robot installation factors with regard to safety:
D The safety of people and equipment
D Use of safety enhancing devices
D Techniques for safe teaching and manual operation of the robot(s)
D Techniques for safe automatic operation of the robot(s)
D Regular scheduled inspection of the robot and workcell
D Proper maintenance of the robot
D Keeping people and The safety of people is always of primary importance in any situation.
equipment safe However, equipment must be kept safe, too. When prioritizing how to
apply safety to your robotic system, consider the following:
D People
D External devices
D Robot(s)
D Tooling
D Workpiece
D Using safety enhancing Always give appropriate attention to the work area that surrounds the
devices robot. The safety of the work area can be enhanced by the installation of
some or all of the following devices:
D Safety fences, barriers, or chains
D Light curtains
D Interlocks
D Pressure mats
D Floor markings
D Warning lights
D Mechanical stops
D EMERGENCY STOP buttons
D DEADMAN switches
D Setting up a safe A safe workcell is essential to protect people and equipment. Observe the
workcell following guidelines to ensure that the workcell is set up safely. These
suggestions are intended to supplement and not replace existing federal,
state, and local laws, regulations, and guidelines that pertain to safety.
D Sponsor your personnel for training in approved FANUC training
course(s) related to your application. Never permit untrained
personnel to operate the robots.
D Install a lockout device to prevent unauthorized persons from
operating the robot.
D Use anti-tie-down logic to prevent the operator from bypassing safety
measures.
D Arrange the workcell so the operator faces the workcell and can see
what is going on inside the cell.
D Clearly identify the work envelope of each robot in the system with
floor markings, signs, and special barriers. The work envelope is the
area defined by the maximum motion range of the robot, including any
tooling attached to the wrist flange that extend this range.
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D Position all controllers outside the robot work envelope.

D Never rely on software as the primary safety element.
D Install flashing lights and/or audible warning devices that activate
whenever the robot is operating, that is, whenever power is applied to
the servo drive system.
D Wherever possible, install safety fences to protect against
unauthorized entry by personnel into the work envelope.
D Install special guarding that prevents the operator from reaching into
restricted areas of the work envelope.
D Use interlocks.
D Use presence or proximity sensing devices such as light curtains, mats,
and capacitance and vision systems to enhance safety.
D Periodically check the safety joints or safety clutches that can be
optionally installed between the robot wrist flange and tooling. If the
tooling strikes an object, these devices dislodge, remove power from
the system, and help to minimize damage to the tooling and robot.
D Make sure all external devices are properly filtered, grounded,
shielded, and suppressed to prevent hazardous motion due to the
effects of electro-magnetic interference (EMI), radio frequency
interference (RFI), and electro-static discharge (ESD).
D Make provisions for power lockout/tagout at the controller.
D Eliminate pinch points. Pinch points are areas where personnel could
get trapped between a moving robot and other equipment.
D Provide enough room inside the workcell to permit personnel to teach
the robot and perform maintenance safely.
D Program the robot to load and unload material safely.
D If high voltage electrostatics are present, be sure to provide appropriate
interlocks, warning, and beacons.
D If materials are being applied at dangerously high pressure, provide
electrical interlocks for lockout of material flow and pressure.
D Staying safe while Advise all personnel who must teach the robot or otherwise manually
teaching or manually operate the robot to observe the following rules:
operating the robot D Never wear watches, rings, neckties, scarves, or loose clothing that
could get caught in moving machinery.
D Know whether or not you are using an intrinsically safe teach pendant
if you are working in a hazardous environment.
D Before teaching, visually inspect the robot and work envelope to make
sure that no potentially hazardous conditions exist. The work envelope
is the area defined by the maximum motion range of the robot. These
include tooling attached to the wrist flange that extends this range.
D The area near the robot must be clean and free of oil, water, or debris.
Immediately report unsafe working conditions to the supervisor or
safety department.
D FANUC recommends that no one enter the work envelope of a robot
that is on. However, if you must enter the work envelope, be sure all
safeguards are in place, and check the teach pendant DEADMAN
switch for proper operation. Take the teach pendant with you, turn it
on, and be prepared to release the DEADMAN switch. Only the
person with the teach pendant should be in the work envelope.
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D Know the path that can be used to escape from a moving robot; make
sure the escape path is never blocked.
D Isolate the robot from all remote control signals that can cause motion
while data is being taught.
D Test any program being run for the first time in the following manner:
WARNING
Stay outside the robot work envelope whenever a program is
being run. Failure to do so can result in injury.
- Using a low motion speed, single step the program for at least one
full cycle.
- Using a low motion speed, test run the program continuously for
at least one full cycle.
- Using the programmed speed, test run the program continuously
for at least one full cycle.
D Make sure all personnel are outside the work envelope before running
production.
D Staying safe during Advise all personnel who operate the robot during production to observe
production operation the following rules:
D Know the entire workcell area. The workcell includes the robot and
its work envelope, plus the area occupied by all external devices and
other equipment with which the robot interacts.
D Understand the complete task the robot is programmed to perform
before initiating production operation.
D Make sure all personnel are outside the work envelope before
operating the robot.
D Never enter or allow others to enter the work envelope during
production operation of the robot.
D Know the location and status of all switches, sensors, and control
signals that could cause the robot to move.
D Know where the EMERGENCY STOP buttons are located on both the
robot control and external control devices. Be prepared to press these
buttons in an emergency.
D Never assume that a program is complete if the robot is not moving.
The robot could be waiting for an input signal that will permit it to
continue activity.
D If the robot is running in a pattern, do not assume it will continue to
run in the same pattern.
D Never try to stop the robot, or break its motion, with your body. The
only way to stop robot motion immediately is to press an
EMERGENCY STOP button located on the controller panel, teach
pendant, or emergency stop stations around the workcell.
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D Staying safe during When inspecting the robot, be sure to

inspection D Turn off power at the controller.
D Lock out and tag out the power source at the controller according to
the policies of your plant.
D Turn off the compressed air source and relieve the air pressure.
D If robot motion is not needed for inspecting the electrical circuits, press
the EMERGENCY STOP button on the operator panel.
D Never wear watches, rings, neckties, scarves, or loose clothing that
D If power is needed to check the robot motion or electrical circuits, be
prepared to press the EMERGENCY STOP button, in an emergency.
D Staying safe during When performing maintenance on your robot system, observe the
maintenance following rules:
D Never enter the work envelope while the robot or a program is in
operation.
D Before entering the work envelope, visually inspect the workcell to
make sure no potentially hazardous conditions exist.
D Never wear watches, rings, neckties, scarves, or loose clothing that
D Consider all or any overlapping work envelopes of adjoining robots
when standing in a work envelope.
D Test the teach pendant for proper operation before entering the work
envelope.
D If it is necessary for you to enter the robot work envelope while power
is turned on, you must be sure that you are in control of the robot. Be
sure to take the teach pendant with you, press the DEADMAN switch,
and turn the teach pendant on. Be prepared to release the DEADMAN
switch to turn off servo power to the robot immediately.
D Whenever possible, perform maintenance with the power turned off.
Before you open the controller front panel or enter the work envelope,
turn off and lock out the 3-phase power source at the controller.
WARNING
Lethal voltage is present in the controller WHENEVER IT IS
CONNECTED to a power source. Be extremely careful to
avoid electrical shock.
HIGH VOLTAGE IS PRESENT at the input side whenever the
controller is connected to a power source. Turning the
disconnect or circuit breaker to the OFF position removes
power from the output side of the device only.
D Release or block all stored energy. Before working on the pneumatic

system, shut off the system air supply and purge the air lines.
D Isolate the robot from all remote control signals. If maintenance must
be done when the power is on, make sure the person inside the work
envelope has sole control of the robot. The teach pendant must be held
by this person.
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D Make sure personnel cannot get trapped between the moving robot and
other equipment. Know the path that can be used to escape from a
moving robot. Make sure the escape route is never blocked.
D Use blocks, mechanical stops, and pins to prevent hazardous
movement by the robot. Make sure that such devices do not create
pinch points that could trap personnel.
WARNING
Do not try to remove any mechanical component from the
robot before thoroughly reading and understanding the
procedures in the appropriate manual. Doing so can result in
serious personal injury and component destruction.
D Be aware that when you remove a servomotor or brake, the associated

axis will fall if it is not supported or resting on a hard stop.
D When replacing or installing components, make sure dirt and debris
do not enter the system.
D Use only specified parts for replacement. To avoid fires and damage
to parts in the controller, never use nonspecified fuses.
D Before restarting a robot, make sure no one is inside the work
envelope; be sure that the robot and all external devices are operating
normally.
D Use appropriate lighting for maintenance work. Take care that the
lighting does not create new dangerous situations.
D If it is necessary to operate the robot during the inspection, pay careful
attention to the robot’s motion and be sure to press the EMERGENCY
STOP button immediately when necessary.
D Be careful not to slip on spilled grease during maintenance.
D Do not climb on the robot.
D Some components might be hot. Take care when working on servo
motors or inside the controller. Wear protective clothing (heart–resistant
gloves, etc.) when working on components that are hot.
D After replacing components, be sure to tighten screws and fasteners
that were loosened.
D The motor and reducer are heavy. Be careful when replacing them.
If the robot collides with a mechanical hard stop, replace the
mechanical hard stop even if it does not seem to be damaged.
D After replacing parts or making adjustments, be sure to test run the
robot according to the following procedure.
1. Using a low motion speed, single step the program for at least one
full cycle.
2. Using a low motion speed, test run the program continuously for
at least one full cycle.
3. As speed is increased. the path may vary slightly. Run through the
program at 5–10% intervals up to 100%.
4. Using the programmed speed, test run the program continuously
for at least one full cycle.
Make sure all personnel are outside the fence before test running.
D After maintenance work, clean the area around the robot of oil, water,
and debris.
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Safety procedure for Follow this safety procedure when entering the safeguarded space for
maintenance maintenance.
Entering safeguarded space for maintenance
1. Stop the robot system.

2. Shut off the power to the robot system, and lock the main breaker to
prevent accidental powering on during maintenance.
2’. If you have to enter the safeguarded space while power is available to
the robot system, you must do the following prior to entering the
safeguarded space:
- check the robot system to determine if any conditions exist that are
likely to cause malfunctions,
- check that the teach pendant works correctly, and
- if any damage or malfunction is found, complete the required
corrections and perform a retest before personnel enter the
safeguarded space.
3. Enter the safeguarded space (see “The Safety Sequence for fence
entry” in “FANUC Robot SAFETY HANDBOOK”).
4. After maintenance is complete, check that the safeguard system is
effective. If it has been suspended to perform the maintenance
working, return it to its original effectiveness.
Keeping machine tools Certain programming and mechanical measures are useful in keeping the
and external devices machine tools and other external devices safe. These measures are
safe outlined below.
D Programming safety Implement the following programming safety measures to prevent

precautions damage to machine tools and other external devices.
D Back-check limit switches in the workcell to make sure they do not
fail.
D Implement “failure routines” in programs that will provide appropriate
robot actions if an external device or another robot in the workcell fails.
D Use handshaking protocol to synchronize robot and external device
operations.
D Program the robot to check the condition of all external devices during
an operating cycle.
D Mechanical safety Implement the following mechanical safety measures to prevent damage
precautions to machine tools and other external devices.
D Make sure the workcell is clean and free of oil, water, and debris.
D Use software limits, limit switches, and mechanical hardstops to
prevent undesired movement of the robot into the work area of
machine tools and external devices.
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Keeping the robot safe Observe the following operating and programming guidelines to prevent
damage to the robot.
D Operating safety The following measures are designed to prevent damage to the robot
precautions during operation.
D Use a low override speed to increase your control over the robot when
jogging the robot.
D Visualize the movement the robot will make before you press the jog
keys on the teach pendant.
D Make sure the work envelope is clean and free of oil, water, or debris.
D Use fuses to guard against electrical overload.
D Programming safety The following safety measures are designed to prevent damage to the
precautions robot during programming:
D Establish interference zones to prevent collisions when two or more
robots share a work area.
D Make sure that the program ends with the robot near or at the home
position.
D Be aware of signals or other operations that could trigger operation of
tooling resulting in personal injury or equipment damage.
D In dispensing applications, be aware of all safety guidelines with
respect to the dispensing materials.
NOTE
Any deviation from the methods and safety practices
described in this manual must conform to the approved
standards of your company. If you have questions, see your
supervisor.
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B–81725EN/01 PREFACE
PREFACE
This manual explains the maintenance and connection procedures for the
mechanical units of the following robots:
Mechanical unit
Model name Maximum load
specification No.
FANUC Robot F–200iB A05B–1517–B211 100kg
The label stating the mechanical unit specification number is affixed in

the position shown below. Before reading this manual, determine the
specification number of the mechanical unit.
Positon of Label Indicating Mechanical Unit Specification Number
p–1
PREFACE B–81725EN/01
Specifications
Items Specifications
Type Stewart Platform type parallel–mechanism
Controlled axes 6 Axes (J1, J2, J3, J4, J5, J6)
Installation Floor, Upside–down
Motion range (all axes are same) 431mm (660 to 1091)
Horizontal 1500mm/sec
Speed
Vertical 300mm/sec
Max. load capacity 100kg
Allowable load moment at wrist 588Nm (60kgfm)
Allowable load inertia at wrist 36kgm2 (367kgfcms2)
Drive method Electric servo drive by AC servo motor
Repeatability "0.1mm
Weight of mechanical unit Approx. 190kg
Ambient temperature 0 to 45_C (No dew,
nor frost allowed)
Ambient humidity
Installation
Normally : 75% RH or less
environment
Short term : MAX 95% RH
(within one month)
Vibration : 4.9m/s2 (0.5G) or less
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B–81725EN/01 Table of Contents
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . s–1
PREFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . p–1
I. MAINTENANCE
1. CONFIGURATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1 DRIVE MECHANISM (J1 TO J6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.2 MAJOR COMPONENT SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2. PREVENTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.1 DAILY CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.2 3–MONTH CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.3 6–MONTH CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.4 ANNUAL CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.5 1.5–YEAR CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.6 3–YEAR CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.7 MAINTENANCE TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3. PERIODIC MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.1 REPLACING GREASE OF THE DRIVE MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.2 GREASING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.3 REPLACING THE BATTERIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4. TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4.1 OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.2 FAILURE AND CAUSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5. ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5.1 MASTERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
5.1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
5.1.2 Resetting Alarms and Preparing for Mastering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
5.1.3 Mastering to a Fixture (Jig Position Master) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
5.1.4 Marking–off Mastering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
5.1.5 Quick Mastering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
5.1.6 Single Axis Mastering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
5.1.7 Mastering Data Entry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
6. REPLACING PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
6.1 NOTE FOR PART REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
6.2 REPLACING MOTORS (FOR ALL AXES) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
6.3 REPLACING LEG UNITS (FOR ALL AXES) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
6.4 REPLACING THE WRIST UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
6.5 REPLACING THE FULL COVER (OPTION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
6.6 REPLACING THE CABLE COVER (OPTION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
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Table of Contents B–81725EN/01
7. WIRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
7.1 WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
8. REPLACING CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
8.1 CABLE FORMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
8.2 CABLE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
II. CONNECTION
1. ROBOT INTERFERENCE AREA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
2. MECHANICAL COUPLING TO THE ROBOT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

2.1 WRIST LOAD CONDITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
2.2 MECHANICAL COUPLING OF END EFFECTOR TO WRIST . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
2.3 SETTING THE LOAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
2.4 END EFFECTOR INTERFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
3. TRANSPORTATION AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

3.1 TRANSPORTATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
3.2 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
3.3 MAINTENANCE AREA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
3.4 AIR CONTROL SET (OPTION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
3.5 INSTALLATION SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
3.6 STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
APPENDIX
A. BOLT TIGHTENING TORQUE TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
B. SPARE PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
C. CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
D. PERIODIC MAINTENANCE TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
c–2
I. MAINTENANCE
B–81725EN/01 MAINTENANCE 1. CONFIGURATION
1 CONFIGURATION
The configuration of the mechanical unit is shown in Fig.1.
J2–axis motor
J2–axis LEG
J3–axis motor
J1–axis motor
J3–axis LEG
J1–axis LEG
J6–axis LEG
J4–axis LEG
J6–axis motor
J4–axis motor J5–axis LEG
J5–axis motor
End–effector mounting face
Top plate
Connector panel
Base plate
Fig.1 Mechanical Unit Configuration
3
1. CONFIGURATION MAINTENANCE B–81725EN/01
1.1 Fig.1.1 shows the drive mechanism.

The mechanical unit is structured as follows: The rotation of the motor
DRIVE MECHANISM drives gear 2 via gear 1, so that the ball screw coupled with gear 2 is
(J1 to J6) rotated. By rotating the ball screw, the ball screw nut and the pipe coupled
with the nut are driven in the axial direction.
Motor
Pipe
Ball screw nut
Ball screw
Gear1 Gear2
Fig.1.1 Drive Mechanism
NOTE
All motors incorporate a brake that is applied when not energized. These brakes are active at
power–off and emergency stop.
4
B–81725EN/01 MAINTENANCE 1. CONFIGURATION
1.2 Table1.2 (a) Motor

MAJOR COMPONENT Motor Specifications Model Axis
SPECIFICATIONS M1 to M6 A06B–0215–B605 αM3/5000i J1 to J6
Table1.2 (b) Ball Screw

Axis Specifications
J1 to J6 A97L–0218–0261
Table1.2 (c) Top Plate Unit

Specifications
A290–7517–T501
5
2. PREVENTIVE MAINTENANCE MAINTENANCE B–81725EN/01
2 PREVENTIVE MAINTENANCE
Optimum performance of the robot can be maintained for a long time by

performing the periodic maintenance procedures presented in this
chapter.
6
B–81725EN/01 MAINTENANCE 2. PREVENTIVE MAINTENANCE
2.1 Clean each part, and visually check component parts for damage before
daily system operation. Check the following items as the occasion
DAILY CHECKS demands.
1) Before turning on power
When air control set is combined
Item Check items Check points
Cleaning the surround- Remove any foreign matter accumulation
1
ings of the joint from the surroundings of the joint.
Air pressure Check air pressure using the pressure gauge
on the air regulator as shown in Fig.2.1. If it
2 does not meet the specified pressure of 0.49
to 0.69 MPa (5–7 kgf/cm2), adjust it using the
regulator pressure setting handle.
Oiler oil mist quantity Check the drop quantity during wrist or hand
motion. If it does not meet the specified value
(1 drop/10–20 sec), adjust it using the oiler
3
control knob. Under normal usage the oiler
becomes empty in about 10 to 20 days under
normal operation.
Oiler oil level Check to see that the oiler level is within the
4
specified level shown in Fig.2.1.
Leakage from hose Check the joints, tubes, etc. for leaks. Repair
5
leaks, or replace parts, as required.
CAUTION
If the robot operates with foreign matters accumulated
around the joint, a malfunction or deformation may occur in
the joint or leg unit.
It is recommended that the full cover option and cable cover
options be used in an environment that suffers a large
accumulation of foreign matters.
Oil inlet Adjusting knob

Oiler mist amount check
Oiler
Pressure gauge
Filter Regulator pressure setting handle
Fig.2.1 Air Control Set (Option)
7
2) After automatic operation

Vibration, abnormal Check whether the robot moves along and
noises, and motor about the axes smoothly without unusual
1 heating vibration or sounds. Also check whether the
temperature of the motors are excessively
high.
Changing repeatability Check to see that the stop positions of the ro-
2 bot has not deviated from the previous stop
positions.
Peripheral devices for Check whether the peripheral devices oper-
3 proper operation ate properly according to commands from the
robot.
Brakes for each axis Check that the end effector drops within 0.5
4
mm when the power is cut.
8
2.2
1) Check the following items once every three months. Additional
3–MONTH CHECKS inspection areas and times should be added to the table according to
the robot’s working conditions, environment, etc.
1 Control unit cable Check whether the cable connected to the
teach pendant is unevenly twisted.
2 Ventilation portion of If the ventilation portion of the control unit is
control unit dusty, tum off power and clean the unit.
2) First quarterly inspection

Check the following items at the first quarterly inspection, then every
year thereafter.
1 Cables used in Check whether the jackets of the mechanical
mechanical unit unit cables are damaged. Also check wheth-
er the cables are excessively bent or uneven-
ly twisted. Check that the connectors of the
motors and connector panels are securely
engaged.See section 7.1.
Cleaning and checking Clean each part (remove chips, etc.) and
2
each part check component parts for cracks and flaws.
Further tightening Further tighten the end–effecter mounting
3
external main bolts bolts and external main bolts.
4 Examination of the oil Stretch each leg, then remove the bellows.
film on the ball screw Examine whether the oil film on the ball screw
has run out. If the legs cannot be stretched,
remove the bellows and the bellow pipe for
examination.
9
Bellows
Pipe for bellows
Replace nylon band

Ball screw
Connect with M6 8
Fig.2.2 Examination of the Oil Film on the Ball Screw
10
2.3 Check the following item once every six months.

6–MONTH CHECKS Item Check items Check points
1 Greasing of the ball screw Grease the ball screw. (See Section 3.2.)
2.4 Check the following items once every year.

ANNUAL CHECKS Item Check items Check points
1 Cables used in Refer to previous item.
mechanical unit
2 Cleaning each parts and Refer to previous item.
inspection
3 Tightness of major Refer to previous item.
external bolts
2.5 Check the following item once every 1.5 year.

1.5–YEAR CHECKS Item Check items Check points
1 Battery Replace battery in the mechanical unit.
Refer to Section 3.3.
2.6 Check the following items once every 3 years.

3–YEAR CHECKS Item Check items Check points
1 Replacement of the Replace the grease in the gear box.
grease in the gear box (See Section 3.1.)
11
2.7 The following tools and instruments are required for the maintenance
procedures contained in this manual.
MAINTENANCE
TOOLS 1) Measuring instruments
Instruments Accuracy/Capacity Applications
Dial gauge accuracy 1/100 mm Measurement of positioning
Slide calipers 150 mm
2) Tools
Cross–point(+)screwdrivers : Large, medium, and small sizes
Conventional(–)screwdrivers : Large, medium, and small sizes
Box screw drivers : M3 – M6
Hexagonal wrench key sets : M3 – M16
(metric)
Adjustable wrenches : Large, Medium and small sizes
Pliers
Cutting pliers
Cutting nippers
Double hexagon offset wrench
Torque wrench : M6–M16
Grease gun
Eye bolt : M10
Rope : allowable weight more than 1 ton
Lock tite : No.242
Lock tite : No.262
Lock tite : No.518 (Seal)
Seal tape
12
B–81725EN/01 MAINTENANCE 3. PERIODIC MAINTENANCE
3 PERIODIC MAINTENANCE
13
3. PERIODIC MAINTENANCE MAINTENANCE B–81725EN/01
3.1 Replace the J1 to J6–axis gear box grease, every three years or 11,520
hours by using the following procedures.
REPLACING GREASE
OF THE DRIVE Table 3.1 Grease for 3–year Periodical Replatement
MECHANISM Supply position Grease name Quantity
J1 to J6–axis gear box Kyodo yushi Each 265 cm3 (230g)
Moly white Re No.00
(Spec.:
A98L–0040–0119#2KG)
Replacing procedure of 1 Remove the full cover (option) from the robot where
grease applicable (see Section 6.5).
Replacing procedure of 2 Turn off the power.
grease 3 Remove the grease seal bolt.
4 Apply new grease from the grease inlet until it comes out
from the grease outlet.
5 Remount the seal bolt at the grease outlet. (For mounting the
seal bolt, coil a new seal tape.)
6 Remount the full cover (option) to the robot where applicable
(see Section 6.5).
NOTE
If greasing is performed incorrectly, the internal pressure of the
grease bath may suddenly increase, possibly causing damage
to the seal, which would in turn lead to grease leakage and
abnormal operation. When performing greasing, therefore,
observe the following cautions.
1 Before starting to grease, open the grease outlet (remove
the bolt from the grease outlet).
2 Supply grease slowly without applying excessive force,
using a manual pump.
3 Whenever possible, avoid using a compressed–air pump,
powered by the factory air supply. If the use of a
compressed air pump is unavoidable, restrict the maximum
greasing rate to 15 cm3/s and the greasing pressure to 7.4
MPa (75 kgf/cm2).
4 Use grease only of the specified type. Grease of a type other
than that specified may damage the reducer or lead to other
problems.
5 After greasing, confirm that no grease is leaking from the
grease outlet and that the grease bath is not pressurized,
then close the grease outlet.
6 To prevent accidents caused by slipping, completely
remove any excess grease from the floor or robot.
14
Seal bolt for grease outlet

Grease for inlet
Fig.3.1 (a) Replacing Grease of Gear Box (J1,J3,J4,J6–axis)
Grease nipple for inlet Seal bolt for outlet
Fig.3.1 (b) Replacing Grease of Gear Box (J2,J5–axis)
Posture at greasing When replacing and replenishing grease, set the robot to a posture with
about the same lengths on all axes.
15
3. PERIODIC MAINTENANCE MAINTENANCE B–81725EN/01
3.2 Supply grease to the parts periodically. If the robot is installed in a severe
environment, apply grease whenever necessary. If water splashes on the
GREASING robot, apply grease immediately. Table 3.2(a) shows greasing points.
Table 3.2 (b) shows substitute greases.
After greasing, slowly make some 20 full–stroke (660 to 1091 mm)
reciprocating motions of the ball screw, so that the grease is applied to the
entire ball screw. If full–stroke motions are impossible, remove the
bellows and the pipe for the bellows, then directly apply grease to the
stroke portion of the ball screw.
Table 3.2 (a) Greasing Points
Positions Grease Amount Greasing interval
J1 to J6 axis ball screw SHELL ALVANIA No. 2 (Spec: A97L–0001–0179#2) 100 cm3 each Date required
Table 3.2 (b) Substitutes for ALVANIA NO.2
MOBIL OIL MOBILACKS GREASE No.2 NIPPON MITSUBISHI OIL EPNOC AP–2
ESSO STANDARD VICON No.2 IDEMITSU KOHSAN EPONEX GREASE No.2
NIPPON MITSUBISHI OIL NIPPON MITSUBISHI MULTINOC 2 COSMO OIL DYNAMAX No.2
To perform greasing when the robot is postured

with the axes 668 mm or more long, remove the
A silencer (M5) and stuff the hole in advance.
Grease bath
Grease nipple
Bellows
Pipe for bellows
SECTION A–A
Fig.3.2 (a) Greasing Points
Posture at greasing When replacing or replenishing grease, posture the robot such that all axes
are 668 mm or shorter. To replace or replenish grease when the robot is
postured with the axes 668 mm or more long, remove the silencer (M5)
and stuff the hole in advance.
16
3.3 The position data of each axis is preserved by the backup battery. The
battery needs to be replaced every 1.5 year. Also use the following
REPLACING THE procedure for replacement when the backup battery voltage drop alarm
BATTERIES occurs.
1 Keep the power on. Press the EMERGENCY STOP button to
prohibit robot motion.
Replacing the battery with the power supply turned off causes all
position data to be lost. Therefore, mastering will be required
again.
2 Remove the battery box cap.
3 Take out the old batteries from the battery box.
4 Insert new batteries into the battery box.
Pay attention to the polarity of batteries.
5 Close the battery box cap.
6 Release the emergency stop.
7 Reset the controller.
Battery case Case cap

Battery : A98L–0031–0005
(Four 1.5 size–D)
Fig.3.3 Replacing Battery
17
4. TROUBLESHOOTING MAINTENANCE B–81725EN/01
4 TROUBLESHOOTING
18
B–81725EN/01 MAINTENANCE 4. TROUBLESHOOTING
4.1 The cause of a failure in the mechanical unit may be difficult to localize,
because failures can arise from many interrelated factors. If you fail to
OVERVIEW take the correct measures, the failure may be aggravated. So, it is
necessary to analyze the symptoms of the failure precisely so that the true
cause can be found.
19
4.2 Table 4.2 lists the major failures that may occur in the mechanical unit and
their probable causes. If you cannot pinpoint a failure cause or are measure
FAILURE AND of which measures to apply, contact FANUC. If you have to replace
CAUSE components or make adjustments to repair the failure, see Sections 5, 6,
and 8.
Table 4.2 Failures and Causes
Symptom Description Cause Measure
Vibration – As the robot operates, its base plate [Securing the plate securing the base- – Re–weld the plate securing the base-
Noise lifts off the floor plate. plate of the robot to the floorplate] plate to the floorplate to secure it.
– There is a gap between the floorplate – A probable cause is that the weld be- – If the weld is not strong enough,
and the plate securing the baseplate of tween the floorplate and the plate se- increase its width and length.
the robot. curing the baseplate of the robot is
– There are cracks at the weld between cracked, so that the plate is not se-
the floorplate and the plate securing cured properly to the floorplate.
the baseplate of the robot. – If the plate securing the baseplate of
the robot is not secured properly to the
floorplate, the plate will float during the
operation of the robot, and the result-
ing impact will cause vibration.
– During the operation of the robot, the [Securing the baseplate of the robot] – If a bolt is loose, apply loctite and
baseplate of the robot is floating from – A probable cause is that the baseplate tighten it to the appropriate torque.
the plate securing the baseplate. of the robot is not secured properly to – Modify the plate securing the base-
– There is a gap between the baseplate the plate securing it. plate of the robot so that its flatness
of the robot and the plate securing it. – Probable causes are loose bolts, the falls within the tolerance.
– The bolts securing the baseplate of the plate securing the baseplate of the ro- – If there is any foreign matter between
robot are loose. bot being not sufficiently flat, and for- the J1 base and base plate, remove it.
eign matter being caught. – Apply adhesive between the base-
– If the baseplate of the robot is not se- plate of the robot and the plate secur-
cured properly to the plate securing it, ing it.
the baseplate will float from the plate
during the operation of the robot, and
the resulting impact will cause vibra-
tion.
– Vibration of rack or floor occurs when [Rack or floor] – Reinforce the rack or floor to make it
the robot is operating. – It is likely that the rack or floor is not more rigid.
sufficiently rigid. – If it is impossible to reinforce the rack
– If the rack or floor is not sufficiently or floor, modify the robot control pro-
rigid, reaction from the robot deforms gram; doing so might reduce the
the rack or floor, leading to vibration. amount of vibration.
– Vibrationbecomes more serious when [Overload] – Check the maximum load that the robot
the robot adopts a specific posture. – It is likely that the load on the robot is can handle once more. If the robot is
– If the operating speed of the robot is greater than the maximum rating. found to be overloaded, reduce the load,
reduced, vibration stops. – It is likely that the robot control pro- or modify the robot control program.
– Vibration is most noticeable when the gram is too demanding for the robot – Vibration in a specific portion can be
robot is accelerating. hardware. reduced by modifying the robot control
– Vibration occurs when two or more program while slowing the robot and
axes operate at the same time. reducing its acceleration (to minimize the
influence on the entire cycle time).
20

Vibration – Vibration was first noticed after the [Broken gear, or bearing] – Operate one axis at a time to deter-
Noise robot collided with an object or the – It is likely that collision or overload mine which axis is vibrating.
(Continued) robot was overloaded for a long period. applied an excessive force on the – Find the source of the vibration while
– The grease of the vibrating axis has drive mechanism, thus damaging the referringto the drive mechanism draw-
not been exchanged for a long period. gear tooth surface or rolling surface of ing of each axis given in the related
a bearing, or reducer. maintenancemanual.
– It is likely that prolonged use of the – Remove the motor, and check whether
robot while overloaded caused fretting there are any fretting on a gear tooth
of the gear tooth surface or rolling sur- surface. If any fretting is found, replace
face of a bearing due to resulting metal the gear.
fatigue. Note) Even a small amount of damage
– It is likely that foreign matter caught in on a gear tooth surface can generate a
a gear, or bearing, caused damage on large amount of noise. Therefore, it is
the gear tooth surface or rolling sur- necessary to check each gear tooth
face of the bearing. surface carefully.
– It is likely that, because the grease has – Check whether any other gear in the
not been changed for a long period, drive mechanism is abnormal. If all the
fretting occurred on the gear tooth sur- gears are found to be satisfactory, the
face or rolling surface of a bearing due reducer must be replaced.
to metal fatigue. – If there is foreign matter caught in a
These factors all generate cyclic vibra- gear, or if a gear tooth is missing,
tion and noise. replace the gear. Also, remove all the
grease from the gear box and wash the
inside of the gear box.
– After replacing the gear add an
appropriate amount of grease.
– If nothing changes after a gear is
replaced, it is likely that a bearing is
damaged.
– Using the robot within its maximum rat-
ing prevents problems with the drive
mechanism.
– Regularly changing the grease with a
specified type can help prevent prob-
lems.
– The cause of problem cannot be identi- [Controller, cable, and motor] – Refer to the R–J3iB Controller Mainte-
fied from examination of the floor, rack, – If a failure occurs in a controller circuit, nance Manual for troubleshooting
or mechanical section. preventing control commands from related to the controller and amplifier.
being supplied to the motor normally, – Replace the pulse coder for the motor
or preventing motor information from of the axis that is vibrating, and check
being sent to the controller normally, whether the vibration still occurs.
vibration might occur. – Also, replace the motor of the axis that
– If the pulse coder develops a fault, is vibrating, and check whether vibra-
vibration might occur because tion still occurs.
information about the motor position – Check that the robot is supplied with
cannot be transferred to the controller the rated voltage.
accurately. – Check whether the sheath of the
– If the motor becomes defective, vibra- power cord is damaged. If so, replace
tion might occur because the motor the power cord, and check whether
cannot deliver its rated performance. vibration still occurs.
– If a power line in a movable cable of the – Check whether the sheath of the cable
mechanical section has an intermittent connecting the mechanical section
break, vibration might occur because and controller is damaged. If so,
the motor cannot accurately respond replace the connection cable, and
to commands. check whether vibration still occurs.
– If a pulse coder wire in a movable part – If vibration occurs only when the robot
of the mechanical section has an inter- assumes a specific posture, it is likely
mittent break, vibration might occur that a cable in the mechanical unit is
because commands cannot be sent to broken.
the motor accurately. – Shake the movable part cable while
– If the controller is installed separately the robot is at rest, and check whether
from the mechanical section, and a an alarm occurs. If an alarm or any
connection cable between them has other abnormal condition occurs,
an intermittent break, vibration might replace the mechanical unit cable.
occur. – Check that the robot control parameter
– If the power source voltage drops is set to a valid value. If it is set to an
below the rating, vibration might occur. invalid value, correct it. Contact
– If a robot control parameter is set to an FANUC for further information if nec-
invalid value, vibration might occur. essary.
21

Vibration – There is some relationship between [Noise from a nearby machine] – Connect the grounding wire firmly to
Noise the vibration of the robot and the – If the robot is not grounded properly, ensure a reliable ground potential and
(Continued) operation of a machine near the robot. electrical noise is induced on the prevent extraneous electrical noise.
groundingwire, preventing commands
from being transferred accurately,
thus leading to vibration.
– If the robot is grounded at an unsuit-
able point, its grounding potential
becomes unstable, and noise is likely
to be induced on the grounding line,
thus leading to vibration.
Rattling – While the robot is not supplied with [Mechanical section coupling bolt] Check that the following bolts for each
power, pushing it with the hand causes – It is likely that overloading or a collision axis are tight. If any of these bolts is
part of the mechanical unit to wobble. has loosened a mounting bolt in the loose, apply loctite and tighten it to the
– There is a gap on the mounting surface robot mechanical section. appropriate torque.
of the mechanical unit. – Motor retaining bolt
– Base retaining bolt
– Joint–securing bolt
– Gearbox–securing bolt
– End effecter retaining bolt
– The increase in backlash has become [Increase in backlash] – Operate one axis at a time to deter-
excessive. – It is likely that excessive force applied mine which axis has the increased
to the drive mechanism, due to a colli- backlash.
sion or overloading, has broken a gear – Remove the motor, and check whether
resulting in an increase in the amount any of its gears are broken. If any gear
of backlash. is broken, replace it.
– It is likely that prolonged use without – Check whether any other gear of the
changing the grease has caused the drive mechanism is damage. If there is
tooth surfaces of a gear to wear out, no damage gear, replace the reducer.
resulting in an increase in the amount – If a gear tooth is missing, replace the
of backlash. relevant component. Also, remove all
– A probable cause is that the tooth sur- the grease from the gear box and wash
face of the gear has worn out because the inside of the gear box.
of long–time use without the replace- – After replacing the gear add an
ment of grease. appropriate amount of grease.
– Using the robot within its maximum rat-
ing prevents problems with the drive
mechanism.
– Regularly changing the grease with a
specified type can help prevent prob-
lems.
– There is lost motion in the bearing of a [Damage to the bearing, release of the – Check the movement of the joints dur-
joint pre–load] ing operation to identify the faulty joint.
– A probable cause is that excessive – Remove each leg, move the top and
force was applied to the bearing of the bottom joints manually to check
joint due to impact or overload, damag- whether the bearings are damaged
ing the bearing or releasing the pre– and whether there is lost motion. If a
load. bearing is damaged or the pre–load is
released, replace the unit containing
the joint.
– This problem can be avoided by avoid-
ing use at overload.
22

Motor – The ambient temperature of the instal- [Ambienttemperature] The teach pendant can be used to moni-
overheating lation location increases, causing the – It is likely that a rise in the ambient tem- tor the average current. Check the aver-
motor to overheat. perature prevented the motor from age current when the robot control pro-
– After a cover was attached to the releasing heat efficiently, thus leading gram is running. The allowable average
motor, the motor overheated. to overheating. current is specified for the robot accord-
– After the robot control program or the [Operating condition] ing to its ambient temperature. Contact
load was changed, the motor over- – It is likely that the robot was operated FANUC for further information.
heated. with the maximum average current – Relaxing the robot control program and
exceeded. conditions can reduce the average cur-
rent, thus preventing overheating.
– Reducing the ambient temperature is
the most effective means of preventing
overheating.
– Having the surroundings of the motor
well ventilated enables the motor to
release heat efficiently, thus prevent-
ing overheating. Using a fan to direct
air at the motor is also effective.
– If there is a source of heat near the
motor, it is advisable to install shielding to
protect the motor from heat radiation.
– After a control parameter was [Parameter] – Input an appropriate parameter as
changed, the motor overheated. – If data input for a workpiece is invalid, described in the manual.
the robot cannot be accelerated or
decelerated normally, so the average
current increases, leading to over-
heating.
Motor – Symptom other than stated above [Mechanical section problems] Repair the mechanical unit while refer-
overheating – It is likely that problems occurred in the ring to the above descriptions of vibra-
(Continued) mechanical unit drive mechanism, tion, noise, and rattling.
thus placing an excessive load on the – Check that, when the servo system is
motor. energized, the brake is released.
[Motor problems] – If the brake remains applied to the
– It is likely that a failure of the motor motor all the time, replace the motor.
brake resulted in the motor running – If the average current falls after the
with the brake applied, thus placing an motor is replaced, it indicates that the
excessive load on the motor. first motor was faulty.
– It is likely that a failure of the motor pre-
vented it from delivering its rated per-
formance, thus causing an excessive
current to flow through the motor.
Grease – Grease is leaking from the mechanical [Poor sealing] – If a crack develops in the casting, seal-
leakage unit. – Probable causes are a crack in the ant can be used as a quick–fix to pre-
casting, a broken O–ring, a damaged vent further grease leakage. However,
oil seal, or a loose seal bolt. the component should be replaced as
– A crack in a casting can occur due to soon as possible, because the crack
excessive force that might be caused might extend.
in collision. – O–rings are used in the locations listed
– An O–ring can be damaged if it is below. Refer to the relevant parts
trapped or cut during disassembling or manual for detailed descriptions of
re–assembling. their replacement.
– An oil seal might be damaged if extra- – Motor–fastening section
neous dust scratches the lip of the oil – Ball screw nut connection section
– Pipe connection section
seal. – Oil seals are used in the locations
– A loose seal bolt might allow grease to stated below. Refer to the relevant
leak along the threads. parts manual for detailed descriptions
– Problems with the grease nipple or of their replacement.
threads. – Joint on the top plate
– Joint on the baseplate
– Gearbox
– Seal bolts are used in the locations
stated below. Refer to the relevant
parts manual for detailed descriptions
of their replacement.
– Joint connection section in the gearbox
– Grease outlet
– Replace the grease nipple.
23

Dropping axis – An axis drops because the brake does [Brake drive relay and motor] – Check whether the brake drive relay
not function. – It is likely that brake drive relay con- contacts are stuck to each other, as
– An axis drops gradually when it should tacts are stuck to each other to keep explained in the relevant manual. If
be at rest. the brake current flowing, thus pre- they are found to be stuck, replace the
venting the brake from operating when relay.
the motor is deenergized. – If the brake shoe is worn out, if the
– It is likely that the brake shoe has worn brake main body is damaged, or if oil or
out or the brake main body is dam- grease has entered the motor, replace
aged, preventing the brake from oper- the motor.
ating efficiently. – Check the load tolerance of the robot.
– It is likely that oil or grease has entered If the tolerance is exceeded, reduce
the motor, causing the brake to slip. the load.
[Overload]
– A probable cause is that a load ex-
ceeding the tolerance of the robot is
mounted.
Displacement – The robot operates at a point other [Mechanical section problems] – If the repeatability is unstable, repair
than the taught position. – If the repeatability is unstable, prob- the mechanical section by referring to
– The repeatability is not within the toler- able causes are a failure in the drive the above descriptions of vibration,
ance. mechanism or a loose bolt. noise, and rattling.
– If the repeatability becomes stable it is – If the repeatability is stable, correct the
likely that a collision imposed an taught program. Variation will not
excessive load, leading to slipping on occur unless another collision occurs.
the base surface or the mating surface
of an arm or reducer.
– Displacement occurs only in a specific [Peripheral unit displacement] – Correct the setting of the peripheral
peripheral unit. – It is likely that an external force was unit position.
applied to the peripheral unit, thus – Correct the taught program.
shifting its position relative to the robot.
– Displacement occurred after a param- [Parameter] – Re–enter the previous mastering data,
eter was changed. – It is likely that the mastering data was which is known to be correct.
rewritten in such a way that the robot – If correct mastering data is unavail-
origin was shifted. able, perform mastering again.
24
B–81725EN/01 MAINTENANCE 5. ADJUSTMENTS
5 ADJUSTMENTS
Each part of the mechanical unit is carefully adjusted at the factory before
shipment. Therefore it is usually unnecessary for the customer to make
adjustments at the time of delivery. However, after for a long period of use
or after parts are replaced, adjustments may be required.
25
5. ADJUSTMENTS MAINTENANCE B–81725EN/01
5.1 Mastering is an operation performed to associate the angle of each robot

axis with the pulse count value supplied from the absolute pulse coder
MASTERING connected to the corresponding axis motor. To be specific, mastering is
an operation for obtaining the pulse count value corresponding to the zero
position.
5.1.1 The current position of the robot is determined according to the pulse
General count value supplied from the pulse coder on each axis.
Mastering is factory–performed. It is unnecessary to perform mastering
in daily operations. However, mastering becomes necessary after:
D Motor replacement.
D Pulse coder replacement.
D Cable replacement.
D Batteries for pulse count backup in the mechanical unit have gone dead.
NOTE
Robot data (including mastering data) and pulse coder data
are backed up by their respective backup batteries. Data will
be lost if the batteries go dead. Replace the batteries in the
control and mechanical units periodically. An alarm will be
issued to warn the user of a low battery voltage.
Mastering method Table 5.1.1 Types of Mastering

Jig position mastering In the F–200iB, this function is not used.
Zero-position master- A marking is provided for each axis of the robot. Master-
ing (eye mark mas- ing is performed by moving the robot to the marking
tering) positions on all axes. In the F–200iB, marking is per-
formed at the position of 668 mm on all axes.
Simplified mastering This is performed at a user–specified position. The cor-
responding count value is obtained from the rotation
speed of the pulse coder connected to the relevant
motor and the rotation angle within one rotation. Simpli-
fied mastering uses the fact that the absolute value of
a rotation angle within one rotation will not be lost.
One-axis mastering This is performed for one axis at a time. The mastering
position for each axis can be specified by the user. It is
effective for mastering for a specific axis only. In the
F–200iB, this function is used for mastering by the use
of a fixture.
Mastering data entry Mastering data is entered directly.
Once mastering is performed, it is necessary to carry out positioning, or

calibration. Positioning is an operation in which the control unit reads the
current pulse count value to sense the current position of the robot.
NOTE
If mastering is performed incorrectly, the robot may behave
unexpectedly. This is very dangerous. So, the positioning
screen is designed to appear only when the
$MASTER_ENB system variable is 1 or 2. After performing
positioning, press F5 [DONE] on the positioning screen.
The $MASTER_ENB system variable is reset to 0
automatically, thus hiding the positioning screen.
26
5.1.2 Before performing mastering because a motor is replaced, it is necessary

Resetting Alarms and to release the relevant alarm and display the positioning menu.
Preparing for
Mastering
Alarm displayed “Servo 062 BZAL” or “Servo 075 Pulse mismatch”
Procedure
Preparing the Robot for
Mastering
Step 1 To reset the ”Servo 062 BZAL” alarm, follow steps 1 to 7.
1 Press MENUS to display the screen menu.
2 Press zero to select [6 SYSTEM].
3 Press F1 [TYPE].
4 Place the cursor on Master/Cal, then press the input key.
5 Place the cursor on $SPC_RESET, then press F4 [TRUE]. The
message “TRUE” appears and disappears immediately.
6 If the message “TRUE” did not appear, retry by repeating the
above step several times.
7 Switch the controller power off and on again.
2 To reset the “Servo 075 Pulse mismatch” alarm, follow steps 1 to 3.
1 When the controller power is switched on again, the message
“Servo 075 Pulse mismatch” appears again.
2 Move the axis for which the message mentioned above has
appeared through "10 degrees in either direction.
3 Press [FAULT RESET]. The alarm is reset.
3 Display the positioning menu by following steps 1 to 6.
1 Press MENUS to display the screen menu.
2 Press zero to select [6 SYSTEM].
3 Press F1 [TYPE].
4 Place the cursor on $MASTER_ENB, then key in “1” and press
[INPUT].
5 Press F1 [TYPE], and select [Master/Cal] from the menu.
6 Select the desired mastering type from the [Master/Cal] menu.
27
5.1.3 Jig position mastering is performed using a mastering jig. This mastering
Mastering to a Fixture is carried out in the predetermined jig position.
(Jig Position Master) Jig position mastering is accurate because a dedicated mastering jig is
used. Jig position mastering is factory–performed. It is unnecessary to
perform it in daily operations.
In the F–200iB, fixture position mastering is performed with the
operation for 1–axis mastering because it is performed for one axis at a
time. ”JIG POSITION MASTER” on the Master/Cal menu is not used.
Operation for fixture
position mastering 1) Remove the full cover (option) from the robot where applicable (see
Section 6.5).
2) As shown in Fig. 5.1.3 (a), remove the nylon band securing the
bellows unscrew the bellows pipe from the gear box and move the
bellow pipe upward with using width across flat.
Bellows
Replace nylon band

Width across flat
(Width 69mm)
Pipe for bellows
Connect with M68

(When connecting
again, use seal)
Fig.5.1.3 (a) Preparation for Mastering
3) As shown in Fig. 5.1.3 (b), place the mastering fixture on the top of
the gearbox.
Mastering fixture
Fig.5.1.3 (b) Mounting of the Mastering Fixture
28
1 Press MENUS.
2 Press NEXT and select SYSTEM
3 Press F1, [TYPE].
4 Select Master/Cal.
SYSTEM Master/Cal JOINT 10%
1 FIXTURE POSITION MASTER

2 ZERO POSITION MASTER
3 QUICK MASTER
4 SINGLE AXIS MASTER
5 SET QUICK MASTER REF
6 CALIBRATE
Press ’ENTER’ or number key to select.
[ TYPE ] LOAD RES_PCA
5 Select 4, Single Axis Master. You will see a screen similar to the
following.
For example of J1–axis mastering.
SINGLE AXIS MASTER JOINT 10%

1/9
ACTUAL POS (MSTR POS) (SEL) [ST]
J1 700.000 ( 0.000) (0) [2]
J2 700.000 ( 0.000) (0) [2]
J3 700.000 ( 0.000) (0) [2]
J4 700.000 ( 0.000) (0) [2]
J5 700.000 ( 0.000) (0) [2]
J6 700.000 ( 0.000) (0) [2]
E1 0.000 ( 0.000) (0) [2]
E2 0.000 ( 0.000) (0) [2]
E3 0.000 ( 0.000) (0) [2]
[ TYPE ] GROUP EXEC
6 Move the cursor to the SEL column for the unmastered axis and press
the numeric key “1.” Setting of SEL is available per one axis or per
plural axes.
7 Turn off brake control as required, then jog the robot to the mastering
position.
8 Enter axis data for the mastering position.
JOINT 30% SINGLE AXIS MASTER JOINT 30%

5/9 5/9
(0.000) (0) [0] J1 700.000 (0.000) (1) [2]
(0.000) (0) [0] J2 700.000 (90.000) (0) [2]
GROUP EXEC
29
9 As shown in Fig. 5.1.3 (c), use Each axis to move the tool in the minus
direction along the axis for which mastering is to be performed, to bring the
bottom face of the ball screw nut in contact with the top face of the
mastering fixture.
Release brake control.
NOTE
Brake control can be released by setting the system
variables as follows:
$PARAM_GROUP.SSV_OFF_ALL: FALSE
$PARAM GROUP.SSV OFF ENB[*]: FALSE (for all axes)
After changing the system variables, switch the control unit
power off and on again.
Ball screw nut
Mastering face
Mastering fixture
Fig.5.1.3 (c) Bringing the Ball Screw Nut in Contact

5/9
J1 700.000 (668.000) (1) [0]
J2 700.000 (0.000) (1) [0]
GROUP EXEC
30
10 Press F5 [EXEC]. Mastering is performed. So, SEL is reset to 0, and

ST is re–set to 2 or 1.
GROUP EXEC SINGLE AXIS MASTER JOINT 30%

1/9
ACTUAL AXIS (MATR POS) (SEL) [ST]
F5 J1 668.000 (668.000) (0) [2]
J2 700.000 (0.000) (0) [2]
J3 700.000 (0.000) (0) [2]
J4 700.000 (0.000) (0) [2]
J5 700.000 (0.000) (0) [2]
J6 700.000 (0.000) (0) [2]
E1 0.000 (0.000) (0) [2]
E2 0.000 (0.000) (0) [2]
E3 0.000 (0.000) (0) [2]
GROUP EXEC
11 When one–axis mastering is completed, press the previous page key

to resume the previous screen.
BACK

3 QUICK MASTER
6 CALIBRATE
[ TYPE ] DONE
12 Select [6 CALIBRATE], then press F4 [YES]. Positioning is

performed.
Alternatively, switch the power off and on again. Positioning is
performed.
13 Perform the operation described up to now for J1– to J6–axes.
14 After completion of positioning on all axes, press F5 ”DONE.”
DONE
F5
15 Apply a sealing compound to the M68 threads of the pipe for the
bellows, then secure the pipe to the gear box.
16 Fasten the bellows to the groove of the bellows pipe with nylon bands.
Care should be taken not to give a twist in the bellows.
17 Remount the full cover (option) to the robot where applicable (see
Section 6.5).
31
NOTE
No check is made on the axis movable range during
mastering. Be very careful when running the robot.
Continuing axis movement may result in the mechanical
stopper being bumped.
5.1.4 Marking–off mastering refers to mastering performed at the position

where a marking–off mark is located. The robot is moved to the
Marking–off Mastering
marking–off positions (668 mm) on all axes to perform mastering.
Marking–off mastering is visual adjustment and, therefore, may not be
accurate. Use this mastering as an emergency measure.
Mastering 1) Press MENUS.
2) Press NEXT and select SYSTEM.
3) Press F1, [TYPE].
4) Select Master/Cal.

3 QUICK MASTER
6 CALIBRATE
[ TYPE ] LOAD RES_PCA DONE
5) Release brake control, and jog the robot into a posture for mastering.
NOTE
Brake control can be released by setting the system
variables as follows:
$PARAM_GROUP.SSV_OFF_ALL: FALSE
$PARAM GROUP.SSV OFF ENB[*]: FALSE (for all axes)
After changing the system variables, switch the control unit
power off and on again.
6) Select Fixture Position Master.

7) Press F4, YES. Mastering will be performed automatically.
Alternatively, switch the power off and on again. Switching the power
on always causes positioning to be performed.
8) After positioning is completed, press F5 [DONE].
Table 5.1.4 Marking–Off Mark Position

All axes 668mm
32
Pipe Pipe
Marking–off is per- Marking–off is per-

formed on the pipe side formed on the pipe side
so that it matches the so that it matches the
top face of the bellow top face of the bellow
pipe. pipe.
Bellow pipe Bellow pipe
Fig.5.1.4 (a) Marking–Off Mark Position Fig.5.1.4 (b) Marking–Off Mark Position
(J1–, J3, J4, and J6–Axes) (J2– and J5–Axes)
33
5.1.5 Simplified mastering is performed at a user–specified position. The

corresponding count value is obtained from the rotation speed of the pulse
Quick Mastering coder connected to the relevant motor and the rotation angle within one
rotation. Simplified mastering uses the fact that the absolute value of a
rotation angle within one rotation will not be lost.
Simplified mastering is factory–performed at the position indicated in
Table 5.1.4. Do not change the setting unless there is a problem.
If it is impossible to set the robot at the position mentioned above, it is
necessary to re–set the simplified mastering reference position using the
following method. (It would be convenient to set up a marker that can
work in place of the eye mark.)
NOTE
1 Simplified mastering can be used, if the pulse count value
is lost, for example, because a low voltage has been
detected on the backup battery for the pulse counter.
2 Simplified mastering cannot be used, after the pulse coder
is replaced or after the mastering data is lost from the robot
control unit.
Procedure
Recording the Quick
Master Reference
Position
Step 1 Select SYSTEM.

3 QUICK MASTER
6 CALIBRATE
3 Release brake control, and jog the robot to the simplified mastering
reference position.
Set quick master ref? [NO] 4 Move the cursor to SET QUICK MASTER REF and press ENTER.
Press F4, YES.
NOTE
If the robot has lost mastery due to mechanical disassembly
or repair, you cannot perform this procedure. In this case,
master to a fixture or master to zero degrees to restore robot
mastery.
34
Procedure
Quick Mastering
Step 1 Display the Master/Cal screen.

3 QUICK MASTER
6 CALIBRATE
2 Release brake control, and jog the robot to the simplified mastering
reference position.
Quick master? [NO] 3 Move the cursor to QUICK MASTER and press ENTER. Press F4,
YES. Quick mastering data is memorized.
4 Move the cursor to CALIBRATE and press ENTER. Calibration is
executed. Calibration is executed by power on again.
5 After completing the calibration, press F5, DONE.
35
5.1.6 One–axis mastering is performed for one axis at a time. The mastering
Single Axis Mastering position for each axis can be specified by the user.
One–axis mastering can be used, if mastering data for a specific axis is
lost, for example, because a low voltage has been detected on the pulse
counter backup battery or because the pulse coder has been replaced.
In the F200iB, this function is also used for mastering by the use of a
fixture.

J1 700.000 (0.000) (0) [2]
J2 700.000 (0.000) (0) [2]
J3 700.000 (0.000) (0) [2]
J4 700.000 (0.000) (0) [2]
J5 700.000 (0.000) (0) [2]
J6 700.000 (0.000) (0) [2]
E1 0.000 (0.000) (0) [2]
E2 0.000 (0.000) (0) [2]
E3 0.000 (0.000) (0) [2]
GROUP EXE
Table 5.1.6 Items Set in One–Axis Mastering
Item Description
Current position The current position of the robot is displayed for each
axis in degree units.
Mastering position A mastering position is specified for an axis to be sub-
jected to one–axis mastering.
SEL This item is set to 1 for an axis to be subjected to
one–axis mastering. Usually, it is 0.
ST This item indicates whether one–axis mastering has
been completed for the corresponding axis. It cannot
be rewritten directly by the user.
The value of the item is reflected in
$EACHMST_DON (1 to 9).
0 : Mastering data has been lost. One–axis mastering
is necessary.
1 : Mastering data has been lost. (Mastering has been
performed only for the other interactive axes.) One–
axis mastering is necessary.
2 : Mastering has been completed.
36
Procedure
Mastering a Single Axis
Step 1 Select SYSTEM.


3 QUICK MASTER
6 CALIBRATE
[ TYPE ] LOAD RES_PCA
3 Select 4, Single Axis Master. You will see a screen similar to the
following.

1/9
ACTUAL POS (MSTR POS) (SEL) [ST]
J1 700.000 ( 0.000) (0) [2]
J2 700.000 ( 0.000) (0) [2]
J3 700.000 ( 0.000) (0) [2]
J4 700.000 ( 0.000) (0) [2]
J5 700.000 ( 0.000) (0) [2]
J6 700.000 ( 0.000) (0) [2]
E1 0.000 ( 0.000) (0) [2]
E2 0.000 ( 0.000) (0) [2]
E3 0.000 ( 0.000) (0) [2]
[ TYPE ] GROUP EXEC
4 Move the cursor to the SEL column for the unmastered axis and press
the numeric key “1.” Setting of SEL is available per one axis or per
plural axes.
5 Turn off brake control as required, then jog the robot to the mastering
position.
6 Enter axis data for the mastering position.

5/9
J1 700.000 (668.000) (1) [2]
J2 700.000 (0.000) (0) [2]
GROUP EXEC
37
7 Press F5 [EXEC]. Mastering is performed. So, SEL is reset to 0, and

ST is re–set to 2 or 1.
GROUP EXEC SINGLE AXIS MASTER JOINT 30%

1/9
F5 J1 668.000 (668.000) (0) [2]
J2 700.000 (0.000) (0) [2]
J3 700.000 (0.000) (0) [2]
J4 700.000 (0.000) (0) [2]
J5 700.000 (0.000) (0) [2]
J6 700.000 (0.000) (0) [2]
E1 0.000 (0.000) (0) [2]
E2 0.000 (0.000) (0) [2]
E3 0.000 (0.000) (0) [2]
GROUP EXEC
8 When one–axis mastering is completed, press the previous page key

to resume the previous screen.
BACK

3 QUICK MASTER
6 CALIBRATE
[ TYPE ] DONE
9 Select [6 CALIBRATE], then press F4 [YES]. Positioning is

performed.
Alternatively, switch the power off and on again. Positioning is
performed.
10 After positioning is completed, press F5 [DONE].
DONE
F5
38
5.1.7 This function enables mastering data values to be assigned directly to a

Mastering Data Entry system variable. It can be used, if mastering data has been lost, but the
pulse count is preserved.
Mastering data entry

method MENUS Step 1 Press MENUS to display the screen menu.
2 Press zero for the next page.
3 Select [6 SYSTEM] and press ENTER.
4 Press F1 [TYPE] to select.
5 Select [Variable]. The system variable screen appears.
5 POSITION SYSTEM Variables JOINT 10%

6 SYSTEM 1/98
7 1 $AP MAXAX 536870912
2 $AP PLUGGED 4
3 $AP TOTALAX 16777216
4 $AP USENUM [12] of Byte
5 $AUTOINIT 2
6 $BLT 19920216
Variables
[ TYPE ]
[TYPE]
F1
6 Change the mastering data.

The mastering data is saved to the $DMR_GRP.$MASTER_COUN
system variable.
SYSTEM Variables JOINT 10%
13 $DMR GRP DMR GRPT

14 $ENC STAT [2] of ENC STATT
[ TYPE ]
39
7 Select $DMR_GRP.
JOINT 30% SYSTEM Variables JOINT 10%

DMR GRPT $DMR GRP 1/1
[2] of ENC STATT 1 [1] DMR GRPT
ENTER
$DMR GRP [1] 1/8
1 $MASTER DONE FALSE
2 $OT MINUS [9] of Boolean
3 $OT PLUS [9] of Boolean
4 $MASTER COUN [9] of Integer
5 $REF DONE FALSE
6 $REF POS [9] of Real
7 $REF COUNT [9] of Integer
8 $BCKLSH SIGN [9] of Boolean
[ TYPE ] TRUE FALSE
8 Select $MASTER_COUN, and enter the mastering data you have

recorded.
JOINT 30% SYSTEM Variables JOINT 10%

FALSE $DMR GRP [1].$MASTER COUN 1/9
[9] of Boolean 1 [1] 95678329
[9] of Boolean 2 [2] 10223045
[9] of Integer 3 [3] 3020442
4 [4] 304055030
5 [5] 20497709
6 [6] 2039490
ENTER
7 [7] 0
8 [8] 0
9 [9] 0
9 Press the previous page key.

10 Set $MASTER_DONE to TRUE.
TRUE FALSE $DMR GRP [1] 1/8
1 $MASTER DONE TRUE
2 $OT MINUS [9] of Boolean
F4
[ TYPE ] TRUE FALSE
11 Display the positioning screen, and select [6 CALIBRATE], then

press F4 [YES].
12 After completing positioning, press F5 [DONE].
DONE
F5
40
B–81725EN/01 MAINTENANCE 6. REPLACING PARTS
6 REPLACING PARTS
This section describes the replacement procedures for the major

components of the mechanical section. When replacing mechanical
components, be sure to follow the respective procedures. See Section 8
for how to replace the cables.
41
6. REPLACING PARTS MAINTENANCE B–81725EN/01
6.1 Once motors are replaced, mastering becomes necessary. Perform

mastering according to Section 5.1 after any of these components is
NOTE FOR PART replaced.
REPLACEMENT Be very careful when carrying and assembling the heavy components
listed below.
Table 6.1 Weight of the Main Parts
Component Weight (approximate)
Servo motor (same motors used in M1 to M6) 6kg
LEG unit. (See Fig. 6.3.) 19kg
Wrist unit. (See Fig. 6.4.) 38kg
Control unit (A cabinet) 120kg
Control unit (B cabinet) 180kg
In case of reusing sealbolts for F–200iB, observe following notes strictly.
(If possible, change them to new sealbolts)
1) Apply LOCTITE No.242 when the reusing sealbolts.
2) Notice the following 3 notes.
a) Remove excessive bits of sealant on the sealbolt.
b) The length of application is 2d (d : diameter of the bolt) from the
tip of the bolt, and spread it evenly around it.
c) Spread LOCTITE No.242 on whole threaded portion and rubbing
2 bolts together in order to spread it to the bottom of the groove.
LOCTITE No.242
Fig.6.1 Standard Application of LOCTITE No.242
42
6.2
REPLACING
MOTORS
(FOR ALL AXES)
Remove
1 Remove the full cover (option) from the robot where applicable
(see Section 6.5).
2 Set the robot to a posture with about the same lengths on all axes,
and lift the top plate with a sling.
3 Turn off the power.
4 Remove two connectors of the motor (1).
5 Remove four motor mounting bolts (2) and then remove the
washer (3).
6 Pull out the motor (1) from the gear box vertically, while being
careful not to scratch the surface of the gear teeth.
7 Remove the nut (7) and washer (6) from the shaft of the motor (1).
8 Pull off the gear (5) from the shaft of the motor (1).
Assembling
1 Grind the flange surface of the motor (1) using an oil stone.
2 Apply new seal (4) to motor (1).
3 Mount the gear (5) on the shaft of the motor (1).
4 Attach the nut (7) and washer (6) to the motor (1).
5 Mount the motor (1) on the J1 base vertically, while being careful
not to scratch the surface of the gear teeth. When mounting, make
sure that the O–ring (8) is in the prescribed place.
6 Attach the four motor mounting bolts (2) and washers (3).
7 Attach the two connectors to the motor (1).
8 Perform mastering.
Section 6.5).
43
Name Specifications Q’ty LOCTITE Torque (N–m)

1 MOTOR A06B–0215–B605 1
2 BOLT A6–BA–6X20 4 Follow the attached tightening torque table.
3 WASHER A97L–0001–0823#M6H 4
4 SEAL A98L–0004–0771#A25 1
5 GEAR 1 A290–7517–X311 1
6 WASHER Contained in item 1. 1
7 NUT Contained in item 1. 1 LT242 7, 4
8 O RING JB–OR1A–G75 1
Fig.6.2 Replacing Motor
44
6.3
REPLACING LEG
Disassembly
UNITS (FOR ALL 1 Remove the full cover (option) from the robot where applicable
AXES) (see Section 6.5).
2 Set the robot to a posture with an equal length of 820 mm or
greater on all axes, and lift the total top assembly (1) with a sling.
4 Remove the two connectors of motor (2).
5 Cut off nylon band (3) on the pipe, and remove bellows (4).
6 Remove set screw (6) of pipe (5).
7 Remove pipe (5) from head (7). To do this, rotate pipe (5) while
securing head (7) so that it is not rotated.
8 Remove M10 bolt (8), M10 washer (9), M8 bolt (10), and M8
washer (11). Remove the leg unit together with joint support 1
(12). Joint support 1 (12) faces the gearbox, and is opposite from
the motor.
Assembly
1 Polish the joint support mounting surface of baseplate (13) with
oil stone.
2 Insert joint pin (15) of a new LEG unit into joint support 1 (14).
Tighten M10 bolt (8) and M10 washer (9) with the specified
torque.
3 Insert joint support 1 (12) and (14) into joint pin (15). Tack it with
M10 bolt (16) and M10 washer (17), then secure them to
baseplate (13) with M8 bolts (10) and M8 washers (11). Finally,
tighten M10 bolt (16) with the specified torque.
4 Mount pipe (5) to head (7). To do this, rotate pipe (5) while
5 Mount set screw (6) of pipe (5).
6 Mount the two connectors to motor (2).
8 Secure bellows (4) to the pipe with nylon band (3).
Section 6.5).
NOTE
When the pipe (5) is to be removed from and mounted to
head (7), the width across flat of the parallel portion of head
(7) and the side of pipe (5) is used. Take great care so that
impact and excessive force are not applied to the pipe (5)
and head (7).
45

1 TOTAL TOP ASSY A05B–1517–K501 1
2 MOTOR A06B–0215–B605 1
3 NYLON BAND – 1
4 BELLOWS A290–7517–X316 1
5 PIPE A290–7517–X401 1
6 SET SCREW A6–SAKT–5X6 1
7 HEAD A290–7517–X402 1
8 BOLT A6–BA–10X20 1 LT262 76
9 WASHER A97L–0001–0823#M10H 1
10 BOLT A6–BA–8X20 4 LT262 37
11 WASHER A97L–0001–0823#M8H 4
12 JOINT SUPPORT1 A290–7517–X303 1
13 BASE PLATE A290–7517–X201 1
14 JOINT SUPPORT1 A290–7517–X303 1
15 JOINT PIN A290–7517–X306 1
16 BOLT A6–BA–10X20 1 LT262 76
17 WASHER A97L–0001–0823#M10H 1
Fig.6.3 Replacing LEG Unit
46
6.4
REPLACING THE
WRIST UNIT Disassembly
(see Section 6.5).
2 Set the robot to a posture with an equal length of 820 mm or
greater on all axes, and lift the total top assembly (1) with a sling.
4 Perform the following for each of the J1– to J6–axes.
1) Cut off nylon band (3) on the pipe, and remove bellows (4).
2) Remove set screw (6) of pipe (5).
3) Remove pipe (5) from head (7). To do this, rotate pipe (5)
while securing head (7) so that it is not rotated.
Assembly
1 Perform the following for each of the J1– to J6–axes.
1) Mount pipe (5) to head (7). To do this, rotate pipe (5) while
2) Mount set screw (6) of pipe (5).
3 Secure bellows (4) on each axis to pipe (5) with nylon band (3).
Section 6.5).
NOTE
1 When pipe (5) is to be removed from and mounted to head
(7), the width across flat of the parallel portion of head (7)
and the side of pipe (5) is used. Take great care so that
impact and excessive force are not applied to pipe (5) and
head (7).
2 After pipe (5) is removed from head (7), LEG unit (8) is
slanted to keep the posture. At this time, take care so that
no impact is applied to LEG unit (8).
47

1 TOTAL TOP ASSY A05B–1517–K501 1
2 MOTOR A06B–0215–B605 6
3 NYLON BAND – 6
4 BELLOWS A290–7517–X316 6
5 PIPE A290–7517–X401 6
6 SET SCREW A6–SAKT–5X6 6
7 HEAD A290–7517–X402 6
8 TOTAL LEG ASSY A05B–1517–K311 6
Fig.6.4 Replacing Wrist Unit
48
6.5
REPLACING THE
FULL COVER
(OPTION)
Disassembly
1 Set the robot in a posture in such a way that its all axes are almost
the same in length, and turn off the power.
2 Remove the M8 screws (3), and then the plates (2).
3 Open Velcro fasteners C, B, and A in that order, and open the top
plate Velcro fastener.
Assembly
1 Set the robot in a posture in such a way that its all axes are almost
the same in length, and turn off the power.
2 Put the jacket (1) on the robot so that Velcro fasteners A and B
face to the connector panel.
3 Align their counterparts an the jacket (1) with the screw holes and
top plate Velcro fastener, and fasten the jacket with the M8 screws
(3) and plates (2).
4 Close Velcro fasteners A and B in that order on the open/close
part of the jacket (1).
5 Close Velcro fastener C on the support plate at the bottom of the
robot.
49

1 JACKET A290–7517–Y222 1
2 PLATE A290–7517–Y219 3
3 BOLT A6–BA–8X10 3 See the torque list in Appendix.
Fig.6.5 Replacing Full Cover (Option)
50
6.6
REPLACING THE
CABLE COVER
(OPTION)
Disassembly
2 Remove the nylon bands.
3 Open the Velcro fasteners.
Assembly
2 Put a cover on each cable with the silver side facing outward, and
close the Velcro fasteners.
3 Fasten the both ends of each cover with nylon bands.
51
Name Specifications Q’ty Torque (N–m)

1 CABLE COVER 3m A290–7517–X223 2 For a power cable (K201) and a pulse coder and
end effector cable (K202)
CABLE COVER 6m A290–7517–X225 2 For a power cable (K201) and a pulse coder and
end effector cable (K202)
2 CABLE COVER 3m A290–7517–X224 1 For a battery cable (K103)
CABLE COVER 6m A290–7517–X226 1 For a battery cable (K103)
Fig.6.6 Replacing Cable Cover (Option)
52
B–81725EN/01 MAINTENANCE 7. WIRING
7 WIRING
53
7. WIRING MAINTENANCE B–81725EN/01
7.1 Fig.7.1 (a) to shows the wiring diagram of the mechanical unit.
WIRING DIAGRAM
Fig.7.1 (a) Wiring Diagram in Mechanical Unit
54
B–81725EN/01 MAINTENANCE 7. WIRING
Fig.7.1 (b) Wiring Diagram Block
55
7. WIRING MAINTENANCE B–81725EN/01
Fig.7.1 (c) Connector Locations
56
B–81725EN/01 MAINTENANCE 8. REPLACING CABLE
8 REPLACING CABLE
Replace the cable every four years. When the cable is broken or damaged,
or shows signs of wear, replace it according to this chapter.
Precautions to be observed when handling the pulse coder cable

The pulse coder cable is provided with a marking tie, as shown below, to
warn against disconnecting the cable during transportation, installation,
or maintenance. If the cable with the marking tie is disconnected,
mastering must be performed again. Therefore, do not disconnect the
cable except when replacement of the cable is necessary.
BATTERY BACKUP
DON’T
DISCONNECT
MARKING TIE
57
8. REPLACING CABLE MAINTENANCE B–81725EN/01
8.1 Fig.8.1 shows the cable clamp position.

When replacing cables, clamp the cable at the position specified in Figure
CABLE FORMING 8.1 using a clamp or a nylon band. Otherwise, cables are loosened or
forcedly pulled to cause their disconnection. Refer to the figures in
section 8.2 for the cable clamp position not listed in the Table.
Table 8.1 Cable Clamp Position
Mark Cable clamping position Mark Cable

No.
58
8.2 This section describes a procedure for periodically replacing all the
mechanical unit cables.
CABLE If you need to replace a specific cable (because, for example, it is
REPLACEMENT damaged), do so by referencing this section. See Section 7.1 for the
configuration of the mechanical unit cables.
Cable replacement makes it necessary to perform mastering. Before
attempting replacement, therefore, see Section 5.1.
The F–200iB has much wiring in its space. Before removing the cables,
therefore, check how the cables run, with the robot at a posture with a
length of 668 mm on all axes, by taking a picture or by other means.
Procedure for replacing
cables K201 and K202
Removal
(see Section 6.5).
2 Set the robot to a posture with a length of 668 mm on all axes and
turn off the power to the control unit.
3 Remove the control unit cable from the connector panel located
at the rear of the robot.
4 Remove the connectors from the motor.
5 Remove the nylon bands secured to the plates (plates 1, 2, and 3)
of the gearbox for each axis.
6 Remove the nylon band secured to the plate (cable clamp 2) of the
baseplate.
7 Remove the nylon band secured to the plate (cable clamp 1) of the
baseplate.
8 Remove the connector panel cover, and remove the grounding
cable and the housing from the connector panel. For K202, also
remove the EE connector and the battery connector.
Assembly
1 Mount new cables to the connector panel as shown in Fig. 8.2 (c).
2 Connect the cables as shown in Fig. 8.2 (a). Secure each cable to
the corresponding plate of the baseplate at the marking position with
a nylon band. Secure the cables for all axes to cable clamp 1 and
the cables for the J1–, J2–, J5–, and J6–axes to cable clamp 2.
3 Secure each cable to the corresponding plate (plate 1, 2, or 3) of the
gearbox for each axis at the marking position with a nylon band.
4 Mount the connectors to the motor.
5 Mount the control unit cable to the connector panel.
6 Perform simple mastering.
Section 6.5).
59
NOTE
Run each cable with great care so that its movable part
does not come in contact with the casting of the baseplate
and the gearbox. After connection, check the cables during
operation because, even if the movable part does not come
in contact while the robot is stationary, it may come in
contact during operation depending on the operating
posture.
In particular, the play portions on the J2– and J5–axes (See
Fig. 8.2 (a)) must be formed upward so that they not come
in contact with the baseplate.
Procedure for replacing

cable K103
Removal
1 Press the emergency stop button to perform the procedure while
the power is on. Note that if the power is turned off, mastering
is required.
2 Remove the battery box from the battery case.
3 Remove the +/– terminal and the nylon band secured to the
battery box.
4 Remove the cable from the battery case, together with the rubber
bushing located on the boundary between the battery case and the
outside.
5 Remove the connector panel cover. Remove the connector
connected to K202 and the nylon band secured to the connector
panel.
6 Remove the cable from the connector panel, together with the
rubber bushing located on the boundary between the connector
panel and the outside.
Assembly
1 Remove the +/– terminal rubber bushing from a new cable.
2 Run the +/– terminal from the inside of the connector panel
through the K203–mounting hole.
3 Mount the connector rubber bushing to the connector panel and
secure it to the connector panel with a nylon band.
4 Connect the cable to the K202 connector and secure it with a
nylon band so that the connector is not disconnected.
5 Mount the connector panel cover.
6 Mount the rubber bushing, removed in 1, to the cable again.
7 Run the +/– terminal from the outside of the battery case and
mount the rubber bushing to the K103–mounting hole of the
battery case.
8 Mount the +/– terminal of the new cable to the battery box and
secure it with a nylon band.
9 Secure the battery box to the battery case.
60
Must be formed upward

Plate 1 Plate 2 so that is does not
touch the baseplate
Must be formed
upward so that is does
not touch the baseplate Cable clamp 2
Cable clamp 2
Plate 2
Plate 1
Cable clamp 1
Rubber bushing
Plate 3 Battery case

Connector panel cover
Rubber bushing
(nine decorative M6 8) Battery box
(Two countersunk 4 20 screws)
Sectional views
Fig.8.2 (a) Replacing the Cable
61
Must be secured with nylon bands.
Rubber bushing
(Battery cable) (K103)
Grounding cable
EE (four M3 5 screws) Connector panel (one M6 10 screw for each)
RM1 housing RP1 housing

(four M4 10 screws) (four M4 10 screws)
Neoprene sponge
Section A–A
Fig.8.2 (b) Replacing the Cable
62
II. CONNECTION
B–81725EN/01 CONNECTION 1. ROBOT INTERFERENCE AREA
1 ROBOT INTERFERENCE AREA
Fig.1 (a) shows the external dimensions of the robot.

When installing peripheral devices, be careful to clear away any objects
that are in the robot’s motion path in normal operation. Fig.(b) shows the
operation range of the robot.
65
1. ROBOT INTERFERENCE AREA CONNECTION B–81725EN/01
Fig.1 (a) Mechanical Unit Operation Area
66
B–81725EN/01 CONNECTION 1. ROBOT INTERFERENCE AREA
Functional work
envelope
Kinematics
work envelope
Fig.1 (b) Robot Operation Area
67
2. MECHANICAL COUPLING TO
THE ROBOT CONNECTION B–81725EN/01
2 MECHANICAL COUPLING TO THE ROBOT
68
B–81725EN/01 CONNECTION THE ROBOT
2.1 Fig.2.1 is diagram to limit loads applied to the wrist. Apply a load within
the region indicated in the graph.
WRIST LOAD
CONDITIONS
X–Y permissible
center of gravity position In cm
Z permissible center of gravity position
Allowable load inertia at wrist
Fig.2.1 Wrist Load Diagram
69
2.2 Fig.2.2 is the diagram for installing end effectors on the wrist.
To fasten the end effector, first position it with two pin holes at C using
MECHANICAL fitting A or B, then lock it using six tapping screws at D. Select screws
COUPLING OF END and positioning pins of a length that matches the depth of the tapped and
EFFECTOR TO pin holes.
WRIST
Depth 20
Equally spaced on
circumference
Depth 20
Equally spaced on
circumference
Section AA’
Fig.2.2 (a) End Effector Mounting Face (Standard Flange)
70
Depth 20
Equally spaced on
circumference
Depth 20
Equally spaced on
circumference
Section AA’
Fig.2.2 (b) End Effector Mounting Face (Special Flange)
71
Depth 20
Equally spaced on
circumference
Depth 20
Equally spaced on
circumference
Section AA’
Fig.2.2 (c) End Effector Mounting Face (ISO Flange–Not Insulated)
72
Depth 20
Equally spaced on
circumference
Depth 20
Equally spaced on
circumference
Section AA’
Fig.2.2 (d) End Effector Mounting Face (Insulated ISO Flange)
73
2.3 Enter the mass and the inertia of the hand mounted to the wrist, as
described below:
SETTING THE LOAD
(1) Press MENUS to display the screen menu.
(2) Press zero for next screen and select SYSTEM.
(3) Press F1, TYPE, to display the screen switching menu and select
variable.
(4) Select item MOTION. The load setting number selection screen is
displayed. Select the load setting number used.
(5) Press F3, DETAIL, to display the load setting screen.
(6) Enter the load weight, the position of the center of gravity of the load,
and the load inertia. The load weight and the load inertia, as used here,
refer to the X, Y, and Z coordinates and the inertia about the X–, Y–,
and Z–axes in the absolute coordinate system with its origin at the
center of the flange, with the robot being set to a posture with zero
degrees.
MOTION/PAYLOAD SET JOINT 10%
1/8
Group 1
1 Schedule No [ 1]: [ ]
2 PAYLOAD [kg] 100.00
3 PAYLOAD CENTER X [cm] 60.00
4 PAYLOAD CENTER Y [cm] 0.00
5 PAYLOAD CENTER Z [cm] 0.00
6 PAYLOAD INERTIA X [kgfcms^2] 361.00
7 PAYLOAD INERTIA Y [kgfcms^2] 0.00
8 PAYLOAD INERTIA Z [kgfcms^2] 361.00
74
Fig.2.3 Setting Load
75
2.4 Fig. 2.4 (a) shows the position of the optional cable interface.
The end effector (RDI/RDO) is provided as standard.
END EFFECTOR
INTERFACE
Fig.2.4 (a) Position of the End Effector Interface
76
Fig. 2.4 (b) shows the pin arrangement of the end effector interface
(RDI/RDO).
End effector interface (RDI/RDO)

(output side)
End effector
Please prepare for user

Hand broken
Pneumatic pressure abnormal
Controller
Fig.2.4 (a) Pin Arrangement of the End Effector Interface (RDI/RDO)
Connector specifications
Table 2.4 (a) Connector Specifications (Mechanical Unit)
Cable name Output (connector panel) Manufacturer

RDI/RDO JMR2524F DDK
Table 2.4 (b) Connector Specifications (User)
Cable name Output (connector panel) Manufacturer

RDI/RDO JMSP2524M straight plug (supplied) DDK
JMLP2524M angle plug
NOTE
For details of dimensions and for other information, refer to
the catalog available from the manufacturer or contact
FANUC.
77
3. TRANSPORTATION AND
INSTALLATION CONNECTION B–81725EN/01
3 TRANSPORTATION AND INSTALLATION
78
B–81725EN/01 CONNECTION INSTALLATION
3.1 1) Transportation using a crane

The robot can be transported by lifting it. When transporting the
TRANSPORTATION robot, be sure to change the attitude of the robot to that shown in
Fig.3.1 (a) and lift by attaching sling to the three M10 eyebolts.
2) Transportation using a forklift
The robots can also be transported using a forklift (Refer to Fig.3.1
(b)). Transport materials are available as an option.
NOTE
For the F200iB, the battery case is separate and, therefore,
transport the robot with the battery case secured to the
connector panel together with the cable of about 7 m, as
shown in Fig. 3.1 (a) and (b).
79
ROBOT POSTURE ON
TRANSPORTATION
NOTE) 1 Machine weight is approximately 190Kg.

2 Eyebolts complied with JISB 1168.
3 Quantity eyebolt 3
sling 3
4 Do not ship with a tool exceeding the rated load attached.
5 Do not lift robot with a base plate attached.
M10 tap depth 20
Crane capacity min 1.0 ton
Sling capacity min 0.5 ton/sling
View A
Eyebolt (M10)
View A
Battery case
Fig.3.1 (a) Transportation Using a Crane
80
ROBOT POSTURE ON
TRANSPORTATION
NOTE) 1 Machine weight is approximately 190Kg.
2 Do not ship with heavy tooling.
3 Do not lift robot with a base plate attached.
View A
Battery case
Fork lift (Capacity : min.1.0ton)
Fig.3.1 (b) Transportation Using a Forklift
81
3.2 Fig.3.2 (a) shows the robot base dimensions. Fig.3.2 (b) shows actual
examples of robot installation.
INSTALLATION In Fig.3.2 (b), the floor plate is imbedded in concrete and fastened with four
M20 (strength classification 4.8) chemical anchors. Also fasten the block to the
robot base using nine M1635 bolts (strength classification 12.9). Next,
position the robot, and weld the base plate to the floor plate. (Foot length is 10
to 15mm.)
It is recommended that the flatness of the block be 0.01. (Blocks are
provided as options.)
Fig. 3.2 (c) and Table 3.2 show the force and the moment that apply to the
baseplate at emergency stop time and at acceleration/deceleration time
and at reset time.
For the F200iB, the battery case is tacked at the position identified in Fig.
3.1 (a) before delivery. The customer is responsible for securing the
battery case to an outside, safe location. Fig 3.2 (d) shows the outline
drawing of the battery case.
For fixing robot

through
Robot center (center of flange) facing depth 7
Front
For fixing robot

through
Fig.3.2 (a) Dimensions of the Robot Base
82
Pin for positioning robot
Welding position
Robot center
(center of
flange)
Block
(plane0.01deg)
Base plate
Robot mounting bolt : Weld after positioning

M16 35 (9pcs)
Strength classification : 12.9 Block (plane0.01deg)
Tightening torque : 32kgm
Chemical anchor :
M20 (4pcs)
Strength classification : 4.8
Tightening torque : 19kgm
Base plate
Note) Bury the base plate in concrete.
Fig.3.2 (b) Actual Installation Example
NOTE
1 Parts to be provided by the customer:
Robot mounting bolts : M16 x 35 (strength classification 12.9) 9pcs.
Chemical anchors : M20 (strength classification 4.8) 4pcs.
Block : thickness 32t 1pcs.
Floor plate : thickness 32t 1pcs.
Straight pin : φ8 2pcs.
2 Installation work (welding, anchoring, etc.) is prepared by the customer.
3 If the robot is operated with any combination other than stated above, it is likely to be dameged.
83
Table 3.2 Force and Moment Apply to the Baseplate
Force in vertical Force in horizontal

Vertical moment Horizontal moment
direction direction
MV [kNm (kgfm)] MH [kNm (kgfm)]
FV [kN (kgf)] FH [kN (kgf)]
At emergency stop 2.25 (230) 70.6 (7200) 10.8 (1100) 44.1 (4500)
At acceleration/
0.49 (50) 44.1 (4500) 1.27 (130) 27.4 (2800)
deceleration
At reset 0.00 (0) 29.4 (3000) 1.08 (110) 18.6 (1900)
Fig.3.2 (c) Force and Moment Apply to the Baseplate
84
(Centering)
(Centering)
(Centering)
(Centering)
(Centering)
(Centering)
Fig.3.2 (d) Battery Case
85
3.3 Fig. 3.3 shows the layout of the maintenance space.

MAINTENANCE
AREA
Mechanical unit maintenance area
Fig.3.3 Maintenance Area
86
3.4 To mount the optional set of three air items, the tapped holes shown in Fig.
3.4 are required. They must be prepared by the customer.
AIR CONTROL SET Fill the oiler having three air components to the specified level with
(OPTION) turbine oil #90 to #140. The machine tool builder is required to prepare
mounting bolts.
Air filter Lubricator
Fig.3.4 (b) Air Control Set (Option)
87
3.5
Table 3.5 Installation Specifications
INSTALLATION
SPECIFICATIONS Items Specifications
Air Pressure 0.49 to 0.69 MPa (5 to 7 kgf/cm2)

pressure Set pressure 0.49 MPa (5 kgf/cm2)
Air flow Max. peak 150 Nȏńmin (0.15 Nm3ńmin) (Note 1)
Weight of mechanical Approx. 190 kg
unit
Allowable ambient 0 to 45°C
temperature
Allowable ambient Usual: Less than 75% RH
humidity Short period (in one month): Max. 95% RH or less
Condensation free
Atmosphere Free of corrosive gases (Note 2)
Vibration Less than 4.9 m/s2 (0.5 G)
NOTE
1 This value indicates the maximum capacity of the optional
air control set.
Adjust the air flow to be less than this value.
2 Contact the service representative, if the robot is to be used
in an environment or a place subjected to severe vibrations,
heavy dust, cutting oil splash and or other foreign
substances.
88
3.6 To store the robot, set it to the same attitude as that used for transportation.
(See II– 3.1)
STORAGE
89
APPENDIX
B–81725EN/01 APPENDIX A. BOLT TIGHTENING TORQUE TABLE
A BOLT TIGHTENING TORQUE TABLE
Those bolts for which no tightening torque is specified must be tightened

according to the following table.
Table A Recommended Bolt Tightening Torques

Unit : Nm (kgf·cm)
Hexagon socket head pan bolt
Hexagon socket head bolt Hexagon socket head bolt Hexagon socket head counter-
(Steel : strength rating of 12.9) (Stainless) sunk bolt
Nominal
(Steel : strength rating of 12.9)
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) –––––––– –––––––– –––––––– ––––––––
93
B. SPARE PARTS LIST APPENDIX B–81725EN/01
B SPARE PARTS LIST
Table B (a) Cables
No. Specifications Function Remarks

K201 A660–8014–T495 J1 to J6 POWER
K202 A660–8014–T496 J1 to J6 PULSE CODER+EE
K103 A05B–1517–D001 BATTERY
Table B (b) Motor

Axis Specifications Remarks
J1 to J6 A06B–0215–B605 Model α M3/5000i
Table B (c) Battery Grease

Name Specifications Remarks
Battery A98L–0031–0005 1.5V, size D
Grease A98L–0040–0119#2KG Kyodo Yushi
Moly white RE No.00
Grease A97L–0001–0179#2 Shell Alvania No.2
Table B (d) Total Units

Total leg assembly A05B–1517–K311 Leg unit (T301 and motor)
Total top assembly A05B–1517–K501 Top plate unit (T401 and T501)
Table B (e) Other Parts

Bellows A290–7517–X316
Stopper A290–7517–X315 Top portion of the ball screw
Table B (f) Units

Leg assembly A290–7517–T301
Pipe assembly A290–7517–T401
Top plate assembly A290–7517–T501
Table B (g) Small Units

Joint fixture assembly A05B–1517–J041 Used to combine V301 with V302
Joint assembly A290–7517–V301
Gearbox assembly A290–7517–V302
Top joint assembly A290–7517–V501
Table B (h) Ball Screw and Gears

Ball screw A97L–0218–0261
Gear 1 A290–7517–X311 Motor side
Gear 2 A290–7517–X312 Ball screw side
94
B–81725EN/01 APPENDIX B. SPARE PARTS LIST
Table B (i) Bearings

Bearing A97L–0118–0515#10–0 Used in the top plate assembly (T501)
Bearing A97L–0218–0462#30202JR Used in the top joint assembly (V501)
and the join assembly (V301).
Bearing A97L–0218–0462#30203JR Used in the joint assembly (V301)
Bearing A97L–0218–0463 Used in the gearbox assembly (V302)
Table A (j) Oil Seals and O–Rings

Seal A98L–0004–0771#A25 Motor auxiliary seal (J1 to J6)
Oil seal A98L–0040–0047#05006509 Used in the top plate assembly (T501)
Oil seal A98L–0040–0047#02503506 Used in joint assembly (V301)
Oil seal A98L–0040–0047#04506009 Used in the top joint assembly (V501)
Oil seal A98L–0040–0049#02003005 Used in the gearbox assembly (V302)
O–ring A98L–0001–0347#S42 Used in the pipe assembly (T401) and
the ball screw nut
O–ring A98L–0001–0347#S60 Used in the top plate assembly (T501)
O–ring JB–OR1A–G75 Used on the motor mounting surface
Table A (k) Seal Bolts, etc.

Seal bolt A97L–0218–0417#060808 Used in the grease outlet of the gear-
box
Seal bolt A97L–0218–0621#061414 Used in the leg assembly (T301)
Seal bolt A97L–0218–0417#030404 Used in the top joint assembly (V501)
Silencer A97L–0118–0026#AN120–M5 Used in the pipe assembly (T401)
Pug A97L–0001–0436#2–1D Used on the bottom of the gearbox
Jacket A290–7517–Y222 Used in the full cover (option)
95
C. CIRCUIT DIAGRAM APPENDIX B–81725EN/01
C CIRCUIT DIAGRAM
Fig.C Robot Internal Circuit Diagram
96
B–81725EN/01 APPENDIX C. CIRCUIT DIAGRAM
97
NO TAG. PERIODIC MAINTENANCE TABLE APPENDIX B–81725EN/01
D PERIODIC MAINTENANCE TABLE
98
B–81725EN/01 APPENDIX D. PERIODIC MAINTENANCE TABLE
99
B–81725EN/01 Index
[Numbers] [I]
1.5–year Checks, 11 Installation, 82
3–month Checks, 9 Installation Specifications, 88
3–year Checks, 11
6–month Checks, 11
[M]
Maintenance Area, 86
Maintenance Tools, 12
[A] Major Component Specifications, 5
Adjustments, 25 Marking–off Mastering, 32
Air Control Set (Option), 87 Mastering, 26
Annual Checks, 11 Mastering Data Entry, 39
Mastering to a Fixture (Jig Position Master), 28
Mechanical Coupling of End Effector to Wrist, 70
[B] Mechanical Coupling to the Robot, 68
Bolt Tightening Torque Table, 93
[N]
Note for Part Replacement, 42
[C]
Cable Forming, 58
Cable Replacement, 59 [P]
Circuit Diagram, 96 Periodic Maintenance, 13
Configuration, 3 Periodic Maintenance Table, 98
Preventive Maintenance, 6
[D]
Daily Checks, 7
[Q]
Quick Mastering, 34
Drive Mechanism (J1 to J6), 4
[R]
[E] Replacing Cable, 57
End Effector Interface, 76 Replacing Grease of the Drive Mechanism, 14
Replacing LEG Units (for All Axes), 45
Replacing Motors (for All Axes), 43
[F] Replacing Parts, 41
Failure and Cause, 20 Replacing the Batteries, 17
Replacing the Cable Cover (Option), 51
Replacing the Full Cover (Option), 49
[G] Replacing the Wrist Unit, 47
Resetting Alarms and Preparing for Mastering, 27
Greasing, 16
Robot Interference Area, 65
i–1
Index B–81725EN/01
Transportation and Installation, 78
Troubleshooting, 18
[S]
Setting the Load, 74
Single Axis Mastering, 36
Spare Parts List, 94 [W]
Storage, 89
Wiring, 53
Wiring Diagram, 54
[T] Wrist Load Conditions, 69
Transportation, 79
i–2
Revision Record
FANUC Robot F–200iB MECHANICAL UNIT MAINTENANCE MANUAL (B–81725EN)
01 Mar., 2002
Edition Date Contents Edition Date Contents

F-200iB Mechanical Unit Maintenance (B-81725EN - 01)

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FANUC Robot F–200iB

D Position all controllers outside the robot work envelope.

D Staying safe during When inspecting the robot, be sure to

D Release or block all stored energy. Before working on the pneumatic

D Be aware that when you remove a servomotor or brake, the associated

Entering safeguarded space for maintenance

1. Stop the robot system.

D Programming safety Implement the following programming safety measures to prevent

The label stating the mechanical unit specification number is affixed in

Positon of Label Indicating Mechanical Unit Specification Number

2. MECHANICAL COUPLING TO THE ROBOT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

3. TRANSPORTATION AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

B. SPARE PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

D. PERIODIC MAINTENANCE TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

The configuration of the mechanical unit is shown in Fig.1.

End–effector mounting face

Fig.1 Mechanical Unit Configuration

1.1 Fig.1.1 shows the drive mechanism.

Ball screw nut

Fig.1.1 Drive Mechanism

1.2 Table1.2 (a) Motor

Table1.2 (b) Ball Screw

Table1.2 (c) Top Plate Unit

Optimum performance of the robot can be maintained for a long time by

Oil inlet Adjusting knob

Fig.2.1 Air Control Set (Option)

2) After automatic operation

2) First quarterly inspection

Pipe for bellows

Replace nylon band

Fig.2.2 Examination of the Oil Film on the Ball Screw

2.3 Check the following item once every six months.

2.4 Check the following items once every year.

2.5 Check the following item once every 1.5 year.

2.6 Check the following items once every 3 years.

Seal bolt for grease outlet

Fig.3.1 (a) Replacing Grease of Gear Box (J1,J3,J4,J6–axis)

Grease nipple for inlet Seal bolt for outlet

Fig.3.1 (b) Replacing Grease of Gear Box (J2,J5–axis)

To perform greasing when the robot is postured

Pipe for bellows

Fig.3.2 (a) Greasing Points

Battery case Case cap

Fig.3.3 Replacing Battery

Symptom Description Cause Measure

Symptom Description Cause Measure

Symptom Description Cause Measure

Symptom Description Cause Measure

5.1 Mastering is an operation performed to associate the angle of each robot

Mastering method Table 5.1.1 Types of Mastering

Once mastering is performed, it is necessary to carry out positioning, or

5.1.2 Before performing mastering because a motor is replaced, it is necessary

Alarm displayed “Servo 062 BZAL” or “Servo 075 Pulse mismatch”

Replace nylon band

Connect with M68

Fig.5.1.3 (a) Preparation for Mastering

Fig.5.1.3 (b) Mounting of the Mastering Fixture

SYSTEM Master/Cal JOINT 10%

1 FIXTURE POSITION MASTER

Press ’ENTER’ or number key to select.

[ TYPE ] LOAD RES_PCA

SINGLE AXIS MASTER JOINT 10%